Bug-O Systems K-BUG 4000, K-BUG 4004, K-BUG 4002, K-BUG 1200, K-BUG 1202 Instructions And Parts Manual

INSTRUCTIONS

AND

PARTS MANUAL

COMPACT

WALL-FOLLOWING

FILLET WELDER

K-BUG 4000
K-BUG 4002
K-BUG 4004

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-4000-IPM-0916

Bug-O Systems is guided by honesty, integrity and
ethics in service to our customers and in all we do.

280 TECHNOLOGY DRIVE CANONSBURG, PENNSYLVANIA 15317-9564 USA

PHONE: [phone] http://www.bugo.com FAX: [phone]

A DIVISION OF WELD TOOLING CORPORATION

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.

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.

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.

2

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.

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 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.

3

COMPACT WALL-FOLLOWING

FILLET WELDER

K-BUG 4000, K-BUG 4002

INSTRUCTIONS AND PARTS MANUAL

TABLE OF CONTENTS

PAGE

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

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

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

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

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

6 ..........Welding Modes

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

7 ..........Intermittent Welding Lock Out

7 ..........Stop Sensor Operation

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

8 ..........Global Parameters

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

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

10 .........Maintenance

11-12 ......Troubleshooting

13 .........K-BUG 4000 Assembly View

14 .........K-BUG 4000 Wiring Diagram

15 .........KBUG-4010 Carriage Assembly / Exploded View

16 .........KBUG-4010 Carriage Assembly / Parts List

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

17 .........KBUG-4090 Torch Clamp Assembly / Parts List

18 .........KBUG-4050 Control Panel Assembly / Exploded View / Parts List

18 .........Accessories

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

20 .........Warranty

4

INTRODUCTION

The K-BUG 4000 is a compact, light weight, wall-travelling unit designed to mechanize horizontal llet
welding. It is able to follow vertical or inclined walls of straight or curved (R > 1000 mm) prole. The
machine is capable of performing continuous and intermittent (stitch) welds.

FEATURES

• Compact - 14.6 x 8.9 x 11.3 in (370 x 226 x 288 mm)

• Lightweight - 14 lb (6.4 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

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

TECHNICAL DATA

Power Input
K-BUG 4000 120VAC / 50-60 Hz / 1 Phase
K-BUG 4002 240VAC / 50-60 Hz / 1 Phase
K-BUG 4004 42VAC / 50-60 Hz / 1 Phase
Weight 14 lb (6.4 kg)
Drive Motor 24 VDC, 12 W, 5000 RPM
Travel Speed 0.3 - 77 in/min (0.1 - 195 cm/min)
Torch Angle Adjustable
Running Angle 90°

DIMENSIONS

Max. 13.3" (337.8 mm)

Min. 9.7" (246.4 mm)

Min. 8.2" (208.3 mm)

Max. 10.8" (274.3 mm)

14.5" (368.3 mm)

5

USER INTERFACE

6

7

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

4. Speed Adjustment Knob - Rotate knob to
adjust carriage travel speed. Turning clockwise

3

(right) will INCREASE speed.

NOTE: Travel Speed Adjustment Knob is also
used for setting the INTERMITTENT WELDING

5

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.

1 2

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 4000 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

S

ensor is

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