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: 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.

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.

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.

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

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)

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

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

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.

TIME SETTINGS

The K-BUG 1200 offers three adjustable time settings - Puddle Build-Up, Pause Time and Crater Fill. The Travel Speed Adjustment knob is used for setting each of the timers, as described below.

Puddle Build-up Time (u)

1. While pressing the Cycle Start button, connect the power cord to an appropriate power supply.

2. The Display will show “u0.0” ashing.

3. Turn the Travel Speed Adjustment knob until the desired build-up time is displayed.

4. Default setting is 1.0 seconds. Available range is 0.0 - 9.9 seconds.

Crater Fill Time (n)

1. Press Cycle Start button once more.

2. The Display will show “n0.0” ashing.

3. Turn the Travel Speed Adjustment knob until the desired crater ll time is displayed.

4. Default setting is 1.0 seconds. Available range is 0.0 -9.9 seconds.

Pause Time (E). After welding, a brief rest before Crater Fill.

1. Press the Cycle Start button once more.

2. The Display will show “E0.0” ashing.

3. Turn the Travel Speed Adjustment knob until the desired stop time is displayed.

4. Default setting is 0.5 seconds. Available range is 0.0 - 9.9 seconds.

When nished setting times, press the Cycle Stop button to exit time setup mode. The machine is now ready to be setup for welding.

Travel

Weld “On”

u E n

Non-Weld

Travel

(time)

A graphic display of the user adjustable time settings.

STOP SENSOR OPERATION

The K-BUG 1200 is equipped with two (2) Stop Sensors. One sensor is placed on the right side of the carriage, the other is placed on the left. The Stop Sensors are normally open switches that engage or close when depressed. If a sensor is tripped during welding, carriage travel will immediately stop and Crater Fill will be performed. Remove the obstacle to reset the Stop Sensor. Press Cycle Start button to begin weld cycle again. NOTE: If Stop Sensor is tripped during intermittent welding, program will reset, NOT resume.

GLOBAL PARAMETERS

A menu of Global Parameters is maintained in the K-BUG 1200. The menu consists of six (6) items as described in Table 1, below. Access to the menu is locked when DIP Switch #1 is in the OFF Position.

Table 1: Global Parameters

Display Description Default Range Units

n.0* Travel Speed Coefcient 20.0 0.1 - 50 n.1 Motor Overload Stop Time 2 0.0 - 9.9 sec n.2* Travel Motor Reduce Ratio 80 20 - 200 base g x 10 : 1 n.3* Diameter of Travel Wheel 50 0.0 - 99.9 mm n.4 Show Mode off off / on

n.5 Operating Units U2 U1 / U2 U1 (cm/min), U2 (in/min) * Indicates parameters NOT to be changed by the User. Changing these parameters can harm machine performance.

ACCESS THE GLOBAL PARAMETER MENU

1. With machine unplugged from A/C power supply, remove the six (6) screws securing the Control Interface (Legend Plate and Main PCB) to the Control Panel.

2. Remove the Control Interface and turn it over.

3. Locate DIP Switch 1 and 2 on the Main PCB, see illustration at right.

4. Turn DIP Switch 1 to the “ON” position.

5. Turn over Control Interface. And secure to Control panel.

6. Plug in machine to A/C power supply of appropriate voltage.

7. “0” should be shown in the Display.

8. Press and release Cycle Start button to cycle through the six parameters (0, 1, 2, 3, 4, 5).

9. Use the Travel Speed Adjustment knob to change the parameter setting.

10. When nished, unplug machine, remove Control Interface and turn it over.

11. Turn DIP switch 1 to the “OFF” position to lock global parameter menu.

12. Re-assemble Control Panel and plug in machine to begin operation.

Rear of Main PCB. Note DIP switch placement on left hand side. Move Switch 1 up to the ON position.

CONVERTING UNITS

By default, the K-BUG 1200 will be factory set to operate in English units (in/min) and the K-BUG 1202 will be set to operate in Metric units (cm/min). If it is necessary to change units, follow the steps to access the Global Parameters Menu, above. Use the Cycle Start button until “5” is shown on the Display. Turn the Travel Speed Adjustment knob right or left to select the desired Units. Choose “U1” for Metric (cm/min) or “U2” for English (in/min).

INSTALLATION AND OPERATION

1. Welding Preparation - Secure the necessary welding supplies

• Welding Power Source (3 phase, 440/380/220V AC)

• Wire Feeder

• Tank of appropriate shielding gas, with pressure and ow regulators and appropriate ttings

• Torch for gas shielded automated welding

• Basic Weld Prep Tools

2. Cable Connections

• Connect welding torch conduit cable to wire feeder

• Connect Weld Contactor lead from Torch to Main Cable Connector on machine body

• Connect Control Cable to the Control Box Connector on the machine body

• Connect Control Power Source Cable to the Welding Power Source

CAUTION: Carefully route power cable as it may become entangled during operation, resulting in damage to people or equipment.

3. Welding Process

• Switch ON the Primary Side Distribution Board of the Welding Power Source

• Switch ON the Control Power Source on the front panel of the Welding Power Source

• Equip the Wire Feeder with wire

• Set the Carriage so the torch is at the weld starting point

• Install the Guide Arms offset in the direction of travel (leading arm slightly shorter than

following arm) for better positioning of the electrode in the joint

• Adjust the target angle and position of the Torch using the Torch Adjustment Slider

• Verify machine is in the proper welding mode. Set stitch welding parameters, if needed

• Verify adequate Shielding Gas Supply

• Start Welding - Switch Welding Switch to AUTO, verify desired travel direction is set and

travel speed is > 0 and press Cycle Start button

• Press Cycle Stop button when welding is complete. Turn Welding Switch to OFF

• Conrm Welding End

CABLE INTERCONNECT DIAGRAM

SHIELDING GAS

WIRE FEEDING & WELDING POWER

WELD CONTACTOR LEADS

WIRE FEEDER

CONTROL PANEL

POWER CABLE

BASE MATERIAL

TORCH CABLE

WELD CONTACTOR LEADS

EARTH CABLE

SHIELDING GAS WELDING CONTROL CABLE WELDING POWER CABLE

120 VAC / 50-60 Hz / 1Ph

240 VAC / 50-60 Hz / 1Ph

SHIELD

GAS

R S

R S T

POWER SOURCE

MAINTENANCE

The K-BUG carriage should be periodically checked and cleaned to maximize service life.

Before use:

Check all screws in the torch clamp and guide rollers. Tighten as needed. Loose fasteners may cause uneven travel or inconsistent weld quality.

During use:

Monitor wheels, motor and welding torch for abnormal noise or overheating.

After each use:

1. Clean control panel to remove dust and other debris.

2. Inspect carriage base, wheels, guide rollers, slide adjustment, magnets and torch for weld spatter or other debris. Clean as needed.

3. Inspect power cable and torch cable for cracked, cut or damaged insulation. Replace as needed.

4. Inspect connectors for damaged pins or loose connections. Replace as needed.

TROUBLESHOOTING

Symptom Cause Repair

Control panel Display is not LIT when machine is

plugged in

No Arc when Welding Auto/Off Switch turned to AUTO

Carriage does not travel when Cycle

Start Button is

pushed

Torch targets wrong

position

Slide is hard to

adjust

Carriage stops

during automatic

welding

Arc continues after Welding Auto/Off Switch is set to OFF

Unable to perform Intermittent Welding

Disconnected Control Cable Verify control cable is properly

connected to machine Faulty Control Cable Replace Cable Control Box Fuse Tripped or

Disconnected

Weld Auto/Off Switch set to OFF Turn Weld Auto/Off Switch to AUTO Loose contact of Welding Leads Check ground connections. Verify good

Faulty or incorrectly wired Welding Auto/Off Switch

Stop Sensor Engaged Disengage Stop Sensor Failed drive component Check Motor and Gearbox. Replace as

Faulty or incorrectly wired Cycle Start

Button

Faulty MAIN PCB Replace MAIN PCB Loose fastener on Torch Clamp or

Torch Adjustment Slider Dust or other debris on slide parts Clean slide parts. Lubricate with light

Obstacle in carriage path Remove obstacles

Stop Sensor engaged Disengage Stop Sensor

Distance traveled exceeds Total Length

The Welding Auto/Off Switch is still set to Auto

Faulty or incorrectly wired Welding Auto/Off Switch

Intermittent Welding is locked Press and hold Travel Speed

Replace fuse. If problem persists,

contact service rep.

contact on clean, unpainted surface.

Check Wiring. Replace Switch, if

needed

Check Wiring. Replace button , if

needed

Check and tighten screws, replace if

needed.

oil

See “Intermittent Welding” on page 7

for instructions to set Total Length

Turn Weld Auto/Off Switch to OFF

Check Wiring. Replace Switch, if

needed.

Adjustment knob for 3 seconds.

TROUBLESHOOTING, CONT’D.

K-BUG ERROR LIST

NO. SYMPTOM CAUSE SOLUTION

E-03 Motion Stop Main PCB EET ROM Error Main PCB Replacement

E-05 Travelling Stop Auto-Stop Travelling Motor Push and release Stop Button

may be overloaded / shorted

IF UNRESOLVED:

1. Check for loose wiring connec tion at drive motor and weave motor if equipped (see below).

2. Replace motor or motor reducer

3. Replace main PCB

K-BUG 1200 ASSEMBLY VIEW

ITEM QTY PART NO. DESCRIPTION

1 1 KBUG-1210 Carriage Assembly 2 1 KBUG-1120 Control Panel Assembly 3 1 KBUG-1100 Torch Clamp Assembly 4 1 KBUG-1230 Angle Slide Assembly 5 1 KBUG-1070 Y-Slide Assembly 6 2 KBUG-1060 Guide Arm Assembly 7 1 KBUG-1290 Cable Anchor Assembly 8* 1 KBUG-2274-XX 120 VAC Power Cord (KBUG-1200, only) 9* 1 KBUG-2273-XX Weld Contact Cable 10* 1 KBUG-2272-XX 240 VAC Power Cord (KBUG-1202, only) 11* 1 KBUG-1003 Metric Hex Key Set

XX= Cable length: 15' is standard, 25' & 50' are optional

* = Not shown

K-BUG 1200 WIRING DIAGRAM

KBUG-1135

DISPLAY & SWITCH

1234567

HEADER-S08

1234567

TS11CS501

DA0 PA0

DA1 PA 1

DA2 PA2

DA3 PA3

DA4 PA4

1234567

J1 J1

MAIN PCB

CN1

DA5 PA5

DA6 PA6

123

12345

END0

END1

END2

END3

EN UP SW

EN DN SW

DA7 PA7

1234567

J1 J1

EN PUSH SW

GND

HEADER-S08 HEADER-S08

DC + 24V

12345

CN2

P-GND

MA CW/CCW

MA PULSE

KBUG-1049

MA PWM

MA RUN/STOP

HEADER-S08

KBUG-1135

12345

CN1

AC-

AC+

EARTH

120 VAC 50 - 60 Hz 1Ph

240 VAC 50 - 60 Hz 1Ph

INPUT POWER

JP7

WELD COM

TORCH

321

JP7-3

(STOP)

EXTERNAL SENSOR

JP7-1

JP7-2 JP7-4

OFF

KBUG-1294

KBUG-1210 CARRIAGE ASSEMBLY / EXPLODED VIEW

KBUG-1210 CARRIAGE ASSEMBLY / PARTS LIST

ITEM QTY PART NO. DESCRIPTION

1 1 KBUG-1216 Body 2 1 KBUG-1012 Magnet Plate 3 4 KBUG-1013 Shaft Bushing 4 1 KBUG-1222 Dust Cover -2 5 1 KBUG-1218 Lever Bracket Pin 6 2 KBUG-1224 Magnet Shaft Bracket 7 1 KBUG-1212 Gear Case 8 1 KBUG-1018 Center Gear 9 1 KBUG-1019 Gear Bushing 10 1 KBUG-1219 Dust Cover 1 11 2 KBUG-1185 Stop Sensor 12 2 KBUG-1023 Wheel Shaft 13 1 KBUG-1024 Bottom Cover 14 1 KBUG-1221 Dust Cover 4 15 2 KBUG-1223 Shaft Gear 16 4 KBUG-1029 Shaft Bearing 17 1 KBUG-1031 Grip 18 2 KBUG-1211 Motor Bk. 19 2 KBUG-1033 Spatter Cover Bushing 20 4 KBUG-1034 Wheel Cover 21 1 KBUG-1035 Spatter Cover 22 4 KBUG-1036 Wheel 23 4 KBUG-1037 Shaft Snap Ring 24 1 KBUG-1038 Lever Bolt 25 1 KBUG-1041 Lever - 2 26 1 KBUG-1042 Magnet 27 1 KBUG-1043 Motor Cover - 1 28 1 KBUG-1217 Lever Guide Key 29 1 KBUG-1045 Gearhead 30 1 KBUG-1046 Handle Cover 31 2 KBUG-1047 DU Bushing (M) 32 1 KBUG-1214 Lever Bracket -D 33 1 KBUG-1049 DC Brushless Motor 34 1 KBUG-1051 Motor Bearing 35 2 KBUG-1213 Spur Gear -S 36 1 KBUG-1215 Spur Gear -C

KBUG-1060 GUIDE ARMS / EXPLODED VIEW / PARTS LIST

ITEM QTY PART NO. DESCRIPTION

1 2 KBUG-1061 Guide Roller Bushing 2 2 KBUG-1062 Guide Roller 3 2 KBUG-1063 Guide Roller Cover 4 2 KBUG-1064 Guide Roller Slide Bracket 5 2 KBUG-1065 Guide Arm

KBUG-1230 ANGLE SLIDE ASSEMBLY / EXPLODED VIEW / PARTS LIST

ITEM QTY PART NO. DESCRIPTION

1 1 KBUG-1134 Knob

2 1 KBUG-1238 Angle Slide Bolt Cover

3 1 KBUG-1233 Shaft Cover 4 1 KBUG-1235 Guide Shaft 5 2 KBUG-1236 Cover

6 1 KBUG-1231 Angle Base

7 1 KBUG-1232 Angle Body 8 1 KBUG-1237 Bushing 9 1 KBUG-1239 Angle Slide Bushing 10 1 KBUG-1234 Slide Bolt 11 3 KBUG-1241 Washer

KBUG-1100 TORCH CLAMP ASSEMBLY / EXPLODED VIEW / PARTS LIST

ITEM QTY PART NO. DESCRIPTION

1 1 KBUG-1111 Torch Clamp (U) 2 1 KBUG-1112 Clamp Fixed Bolt 3 1 KBUG-1113 Clamp Fixed Knob 4 1 KBUG-1114 Torch Clamp (D) 5 1 KBUG-1115 Torch Clamp Bracket

KBUG-1120 CONTROL PANEL ASSEMBLY / EXPLODED VIEW / PARTS LIST

ITEM QTY PART NO. DESCRIPTION

1 1 KBUG-1121 Panel 2 2 KBUG-1122 Toggle Switch Cover 3 1 KBUG-1123 Legend Plate 4 2 KBUG-1124 Push Button Cover (BS) 5 1 KBUG-1125 Display Lens

6 1 KBUG-1126 Main PCB 7 1 KBUG-1127 Push Button Cover - 2 8 1 KBUG-1128 Push Button Cover -1 9 1 KBUG-1129 Volume Knob 10 1 KBUG-1131 Fuse Holder w/ Fuse 11 1 KBUG-1132 Power Connector (Female) 12 1 KBUG-1133 Torch Connector (Female) 13 1 KBUG-1225 Dust Cover 14* 1 KBUG-1173 Weld Contact Connector (Male)

15* 1 KBUG-1174 Power Connector (Male)

* Not Shown

SBG-450-_-___-__ GUN & CABLE ASSEMBLY / EXPLODED VIEW / PARTS LIST

Whip Length: 15 (15 ft / 4.6 m) or 25 (25 ft / 7.6 m)

Wire Size: 035, 040, 045, 052, 116, 564

Connector Type: E (Euro), L (Lincoln ¾"), M (Miller), T (Lincoln, small)

PARTS LIST WIRE SIZE

.035

ITEM QTY PART NO. DESCRIPTION

1 1 BUG-3159-35 16S-35 (.9 mm) Contact Tip X

1 1 BUG-3159-45 16S-45 (1.2 mm) Contact Tip X

1 1 BUG-3159-52 16S-52 (1.4 mm) Contact Tip X

1 1 BUG-3159-116 16S-116 (1.6 mm) Contact Tip X

1 1 BUG-3159-564 16S-564 (2.0 mm) Contact Tip X

1 1 PWS-4436-1.0 16S-40 (1.0 mm) Contact Tip X

2 1 PWS-4447 27S62 H.D. Nozzle ⅝" X X X X X X

3 1 PWS-4449 PX57HD Gas Diffuser X X X X X X

4 1 CWO-8017 Case w/ Binder Screws (Front) X X X X X X

5 1 PWS-4411 Case w/ Binder Screws (Back) X X X X X X

6 1 STW-3044 450 Amp Cable X X X X X X

7 1 R174-T Connector, Small Lincoln

7 1 R174-L Connector, ¾" Lincoln

7 1 R174-M Connector, Miller

7 1 R174-X Connector, Euro

8 1 CWO-8009 44-3545-15 Cable Liner X X X

8 1 CWO-8011 44-116-15 Cable Liner X X

8 1 CWO-8012 44-564-15 Cable Liner X

** 1 SBG-1004 Gas Hose Assembly X X X X X X

** 2 SBG-1005 Gas Hose Clamps X X X X X X

** Not shown. Required only with standard Lincoln guns (SBG-450-L).

(.9 mm)

.040 (1.0)

.045 (1.2)

.052 (1.4)

1/16 (1.6)

5/64 (2.0)

ACCESSORIES

KBUG-1067 Magwheel Add-On Kit

Magnetic guide wheels available for curved or irregular seams.

KBUG-1054 Cable Anchor

The cable anchor acts as a strain relief to keep the supply cable from dragging the torch out of position.

KBUG-1170 7" (178 mm) Long Arm Extension Kit

The long arm extension kit allows the user to relocate the welding torch away from the carriage body for welding special applications.

MSQ-150 30mm Magsquare

The Magsquare is used to activate the limit switch to stop machine travel and welding process.

WARRANTY

LIMITED WARRANTY

FOR A PERIOD OF TWELVE (12) MONTHS FROM DELIVERY, BUG-O SYSTEMS WARRANTS TO THE ORIGINAL PURCHASER (DOES NOT INCLUDE AUTHORIZED DISTRIBUTORS), THAT A NEW MACHINE IS FREE FROM DEFECTS IN MATERIAL AND WORKMANSHIP AND AGREES TO REPAIR OR REPLACE, AT ITS OPTION, ANY DEFECTIVE PARTS OR MACHINE. THIS WARRANTY DOES NOT APPLY TO MACHINES, WHICH AFTER OUR INSPECTION, ARE DETERMINED TO HAVE BEEN DAMAGED DUE TO NEGLECT, ABUSE, OVERLOADING, ACCIDENT OR IMPROPER USAGE. ALL SHIPPING AND HANDLING CHARGES WILL BE PAID BY CUSTOMER.

BUG-O SYSTEMS MAKES NO WARRANTY OF MERCHANTABILITY AND MAKES NO OTHER WARRANTY, EXPRESSED OR IMPLIED, BEYOND THE WARRANTY EXPRESSLY SET FORTH ABOVE. BUYER’S REMEDY FOR BREACH OF WARRANTY, HEREUNDER, SHALL BE LIMITED TO REPAIR OR REPLACEMENT OF NON-CONFORMING PARTS AND MACHINES. UNDER NO CIRCUMSTANCES SHALL CONSEQUENTIAL DAMAGES BE RECOVERABLE.

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 HE CANNOT GIVE YOU THE NECESSARY SERVICE, WRITE OR PHONE US TO TELL US EXACTLY WHAT DIFFICULTY YOU HAVE EXPERIENCED. BE SURE TO MENTION THE MODEL AND SERIAL NUMBERS.

MODEL ____________________________ SERIAL NO. ________________________

DATE PURCHASED: _________________

BUG-O Systems K-BUG 1200 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual