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.

2

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.

3

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

4

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.

5

GETTING STARTED

The MDS-1004 PROGRAMMABLE MODULE is a controller for the Modular Drive Unit, and
must be installed on a Modular Drive Unit. Please refer to the Modular Drive Unit instruction manual
for further instructions on setting up the Modular Drive Unit.

NOTE: BUG-O Systems recommends becoming familiar with the controls through
programming and dry-running the machine several times before welding or cutting.

Begin by powering up the Modular Drive Unit. During power-up, a boot screen similar to figure
1 is displayed. This screen provides software and hardware version information.

Figure 1: Boot Scr een.

The boot screen is promptly followed by the Main Operating Screen (figure 2). This screen is
divided in two sections, with machine status information displayed in the upper section and control
functions displayed in the lower section. These functions change from screen to screen and vary
depending on machine status. When the machine is stopped, its position is displayed on the left
side of the lower section. The status information shown on the Main Operating screen includes
tractor speed during welding, the weld contactor status (not shown in figure 2), and the mode of
operation.

Figure 2: Main Operating Scr een.

6

BASIC SETUP

From the Setup Menu (figure 3), the User will select measurement units and which weld

contactors to use, as well as configure the stitch parameters.

From the Main Operating Screen, use button to access the Setup Menu.

Figure 3 Setup Menu.

The following controls are available in the Setup Menu:

Unit selector. Select between English (in) and Metric (mm) units.

Contact selector. Choose which contactor(s) will be used - Drive unit contactor,

Programmable module contactor, both or neither.

Stitch Parameter setup. Configure and save stitch parameters.

Exit. Return to Main Operating screen.

STITCH PROGRAM SETUP

To configure the stitch parameters use button from the Setup menu. The User will be
prompted to set the stitch parameters one at a time. Each setup screen shows the parameter to be
set and its current value. The setup screen for travel speed while welding is shown in figure 4.

Figure 4: Setup scr een for travel speed while welding.

7

STITCH PROGRAM SETUP (CONT’D.)

The following controls are used when configuring the stitch parameters:

Increase or Decrease value

Enter. Accept value and proceed to next parameter

Undo. Reset current parameter

Save.

The stitch parameters are listed below in the order that they appear during setup.

Travel speed of the tractor when welding.

NOTE: This is the default speed setting when the unit is powered up. T ractor speed
can also be changed while welding or from the Main Operating screen, but those changes
will NOT be saved.

Puddle buildup time.

Weld length.

Back-step distance after the weld.

Crater-fill time.

Skip distance.

Number of welds to perform before stopping.

Home Distance. User defines Home position relative to the start of the first weld. Use this

feature to minimize machine interference when changing work pieces.

8

STITCH PROGRAM SETUP (CONT’D.)

End of Cycle Action. Select between Stop at Limit or Rapid Return mode. With

Stop at Limit, the machine will stop in place upon completion of the last weld in the
program. In Rapid Return mode, the machine will return to Home upon completion of the
last weld.

MODES OF OPERATION

The MDS-1004 offers three operating modes - New, Resume, and Manual. The current mode

is displayed in the lower right corner of the upper screen portion for any operating screen (see figure

2).
From the Main Operating screen, use button to change the operating mode.

New Stitch Weld Mode

Use New stitch weld mode when setting up a new weld start position or a new weld pattern.

This is the default operating mode for the MDS-1004. After setting-up the stitch program, position
the drive unit so that the welding gun is positioned at the beginning of the first weld. To begin
welding, ENABLE the weld contactor(s) then START the machine in forward.

NOTE: It is not necessary to ENABLE and ST ART at the same time.

Resume Mode

Resume mode can only be used after a stitch weld has been started in New stitch weld mode.

Resume mode allows the User to stop the machine during a weld pattern and resume welding in
the same location or move the machine anywhere within the weld pattern then resume welding at
the machine's current position. This is useful if a previous weld was not complete or has to be re­welded.

Resume mode is also used when the same weld pattern is to be performed on multiple work

pieces. To do this, the User should set an appropriate Home Distance and select Rapid Return for
the End of Cycle Action. Upon completion of the last weld, the machine will return to the Home
position and the operating mode will default to Resume mode. Position the new work piece and
START the machine in forward to repeat the stitch weld pattern. The machine will advance to the
start of the first weld then begin welding.

Manual Mode

Manual mode gives the User full control over the weld process and allows the User to weld

without configuring a stitch program. This is useful for creating continuous welds. When operating
in Manual mode, ENABLING the weld contactor will immediately turn it ON. Motion must be started
and stopped separately. DISABLE the weld contactor to turn it OFF.

CAUTION: In manual mode, enabling the contactor will turn it ON, immediately!

9

ENABLING CONTACTOR(S)

From the Main Operating screen, use button to enable or disable the selected weld

contactor(s). An icon will appear in the upper right hand corner of the display, indicating that the
contactor is ON or ENABLED. When the contactor is DISABLED, no status icon appears on the
operating screen (refer to figure 2).

NOTE: User must ENABLE weld contactor before ST ARTING in New or Resume mode.

Contactor ENABLED. Contactor will cycle ON and OFF according to the stitch weld

program after the machine is started.

CAUTION: In manual mode, enabling the contactor will turn it ON!

Contactor ON.

MOTION CONTROL

The Modular drive unit can operate in forward or reverse. Motion control options vary based on

the current state of the machine. An overview of the motion control options is provided below.

START machine in the forward direction.

Start machine in the reverse direction.

Increase or Decrease value. This icon indicates that the setting in the top half of the

screen can be adjusted by turning the corresponding knob.

STOP machine motion.

CAUTION: STOPPING the machine in manual mode will NOT turn weld contactor OFF.
User must DISABLE contactor .

Return to Home.

After the machine is started and is moving, the unnecessary controls are removed from the
bottom half the display as shown in figure 5. Notice how the Select Mode button is now the Stop
button.

10

Figure 5: Machine Running Scr een

STITCH PROGRAM EXAMPLE

The following is a step-by-step example for setting up and using the MDS-1004 to perform

stitch welding.

Program the MDS-1004 to weld 6 stitches, 3.5 in. long and spaced 9.0 in. apart. Set puddle
build-up and crater fill times both at 0.3 seconds, and back-step distance to 0.1 inch. Assume
this pattern will be used on several work pieces, so the machine should be set to return 6.0 in.
beyond the start of the first weld to allow change-out of work pieces.

1. Connect MDS-1004 to Modular Drive Unit.

2. Set-up the Modular Drive Unit on the appropriate rail.

3. Connect weld contactor on Modular Drive Unit to welding feed system.

4. Turn Modular Drive Unit ON.

5. Change Operating Mode to MANUAL . Use Mode Select button .

6. Use Motion Controls to position welding gun at start of first weld .

7. Change Operating Mode to NEW STITCH WELD . Use Mode Select button .

8. Go to the Setup menu .

9. Set Units to ENGLISH (IN).
a. Open the Unit Selector menu .
b. Use control knob to select desired units.
c. Press ENTER to accept changes and return to Setup menu.

11

10.Select Contactor(s) to be used.
a. Open Contact Selector menu .
b. Use control knob to select desired contactor arrangement.
c. Press ENTER

to accept changes and return to Setup menu.

11.Setup Stitch Parameters.
a. Open Stitch Parameter Setup
b. Press ENTER
c. Set Tractor speed

after each parameter is set.

. Use control knob to adjust speed to 10 in/min.

.

d. Set Puddle buildup time . Use control knob to adjust time to 0.3 sec.
e. Set Weld length . Use control knob to adjust length to 3.5 in.
f. Set Back-step distance . Use control knob to adjust distance to 0.1 in.
g. Set Crater fill time . Use control knob to adjust time to 0.3 sec.
h. Set Skip distance . Use control knob to adjust distance to 9 in.
i. Set Number of welds . Use control knob to adjust number of welds to 6.
j. Set Home distance . Use control knob to adjust distance to 6.0 in.
k. Select End of cycle action. Use control knob to select Rapid Return mode .
l. Save Stitch Parameters .

12.EXIT Setup Menu and return to Main Operating screen.

13. Enable weld contactor. Use Contactor Enable button from Main Operating Screen.
Look for the ENABLED icon in upper right corner of display .

14.Start welding. Use Start forward motion button to begin weld program.

15.Adjust machine speed while welding. From the Main Operating screen, use the control knob
to adjust this speed.

NOTE: This example assumes the use of FCAW , 0.045" diameter wire; 75 Ar/25 CO2

12

shielding gas; 220 ipm wire feed; 24V .

WARRANTY

Model ____________________________

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.

Serial No. _________________________
Date Purchased: ___________________

13

NOTES: