BUG-O Systems MDS-1004 User Manual

INSTRUCTION

MANUAL

MDS-1004

PROGRAMMABLE

STITCH MODULE

FOR THE MODULAR DRIVE SYSTEM

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-MDS-1004-IPM-0208

A DIVISION OF WELD TOOLING CORPORATION

280 TECHNOLOGY DRIVE CANONSBURG, PENNSYLVANIA USA 15317-9564

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

SAFETY

PROTECT YOURSELF AND OTHERS FROM SERIOUS INJURY OR DEATH. KEEP
CHILDREN AWAY. BE SURE THA T 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.

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. In none exist, use
International Electric Code (IEC) 950.

1) Do not plug in the power cord with out
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 verify 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 worksite and store in a
safe location when not in use.

F ALLING 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.

POSSIBLE.

READ INSTRUCTIONS.

Read the instruction manual before
installing and using the equipment.

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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 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.

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PROGRAMMABLE STITCH MODULE

INSTRUCTIONS MANUAL

TABLE OF CONTENTS

PAGE

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

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

6 ..........Getting Started

7 ..........Basic Setup

7 ..........Stitch Program Setup

9 ..........Modes of Operation

10 ..........Enabling Contactor

10 ..........Motion Control

12 ..........Stitch Program Example

13 ..........Warranty

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Patents Pending

INTRODUCTION

The MDS-1004 PROGRAMMABLE MODULE provides stitch controls for welding or cutting
with the Modular Drive System. The graphic display interface allows the user to view the exact
value of each stitch parameter for precise and repeatable configuration. The Programmable Module
contains an extra weld contactor output which can be enabled or disabled independent of the
Modular Drive Unit contactor.

Display

Controls

2-Pin Contactor Output

FEATURES

• Exact, repeatable stitch configuration. Each stitch parameter is displayed while being set;
allowing each parameter to be exactly set each time a job is set up.

• Two contactor outputs. Programmable Module includes a 2-pin contactor output which can
be enabled or disabled independent of the Modular Drive Unit contactor.

• User defined home position. Module can be configured to return the machine to a position
before the weld start location for work piece change-out without gun interference. One button
will start the whole welding program again.

• No external limit switches. User defines whether module will stop the machine or return it to
the home position upon completion of the last weld of the program.

• Resume mode. Stitch welds stopped mid-job can be restarted without interrupting the weld
pattern.

• Independent timers for Puddle-buildup and Crater-fill.

• Closed loop feedback ensures the traveled distances match the set distances.

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