BUG-O Systems Modular Drive System User Manual

INSTRUCTIONS

AND

PARTS MANUAL

MODULAR DRIVE

SYSTEM

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-MDS-IPM-0215

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

1) The equipment is not waterproof. Using the unit in a wet environ- ment 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.

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.

EQUIPMENT DAMAGE

ELECTRIC SHOCK can kill.

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 apply ing power or equipment damage may occur.

POSSIBLE.

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 equip ment power cord ground. Verify the

equipment is grounded in accor-

dance with all applicable local and national electrical safety codes. If none exist, use International Electric Code (IEC) 950.

READ INSTRUCTIONS.

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 mov ing except by removing power or by using the STOP control.

Read the instruction manual before installing and using the equipment.

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

HIGH FREQUENCY WARNINGS

SPECIAL PRECAUTIONS ARE REQUIRED WHEN USING PLASMA,

TIG OR ANY WELDING PROCESS THAT USES HIGH FREQUENCY TO

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.

STRIKE AN ARC.

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.

MODULAR DRIVE SYSTEM

INSTRUCTIONS AND PARTS MANUAL

TABLE OF CONTENTS

PAGE

5.............. Introduction / Standard Features

6.............. Additional Features

7.............. Setup

8.............. Master Drive Unit / Technical Data / Dimensions

9 ........... MPD-1000 Master Drive Unit / Exploded View / Parts List

10 ......... Master Drive Unit / Wiring Diagram

11 ......... AC Power Wiring Diagram / Electrical Component Chart

12 ......... Signal Wiring / Parts List

13............ Modules / Technical Data / Dimensions

14 ......... MDS-1002 Straight Module

15-16 ... MDS-1003 Stitch Module

17 ......... MDS-1004 Programmable Module

18-19 ... MDS-1005 / MDS-1005-DIAL / Weaver Control Modules

20 ......... MDS-1005 / MDS-1005-DIAL / Weaver Control Module Replacement Parts

21 ......... Digital Readout Calibration

22............ WPD-1000 Linear Weaver / Introduction / Features

23 ......... Linear Weaver / Technical Data / Dimensions

24-25 ... Linear Weaver / Setup

26 ......... WPD-1100 Linear Weaver / Exploded View

27 ......... WPD-1100 Linear Weaver / Parts List

28............ WPD-2100 Pendulum Weaver II / Introduction / Features

29-30 ... Pendulum Weaver II / Installation / Setup and Alignment

31 ......... Pendulum Weaver II / Technical Data / Dimensions

32 ......... WPD-2100 Pendulum Weaver II / Exploded View / Parts List

33 ......... WPD-2120 Pendulum Weaver II / Electronics / Exploded View / Parts List

34 ......... WPD-2115 Pendulum Gear Box / Exploded View

35............ Weaver Unit / Wiring Diagram

36............ Carriages

37............ Detailed Setup

38............ MDS-1055 Universal Limit Kit

39............ MDS-1060-_ Remote Control Cable

39............ CAS-__ Automatic Height Control

40............ Accessories

41............ Aluminum Rigid Rail

42............ Semi Flex Rail

43............ Hi-Flex Rail

44............ Standard Magnet Assemblies

45-46 ...... Vacuum Support Kit

47-56 ...... Troubleshooting Guide

57............ Warranty

INTRODUCTION

The Modular Drive System is the only product in the industry that allows the user to custom congure one machine for various applications. The system consists of drives, plug-in control modules and carriages that are easily assembled. The modular design allows the operator to quickly upgrade or recongure the machine for straight line cutting and welding, stitch welding or weave welding. The system will run in any position using Aluminum Rigid Rail, Aluminum Semi-Flex Rail [with a minimum radius of 15' (4.57 m)], Bent Rigid Rail or Hi-Flex Rail [with a minimum radius of 40" (1 m)].

The straight line cutting and welding conguration consists of a carriage, master drive, racking group and control module. The optional MDS-1060-10 Remote Control Cable can be used to remote the control module.

A number of straight line control modules are available. The MDS-1002 Straight Line Module provides simple direction and speed control for continuous cutting or welding. The MDS-1003 Stitch Module provides a straight line and stitch welding mode with skip time, weld time and crater/puddle buildup time. The MDS1004 Programmable Stitch Module provides digital display of all stitch welding parameters. The MDS-1004 Stitch Module has closed position feedback so all distances are set in inches or mm as opposed to time and are repeatable. The MDS-1055 Universal Limit Kit adds cycler, stop at limit and rapid return functions to the MDS-1002 and MDS-1003 modules. The MDS-1004 Programmable Module has built in stop at limit and rapid return modes. For more features, see the appropriate pages on each of the modules.

The Master Drive is rated at 60 lbs (27 kg) vertical load. (International Robotics Standards Rating)** The machine is equipped with overload protection.

STANDARD FEATURES

The Master Drive Unit incorporates the following standard internal features:

• High torque, low inertia motor for precise stops and starts.

• Dedicated fail-safe brake with three times the stopping and holding power of the motor.

• Motor overload protection which turns off the motor and engages the brake when excessive load is

placed on the machine.

• Closed loop speed control for adjustable and repeatable control of critical welding or cutting parameters.

• Closed loop position control to prevent position creep when the machine stops to perform an operation

such as crater ll at the end of a stitch weld.

**The International Robotics Standards Rating requires a minimum of 2:1 continuous-duty safety margin on all power train and electronics components.

ADDITIONAL FEATURES

1. Control Module that is easily remoted or changed.

2. Master Power Drive Module that is recongurable by the user, for different applications, by

adding or changing mating modules and accessories.

3. Clutch, to enable rapid manual repositioning of the carriage anywhere on the track.

4. Wheel engagement knob, which enables placement of the releasable carriage anywhere on

the track.

5. Optional cable mounting bar with anchor clamp to keep the welding cables and contact wires away from the work surface.

6. Contactor ON/OFF switch.

7. Power Entry Box with:

a) Input Power Fuse b) Machine ON/OFF Switch c) Power Cord Mating Connector

8. Standard Carrying Handle.

9. Digital speed readout for more repeatable welding/cutting.

10. Optional Carrying Handle and Mounting Bar.

11. Remote Weld Contactor Receptacle.

SETUP

1) WHEEL ADJUSTMENT AND ALIGNMENT

Always check for proper carriage wheel adjustment before using the machine. Turn the wheel engagement knob (A) on the side of the carriage until the wheels are fully moved towards the center of the carriage (engaged). Then rotate the master drive clutch knob (B) fully counter clockwise to disengage the drive pinion. Slide the carriage onto the end of a track. The wheels should slide into the track V-grooves and the carriage will move smoothly along the track if the wheels are properly aligned.

The wheels along one side of the carriage have stainless steel shim washers (C) underneath. These wheels are adjustable. Readjust these wheels (if

necessary) by rotating the hex bolt (D) with a 1/2" wrench.

Grasp the sides of the carriage. The wheels are too loose if it is possible to move the carriage from side to side or up and down. Use a nger to keep one of the adjustable wheels from rotating as the carriage is manually pushed along the track. The wheels are adjusted too tight if rm nger pressure is not enough to prevent wheel rotation. Repeat the process for the other adjustable wheel.

2) POSITIONING THE MACHINE ON THE TRACK

Position the rail using magnet plates or vacuum cups. Wipe the track grooves free of weld splatter and other debris. This will prevent binding and premature rail and wheel wear. Lubricate the rack using a dry spray, if desired, for extended track life.

Turn the wheel engagement knob (A) on the side of the carriage fully counter clockwise to disengage the wheels. Then rotate the Master Drive clutch knob (B) fully counter clockwise to disengage the drive pinion. The carriage can now be placed anywhere on the track. Turn the wheel engagement knob (A) clockwise to engage the wheels rmly in the V-grooves. Verify all four wheels are in the grooves. Manually move the carriage along the track to verify the motion is smooth and the wheel alignment is correct. Rotate the Master Drive clutch knob (B) fully clockwise while gently rocking the machine forward and backward to fully engage the drive pinion. The rocking motion is necessary to help insure proper gear mesh.

3) REMOTE CONTACTOR WIRING

Connect the remote weld contactor to the welding source as shown below:

Pins A and B ................. connection for Output #1

Pins C and D ................ connection for Output #2

4) GUN AND TORCH SETUP

For cutting, insert the cutting torch into the torchholder on the rack. Adjust the torchholder, the clamp block and the rack to position the torch for cutting. Connect the hose assembly to the manifold and the cutting torch. The manifold acts as a strain relief on the supply hoses as well as a quick shut-off valve for the gases. Once the torch valves are adjusted, the manifold eliminates the need for continuous adjustments and keeps the supply lines from dragging the torch out of position.

5) MACHINE OPERATION

Turn the main power ON at the power entry box. Set parameters on control module in use.

MASTER DRIVE UNIT / TECHNICAL DATA

Power Requirements:

Part Number Voltage / Hz Amps

MPD-1000 120 VAC/50-60 Hz 2A MPD-1002 240 VAC/50-60 Hz 3A MPD-1004 42 VAC/50-60 Hz 6A

Dimensions: 7.75" L x 6.00" W x 4.25" H

(197 x 152 x 108 mm)

Load Capacity: Vertical - 60 lbs (27 kg) [International Robotics Standards Rating]** Horizontal - 100 lbs (45 kg)

Speed Range: 2-120 in/min (51-3048 mm/min)

Net Weight: 10 lbs (4.5 kg)

Shipping Weight: 13 lbs (5.9 kg)

DIMENSIONS

7.13

(181 mm)

6.00

(152 mm)

7.75

(197 mm)

4.25

(108 mm)

** The Master Drive is rated at 60 lbs (27 kg) vertical load. The International Robotics Standards Rating requires a minimum of 2:1 continuous-duty safety margin on all power train and electronics components. The machine is equipped with overload protection.

CAUTION: The Speed Control Card in the Master Drive is NOT interchangeable

with the speed card in the Linear or Pendulum Weavers.

MPD-1000 MASTER DRIVE UNIT / EXPLODED VIEW / PARTS LIST

ITEM QTY PART NO. DESCRIPTION

1 1 BUG-1034 Panel Connector, 4-T, Male 2 1 WPD-1013 Rubber Ring Gasket 3 1 BUG-9444 Tool Kit 4 4 FAS-0104 Pan Hd Screw 4-40 x 318 Lg

5 2 FAS-0107 Pan Hd Screw 4-40 x 3/4 Lg 6 6 FAS-0114 Pan Hd Screw 6-32 x 3/8 Lg 7 4 FAS-0504 Soc Hd Cap Scr 4-40 x 3/8 Lg 8 4 FAS-0557 Soc Hd Cap Scr 1/4-20 x 3/4 Lg 9 3 FAS-0902 Fit Hd Soc Scr 4-40 x 1/4 Lg 10 19 FAS-0905 Fit Hd Soc Scr 4-40 x 1/2 Lg 11 11 FAS-0914 Fit Hd Soc Scr 6-32 x 3/8 Lg 12 1 FAS-0915 Fit Hd Soc Scr 6-32 x 1/2 Lg 13 8 FAS-0923 Fit Hd Soc Scr 8-32 x 5/16 Lg 14 6 FAS-1305 Hex Nut 4-40 15 3 FAS-1310 Hex Nut 6-32 16 2 FAS-1325 Hex Nut 8-32 Nylon 17 1 FAS-2823 Fit Hd Sit Scr 8-32 x 1 1/2 Lg 18 1 GOF-3012 Spacer 1/2 OD x 5/16 Lg

19 1 GOF-3014 Pinion

20 4 MDS-1019 Snap Rivet, Black *21 1 BUG-9454 V-Lock Cord 120VAC

22 1 MPD-1006 Side Panel

23 1 MPD-1007 Heat Sink

24 1 MPD-1008 Filter

25 1 MPD-1009 Fan Assembly

26 1 MPD-1011 Base Panel

27 2 MPD-1012 Mounting Block 28 1 MPD-1090 Matched Clutch Plts **29 1 BUG-2593 Glide Flat 30 1 MPD-1015 Gear Motor (60:1) 31 1 MPD-1016 Clutch Assembly (Includes items 32 through 37)

32 1 BUG-1216 Ball Joint

33 1 BUG-1857 Knob 34 1 FAS-0945 Fit Hd Soc Scr 10-32 x 1/2 Lg

35 1 FAS-1341 Hex Jam Nut 10-32 36 2 FAS-1390 Hex Nut 3/8-16 37 1 MPD-1017 3/8-16 Threaded Stud

38 1 MPD-1018 Wiring Harness-Speed Board to Motor 39 1 MPD-1019 Wiring Harness-Interconnect to Speed Bd/Control

40 1 MPD-1020 Wiring Harness-Interconnect to Speed Bd/Power

5 47

41 1 MPD-1025 Power Entry Module * 42 1 MPD-1067 Fuse 6A 43 1 MPD-1029 Connector Cover Plate 44 1 MPD-1031 Cover Panel (Includes item #20) 45 1 MPD-1038 Gasket for 50-Pin Connector 46 1 MPD-1039 Gasket for 50-Pin/3-Pin Connector 47 1 MPD-1042 Inductor, Potted-with Connectors 48 1 MUG-1617 Cable Connector, 4-T, Female, Elbow *49 1 PCB-1000 Speed Board * 50 1 PCB-1005-120 Power Supply Assembly 165W 120VAC

51 1 PCB-1010 Interconnect Board 52 1 PCB-1012 Position Card

53 6 WAS-0201 #4 Internal Star Lockwasher 54 3 WAS-0211 #6 Internal Star Lockwasher 55 1 WPD-1012 Brake Assembly

* See Electrical Component Chart for 240 VAC and 42 VAC Part Numbers **Included in Item 28.

CAUTION: The Speed Control Card in the Master Drive is NOT interchangeable with the speed card in the Linear or Pendulum Weavers.

MASTER DRIVE WIRING DIAGRAM MPD-1000/ MPD-1002/ MPD-1004

120V AND 240V WIRING ONLY SEE FIGURE 1 FOR 42V WIRING

NOTES:

Encoder card and brake are mounted on the motor. 18 pin connectors are not wired 1:1.

The Connector on one end is ipped.

For example, Pin 1 goes to connector 18.

Most signals on the 50 pin connector come in one 50 pin connector and exit on the other 50 pin connector.

Pinouts for connectors can be determined from screen print.

AC POWER WIRING DIAGRAM

PEM

BLK

RED

*F2

FUSE BOX

42 VAC

BLK BLU

RED

GRN

RED

RED BLK

BLK

RFI

115 VAC

240 VAC

GRN

POWER

OUT

BLK

BLU

PS PS

DC OUT

RED

DC OUT

ELECTRICAL COMPONENT CHART

MPD-1000 MPD-1002 MPD-1004 ITEM DESCRIPTION 120 VAC 240 VAC 42 VAC

F1,F2* Fuses (2) MPD-1067 6A (2) MPD-1067 6A (2) MPD-1067 6A

PC Power Cord MPD-1030 MPD-1032 MPD-1034

PS Power Supply PCB-1005-120 PCB-1005-240 PCB-1005-42

J1 Connector w/Pins MPD-1021 MPD-1021 MPD-1021

PEM Power Entry Module MPD-1025 MPD-1025 MPD-1025

RFI Filter Module MPD-1008 MPD-1008 MPD-1008

*F2 replaced with bus wire on 120 VAC

PART NO.

SIGNAL WIRING

A B C D

FROM

CONTROL

MODULE

WHT/RED WHT/BLK WHT/OR

RED

BLK

PUR PUR YEL YEL

50 LINE

RIBBON

+ 15 V GND

- 15 V

FAN + FAN -

CONTACT

2 3 4

CONTACT

INPUTS

INTERCONNECT

+ 15 V GND

- 15 V

SPEED

CARD

SIGNALS

OUTPUTS

PCB 1

WHT/RED WHT/BLK WHT/OR

18 LINE

50 LINE

RIBBON

MOTOR

OUT

POSITION

IN AND BRAKE

OUT

SPEED

CONTROL

PCB 2

OSCILLATOR

ACCESSORIES

BLK

RED

10 LINE

RIBBON

CHOKE

PCB 3

POSITION

GEAR

MOTOR

BRAKE

PARTS LIST

ITEM DESCRIPTION PART NO.

B Brake Assembly WPD-1012

Cl Contactor Cable Assembly MPD-1036

C2 DC Power Cable Assembly MPD-1020

C3 Speed Card Cable Assembly MPD-1019

C4 Motor Wiring MPD-1018

CK Inductor Pot Assembly (Choke) MPD-1042

F Fan Assembly MPD-1009

M Gear Motor MPD-1015

PCB1 Interconnect Card PCB-1010

PCB2 Tractor Speed Card PCB-1000

PCB3 Position Sensor Card PCB-1012

PS Power Supply (see AC Wiring Diagram)

MODULES / TECHNICAL DATA

MDS-1002 STRAIGHT LINE MODULE MDS-1003 STITCH MODULE MDS-1004 PROGRAMMABLE MODULE MDS-1005 WEAVER CONTROL MODULE

Dimensions: 7.50" L x 6.00" W x 2.50" H

(191 x 152 x 64 mm)

Net Weight: 1.75 lbs (0.8 kg)

Shipping Weight: 3.0 lbs (1.4 kg)

MDS-1005-DIAL WEAVER CONTROL MODULE

Dimensions: 7.50" L x 6.00" W x 3.38" H

(191 x 152 x 86 mm)

Net Weight: 3 lbs (1.4 kg)

Shipping Weight: 8 lbs ( 3.63 kg)

DIMENSIONS

6.00"

(152 mm)

MDS-1002 MDS-1003 MDS-1004 MDS-1005

Dial Weaver Control Module

6.00"

(152 mm)

2.50"

(64 mm)

7.50"

(191 mm)

3.38"

(86 mm)

7.50"

(191 mm)

MDS-1002 STRAIGHT MODULE

The MDS-1002 Straight Module provides direction and speed control for continuous cutting or welding.

DIGITAL READOUT

SPEED CONTROL

CARRIAGE TRAVEL SWITCH

WELD CONTACT (PLASMA)

SPEED CONTROL: Sets the tractor speed from 2-120 in/min (5.1-304.8 cm/min).

CARRIAGE TRAVEL SWITCH: Provides FORWARD/STOP/REVERSE direction control.

Stop at limit in direction of travel & Cycle between limits can be controlled with the installation of the MDS-1055 Universal Limit Kit. (Ref to pg. 38)

DIGITAL READOUT: The display is dual function.

a) PRESET SPEED - Displayed when the CARRIAGE TRAVEL SWITCH is OFF or motion

is halted by a motor overload condition. b) MEASURED SPEED - Displayed when power is applied to the motor. (This will be the same as the Preset Speed.)

Factory settings of 120 Volt machines are set to in/min, 240 and 42 Volt machines are set cm/min.

WELD CONTACT: Opens/closes a pair of independent 1 Amp contacts (pins A & B and C & D) at the weld

contactor receptacle.

NOTE: A safety interlock will automatically open the weld contacts if the motor overload protection halts ma-

chine motion. Clear the overload by turning the carriage travel switch to OFF. Resetting the overload

fault will not cause the contacts to automatically reclose. Use the weld contact switch to restart the

welder plasma unit after clearing the overload.

REPLACEMENT POTS AND SWITCHES

CARRIAGE TRAVEL: Switch and Spacer MDS-1112

Black Pointer Knob BUG-9694

SPEED CONTROL: 10 K Ω Pot, 3-3/4 turn PCB-1026

Black Knob MDS-1018 Knob Seal Nut MDS-1046

WELD CONTACT: Switch and Spacer MDS-1115

Toggle Switch Boot MDS-1047

MDS-1003 STITCH MODULE

The MDS-1003 Stitch Module provides direction and speed control for continuous welding and cutting. In addition, a stitch welding mode is provided, with adjustments for skip time (welder off), weld on time and puddle buildup/crater ll time.

MDS-1003

SKIP TIME

SPEED CONTROL

MODE

STITCH MODULE

DIGITAL READOUT

WELD TIME

PUDDLE BUILDUP/CRATER FILL TIME

CARRIAGE TRAVEL SWITCH

WELD CONTACT (PLASMA)

SPEED CONTROL: Sets the tractor weld speed from 2-120 in/min (5.1-304.8 cm/min).

CARRIAGE TRAVEL SWITCH: Provides FORWARD/STOP/REVERSE direction control.

DIGITAL READOUT: The display is dual function.

a) PRESET SPEED - Displayed when the CARRIAGE TRAVEL SWITCH is OFF

or motion is halted by a motor overload condition.

b) MEASURED SPEED - Displayed when power is applied to the motor. (This will

be the same as the Preset Speed.)

Factory settings of 120 Volt machines are set to in/min, 240 and 42 Volt machines are set cm/min.

WELD CONTACT: Opens/closes a pair of independent 1 Amp contacts (pins A & B and C & D) at the

weld contactor receptacle. In STITCH mode, this switch acts as a weld contact enable and the stitch module cycles the contacts on and off.

NOTE: A safety interlock will automatically open the weld contacts if the motor overload protection halts

machine motion. Clear the overload by turning the carriage travel switch to OFF. Resetting the overload fault will not cause the contacts to automatically reclose. Use the weld contact switch to restart the welder after clearing the overload.

MDS-1003 STITCH MODULE, CONT’D.

STITCH/CONTINUOUS: Selects between cyclic (Stitch) welding and continuous welding or cutting.

a) CONTINUOUS - Selects continuous welding or cutting.

b) STITCH - Selects the cyclic (Stitch) welding mode. This mode consists of four continuously repeated steps.

1) The machine stops moving for the selected time to perform Puddle Buildup. (PIERCE WHEN PLASMA CUTTING)

2) The machine welds at the selected welding speed for the time selected using the Weld Time control.

3) The machine stops moving for the selected time to perform Crater Fill.

4) The machine turns off the welder and moves at maximum speed to

where the next weld needs performed. This location is determined by

setting a Skip Time control.

WELD TIME: This control functions only when the mode switch is set to Stitch. Weld time sets a weld

length time from 1-50 seconds. This corresponds to a weld length of approximately 0.03-100 inches (0.82540 mm). NOTE: The operator must manually enable the weld contactor by turning on the Weld Contact or the welder will never cycle on and off.

SKIP TIME: This control functions only when the mode switch is set to Stitch. Skip time sets how long the machine travels between welds (0.3-15 seconds). This corresponds with a skip length of approximately 0.630 inches (15-762 mm). The machine always moves between welds at maximum speed.

PUDDLE BUILDUP / CRATER FILL TIME: This control functions only when the mode switch is set to Stitch. Puddle Buildup/Crater Fill Time sets the time the machine is stopped at the beginning and end of

every weld (0-1.5 sec).

REPLACEMENT POTS AND SWITCHES

WELD CONTACT: CARRIAGE TRAVEL SWITCH: Switch and Spacer MDS-1116 Switch and Spacer MDS-1112

Toggle Switch Boot MDS-1047 Black Pointer Knob BUG-9694

PUDDLE BUILDUP/CRATER FILL TIME: WELD TIME: 500K Ω Pot, 3/4 turn MDS-1053 500K Ω Pot, 3/4 turn MDS-1053

Black Knob MDS-1018 Black Knob MDS-1018 Knob Seal Nut MDS-1046 Knob Seal Nut MDS-1046

SKIP TIME: SPEED CONTROL:

500K Ω Pot, 3/4 turn MDS-1053 10K Ω Pot, 3 turn PCB-1026 Black Knob MDS-1018 Black Knob MDS-1018 Knob Seal Nut MDS-1046 Shaft Seal Nut MDS-1046

MODE:

Switch and Spacer MDS-1115 Toggle Switch Boot MDS-1047

MDS-1004 PROGRAMMABLE MODULE

The MDS-1004 PROGRAMMABLE MODULE provides stitch controls for welding or cutting with the Modular Drive System. All stitching parameters are set and displayed on a graphic screen. This allows each setting to be set exactly the same every time. See MDS-1004 Manual for detailed instructions.

Display

Controls

Extra Contactor Output

FEATURES

• Each stitch setting is displayed while being set. This allows each setting to be exactly set each time a job is set up.

• Closed loop encoder feedback is employed to ensure the traveled distances match the set distances.

• The module provides an extra contactor output. This output and the output on the Modular Drive can

be disabled or enabled independently.

• The module will stop the machine or return it to start after a preset number of welds. This eliminates the need for external limit switches.

• This unit can return past the start location to allow for work piece changes. One button will start the whole welding procedure.

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

• Puddle-buildup and Crater-ll timers are independent.

WEAVER CONTROL MODULES

MDS-1005 WEAVER CONTROL MODULE

The MDS-1005 Weaver Control Module provides weave welding control functions.

MDS-1005

WEAVE SPEED

DWELL LEFT

STEERING

CONTROL

TRACTOR SPEED

CONTROL

MODE SELECTOR

SWITCH

START/STOP

WEAVE

MODULE

WEAVE AMPLITUDE

DIGITAL READOUT

DWELL RIGHT

CARRIAGE TRAVEL SWITCH

WELD CONTACT

MDS-1005-DIAL WEAVER CONTROL MODULE

The MDS-1005 Dial Weaver Control Module provides weave welding control functions with 3 turn digital dial pots for the weave speed, weave amplitude, dwell left and right. The addition of the dial pots allows for precise and repeatable setting of all parameters. The dial pots also enable repeatable parameter settings from machine to machine. All dials vary from 0-300 which corresponds to the setting the parameter from 0 to its MAX value. For example, a 300 setting for weave amplitude corresponds to 2" of weave amplitude which is its max value. The DIGITAL READOUT provided for the tractor speed displays in either inches per minute or centimeters per minute directly.

WEAVE SPEED

DWELL LEFT

STEERING

CONTROL

TRACTOR SPEED

CONTROL

MODE SELECTOR

SWITCH

START/STOP

WEAVE AMPLITUDE

DIGITAL READOUT

DWELL RIGHT

CARRIAGE TRAVEL SWITCH

WELD CONTACT

WEAVER CONTROL MODULES, CONT’D.

AMPLITUDE (WEAVE): Continuously adjustable up to a 2" (51 mm) maximum weaver stroke.

CARRIAGE TRAVEL SWITCH: Provides FORWARD/STOP/REVERSE direction control.

DIGITAL READOUT: Three tractor display modes exist.

a) PRESET SPEED - Displayed when the CARRIAGE TRAVEL SWITCH is OFF or motion is

halted by a motor overload condition.

b) CONTINUOUSLY MEASURED SPEED - Displayed when the MODE SELECTOR SWITCH

setting is RUN or NO WEAVE. (This will be the same as the Preset Speed.)

c) SAMPLED SPEED - The tractor motion alternates between moving at the Preset Speed and

stopping when the MODE SELECTOR SWITCH is set to STEP or STOP ON DWELL. This is referred to as “stepping” the tractor. To avoid having the display continuously uctuate between the zero speed and the actual speed, the readout measures the travel speed near the end of each tractor step. This speed is then displayed until another sample is taken at the end of the next tractor step. This provides a stable display of the measured travel speed. (This will be the same as the Preset Speed.)

Factory settings of 120 Volt machines are set to in/min, 240 and 42 Volt machines are set cm/min.

LEFT AND RIGHT DWELL: The left and right dwell controls have a 0-3 second adjustment range.

MODE SELECTOR SWITCH: Four welding modes are available.

1) RUN - In this mode, power to the drive unit is always on

and the machine travels continuously both during weave and dwell. Weave speed and dwell time both affect the weave pattern.

2) STEP - The unit travels only during dwell and stops during the weaver cross stroke. Changing weave speed does not effect the weld pattern-dwell time does.

3) TRACTOR STOP ON DWELL - The tractor travels during the weave stroke; the tractor and weaver stop during dwell.

4) NO WEAVE - In this mode oscillation is stopped. Only the tractor is powered. This mode is used for stringer passes.

SPEED CONTROL (TRACTOR): Sets the tractor speed from 2-120 in/min (5.1-304.8 cm/min).

START/STOP: This enables/disables all tractor and weaver motion.

STEERING: The three-turn steering knob has a +/- 2" (51 mm) range.

WEAVE SPEED CONTROL: Sets the weave speed from 0-100 in/min (0-254 cm/min).

WELD CONTACT: Opens/closes a pair of independent 1 Amp contacts (pins A & B and C & D) at the weld

contactor receptacle.

NOTE: A safety interlock will automatically open the weld contacts if the motor overload

protection halts machine motion. Clear the overload by turning the carriage travel switch to off. Resetting the overload fault will not cause the contacts to automatically reclose. Use the weld contact switch to restart the welder after clearing the overload.

MDS-1005 / MDS-1005-DIAL WEAVER CONTROL MODULE REPLACEMENT PARTS

REPLACEMENT POTS AND SWITCHES MDS-1005 MDS-1005-DIAL

WELD CONTACT:

CARRIAGE TRAVEL SWITCH:

DWELL RIGHT:

AMPLITUDE:

WEAVE SPEED:

STEERING CONTROL:

DWELL LEFT:

TRACTOR SPEED CONTROL:

MODE SELECTOR SWITCH:

START/STOP:

Switch and Spacer MDS-1114

Toggle Switch Boot MDS-1047

Switch and Spacer MDS-1117

Toggle Switch Boot MDS-1047

500K Ω Pot MDS-1053

Black Knob MDS-1018

Knob Seal Nut MDS-1046 50K Ω Pot, 3 turn MDS-1079 Knob, Digital Dial BUG-3297

Dial Spacer BUG-3302

10K Ω Pot MDS-1052 MDS-1078 (3 turn)

Black Knob MDS-1018

Knob Seal Nut MDS-1046 Knob, Digital Dial BUG-3297

Dial Spacer BUG-3302

10K Ω Pot MDS-1052 MDS-1078 (3 turn)

Black Knob MDS-1018

Knob Seal Nut MDS-1046 Knob, Digital Dial BUG-3297

Dial Spacer BUG-3302

10K Ω Pot, 3 turn PCB-1027

Black Knob BUG-5757

Knob Seal Nut BUG-5759

500K Ω Pot MDS-1053

Black Knob MDS-1018

Knob Seal Nut MDS-1046 50K Ω Pot, 3 turn MDS-1079 Knob, Digital Dial BUG-3297

Dial Spacer BUG-3302

10K Ω Pot, 3 turn PCB-1024

Knob MDS-1044

Shaft Seal Nut BUG-5759

Switch and Spacer MDS-1113

Black Pointer Knob BUG-9694

Switch and Spacer MDS-1115

Toggle Switch Boot MDS-1047

DIGITAL READOUT CALIBRATION

Internal Control Module adjustments enable the user to change between cm/min and in/min. The display can also be recalibrated, if required, to give an accurate speed readout.

STEP 1: Remove endplate.

STEP 2: Set Switch 1 & 2:

SW 1 SW 2

in/min Down Down

cm/min Up Down

STEP 3: Apply power to the Modular Drive.

Maximize the tractor speed using the Control Module front panel. Do not change this speed for the rest of the procedure.

STEP 4: Calculate the speed of the

machine by measuring how far it moves in a certain amount of time.

STEP 5: Set the speed display to

the measured speed using a small slotted screwdriver.

STEP 6: Verify accuracy of speed

display to actual speed

and repeat steps 4 & 5 as needed.

STEP 7: Reinstall endplate.

WPD-1100 LINEAR WEAVER

INTRODUCTION

The Linear Weaver and Weaver Control Module add weave welding capability to the Modular Drive System. The Linear Weaver bolts onto the front of the carriage and the Weaver Control Module plugs into the top of the Master Drive Unit. The optional MDS-1060 Remote Control Cable can be used to remote the Control Module.

FEATURES

The Linear Weaver and Weaver Control Module incorporate the following standard features:

• High torque, low inertia motor for precise stops and starts.

• High speed Linear Weaver for weaving, with independent control of right and left dwell times.

• High motor gearing which prevents the crossarm from moving when the unit is turned off.

• Closed loop speed control for adjustable and repeatable control of critical welding or cutting parameters.

• Closed loop position control to prevent drift from the center weld position.

• Clutch, to enable rapid installation or replacement of the weaver cross arm.

• Gun mounting group with adjustable racking block for accurate positioning of the gun.

• Contactor ON/OFF switch.

The gure below shows how the Linear Weaver and Weaver Control Module connect to the carriage and Master Drive Unit.

GUN MOUNTING GROUP

LINEAR WEAVER

CROSS ARM

LINEAR WEAVER

WEAVER

CONTROL

MODULE

WEAVER CLUTCH (KNOB ADJUSTMENT)

CARRIAGE

MASTER DRIVE UNIT

TECHNICAL DATA

WPD-1100 LINEAR WEAVER Power Receives power from Master Drive. Requirements: Uses 70 additional watts.

Dimensions: 7.25" L x 5.50" W x 5.37" H (184 x 140 x 137 mm)

Net Weight: 13.5 lbs (6.0 kg)

Shipping Weight: 16.5 lbs (7.5 kg)

Speed: 2-110 in/min (51-2794 mm/min)

Cycles: 2.5 cycles per second at 1/8" (3mm) stroke

1.6 cycles per second at 1/4" (6mm) stroke

1.0 cycles per second at 1/2" (12mm) stroke

0.7 cycles per second at 1.0" (25mm) stroke (at maximum speed and 0 dwell)

Load Capacity: 10 lbs (4.5 kg)

DIMENSIONS

9.74

(247.4 mm)

7.25

(184 mm)

(432 mm)

17.0

5.37

(137 mm)

5.50

(140 mm)

LINEAR WEAVER SETUP

1) WEAVER CONTROL MODULE AND LINEAR WEAVER INSTALLATION

The Weaver Control Module plugs into the top of the Master Drive Unit. Use a at head screw driver to rmly secure the four corners of the module. Place the Linear Weaver on a at surface, connector side up. Remove connector cover plate from MPD-1000. Loosen, but do not remove, the bolts that hold the Master Drive Module to the carriage. Plug the Master Drive Module into the Linear Weaver. The connectors should t together easily and do not need forced. Attach the Linear Weaver to the carriage using the two weaver mounting bolts. DO NOT SUBSTITUTE LONGER

BOLTS. Retighten the bolts that hold the Master Drive Unit to the carriage.

2) CROSSARM WHEEL ADJUSTMENT AND ALIGNMENT

Always check the crossarm wheel adjustment before using the machine. The wheels are too loose and need adjustment if the crossarm can move up and down. Normal gear backlash will permit crossarm side to side movement of approximately 0.02" (0.5 mm). If the wheels need adjustment, remove the left and right weaver end covers. The two top wheels are adjustable. Loosen the hex bolt (A) until the adjustable bushing (B) can be rotated. Correct the wheel alignment by rotating adjustable bushing (B).

Check for proper alignment by using a nger to keep one of the wheels from rotating while manually moving the crossarm. The wheels are adjusted too tight if rm nger pressure is not enough to prevent wheel rotation. Once aligned, hold the adjustment bushing (B) still while tightening the hex bolt (A). Recheck alignment.

3) REALIGNING THE CROSSARM

(includes crossarm INSTALLATION and REMOVAL)

Rotate the clutch knob (C) fully counterclockwise. This disengages the drive pinion from the rack. Remove the two socket head screws from the crossarm (D). The crossarm may be removed from or installed into the Linear Weaver at this time. Turn on the AC power. Rotate the four-turn steering control knob and the weave speed knob on the Weaver Control Module fully clockwise. Turn the start/stop switch to START. Set the mode selector switch to NO WEAVE. Align the crossarm (D) so that 1 7/8" (48 mm) of the crossarm protrudes from the left side of the Linear Weaver. To insure proper gear mesh, gently rock the crossarm back and forth about 1/16" (2 mm) while engaging the pinion using the clutch knob (C).

Set the weave amplitude to maximum. Use the steering knob on the control module to move the crossarm to both the extreme left and the extreme right. Perform measurements to determine if The crossarm is installed too far left or too far right. Repeat the crossarm realigning procedure changing the 1 7/8" (48 mm) dimension as required. Reinstall the two crossarm screws.

CAUTION: IMPROPER GEAR MESH MAY CAUSE PINION, RACK, OR LINEAR WEAVER DAMAGE.

LEFT SIDE

LINEAR WEAVER SETUP, CONT’D.

4) REMOTE CONTACTOR WIRING

Connect the remote weld contactor on the Master Drive to the welding source as shown below.

Pins A and B ...................connection for Output #1

Pins C and D ...................connection for Output #2

5) GUN AND SETUP

For welding, insert the welding gun into the all-position clamp on the rack. Adjust the clamp, the clamp block and the rack to position the gun for welding. Connect the weld contactor connector to the rear of the Master Drive Unit. Route the welding cable and weld contactor wires through the cable anchor clamp. Turn on the AC power. Use the steering knob on the control module to move the crossarm to both the extreme left and then the extreme right. Turn on the oscillator, at the same time, with the controls set to maximum weave width. Readjust the crossarm or the gun if the racking xture hits the case during operation.

6) MACHINE OPERATION

Turn the main power ON at the power entry box. Set the following parameters using the MDS-1005 Control Module (Ref. pg. 18 for illustration):

Weld Mode Selector Switch

Tractor Speed Control

Steering Control

Weave Amplitude

Weave Speed

Left and Right Dwells

The Start/Stop control will turn on the weaver. To start welding, push the weld contactor switch “ON” (momentarily) which will turn on the wire feeder/weld current. Use the carriage travel switch to select a forward or reverse carriage travel direction.

CAUTION: The Speed Control Card in the Linear Weaver is NOT interchangeable with the speed card in the Master Drive or Pendulum Weaver.

WPD-1100 LINEAR WEAVER / EXPLODED VIEW

6,58

7,58

BUG-5933

___ Coil (Not Shown)

WPD-1100 LINEAR WEAVER / PARTS LIST

ITEM QTY PART NO. DESCRIPTION

1 1 BUG-1590-KM Gear Motor (80:1) 2 1 BUG-1853 Machine Rack 7 1/2" (191 mm) Lg

3 4 BUG-2593 Glide Flat 4 1 BUG-5455 Gun Mounting Group

5 1 BUG-5462 Right Angle Clamp 6 2 CWO-4021 Adj Leg & Wheel Assembly 7 2 CWO-4020 Fixed Leg & Wheel Assembly 8 1 WPD-1178 Post w/Fasteners

9 1 WPD-1150 Cross Arm

10 1 BUG-9447 Wrench 11 8 FAS-0114 Pan Hd Scr 6-32 x 3/8 Lg 12 6 FAS-0124 Pan Hd Scr 8-32 x 3/8 Lg 13 1 WPD-1028 Pinion, 3/4 PD, 24 Teeth 14 2 FAS-0557 Soc Hd Cap Scr 1/4-20 x 3/4 Lg 15 4 FAS-0815 Flt Hd Slt Scr 6-32 x 1/2 Lg 16 10 FAS-0905 Flt Hd Soc Scr 4-40 x 1/2 Lg 17 10 FAS-0925 Flt Hd Soc Scr 8-32 x 1/2 Lg 18 4 FAS-1305 Hex Nut 4-40 19 1 FAS-1325 Hex Nut 8-32 Nylon 20 1 FAS-2121 Pan Hd Scr 8-32 x 1 1/4 Lg 21 2 MDS-1034 Spacer Washer .125 ID x .255 OD x .06 Thk 22 1 MPD-1013 Clutch Plate 23 1 MPD-1042 Inductor, Potted w/Connectors

24 1 PCB-1001 Speed Board

25 4 WAS-0201 # 4 Internal Star Lockwasher

26 1 WPD-1001 Ground Harness

27 1 WPD-1002 Weaver Base Plate Assembly**

28 1 WPD-1103 Dust Plate 29 1 WPD-1004 Motor Mount Plate 30 1 WPD-1106 Oscillator Mount Plate 31 2 WPD-1110 Side Panel

32 1 WPD-1020 Cover Panel

33 1 WPD-1022 Wiring Harness-Speed Board to Motor

34 1 WPD-1023 Connector, 50-Pin, M 35 1 WPD-1025 Pot/Gear Assembly (Includes items 36 thru 41) 36 1 BUG-5235 Flexible Coupling 37 1 BUG-5596 Gear, 72 Teeth

38 1 SFX-1218 Flange Bearing

39 1 WPD-1026 Shaft .250 Dia x .675 Lg 40 1 WPD-1027 Pot Mounting Bracket 41 1 WPD-1037 Potentiometer w/Wiring

42 1 WPD-1029 Encoder/Speed Board Wiring Harness

43 1 WPD-1030 Pinion/Encoder Assembly (Includes items 44 thru 48)

44 1 BUG-6059 Encoder

45 2 FAS-0904 Flt Hd Soc Scr 4-40 x 3/8 Lg 46 1 WPD-1031 Pinion Assembly

47 1 WPD-1033 Encoder Spacer 48 1 WPD-1034 Encoder Card

49 1 WPD-1035 Clutch Assembly (Includes items 50 thru 55) 50 2 FAS-1340 Hex Nut 10-32 51 1 SFX-1224 Sleeve 52 2 WAS-0230 #10 Washer 53 1 WPD-1038 Thumb Screw Knob with 1.75" Stud 54 1 WPD-1166 Clutch Linkage 55 1 WPD-1043 Black Nylon Spacer .118" Thick 56 1 STOF-0804 Spacer, 3/8"OD, 1/4"ID, 3/8" Long, Alum 57 1 WPD-1167 10-32 Shoulder Bolt, 3/8" Long 58 4 WAS-0240 1/4 Flat Washer

**(Includes (2) BUG-5933 Helicoils 1/4 x 20 x 1/4 Lg - Not Shown)

WPD-2100 PENDULUM WEAVER II

INTRODUCTION

The Pendulum Weaver and Weaver Control Module add a pendulum-type weaving motion to the Modular Drive System. The Pendulum Weaver is particularly useful for weaving llet welds in a corner joint. The weaver motor box is mounted to the front of the carriage using standard racks and rackholders.

FEATURES

• High torque, low inertia motor for precise starts and stops.

• Heavy duty planetary gear box with powerful output shaft for rotating welding gun and attachments for the gun.

• High speed pendulum motion with independent control of right and left dwell times.

• High motor gearing ratio, that prevents the welding gun from moving by backdriving the gear train when power is off.

• Closed loop speed control for adjustable and repeatable control of critical welding or cutting parameters.

• Closed loop position control to prevent drift from the center position.

• Gun mounting group with adjustable racking block for accurate positioning of the gun.

• Weld Contactor ON/OFF switch.

PENDULUM WEAVER II SETUP

INSTALLATION

The Weaver Control Module plugs into the Master Drive Unit. Use a at blade screwdriver to rmly secure the four corners of the module.

Remove connector cover plate from MPD-1000. Plug the Pendulum Weaver Electronics box into the front end of the Master Drive Unit. Secure the box to the drive unit by using the four captive screws on the electronics box.

Bolt the mounting plate onto the front of the carriage, below the electronics box, and bolt the rackholder onto the mounting plate. Insert the 14" (355 mm) rack through it.

Several different arrangements can be used to mount the gearbox on the rack and to position the welding gun. One recommended assembly method is shown below: bolt the racks, gearbox, and clamps together as shown in the diagram.

Finally connect the gearbox to the electronics box using the cable supplied, with 6-pin connectors on each end.

SETUP AND ALIGNMENT

Attach the rail parallel to the weld joint, with magnet bars or vacuum cups. Position the drive carriage on the rail - see Modular Drive instructions if necessary.

Insert the welding gun into the clamp on the pendulum weaver. Adjust the racks and clamps to align the welding gun tip with the weld joint, and tighten rmly in place.

IMPORTANT!

When the welding gun is clamped in place with the nozzle pointing into the weld groove, the centerline of the wire must pass through the axis of the gearbox output shaft, as shown in Figure A, which is a view looking along the shaft. Figure B shows the side view of the same.

For a llet weld, the nozzle will be at a 45

angle as shown in Figure C, and will swing equally in both directions.

Figure A

Figure C

Figure B

CAUTION: The Speed Control Card in the Pendulum

Weaver is NOT interchangeable with the speed card in the Master Drive or Linear Weaver.

TECHNICAL DATA

WPD-2100 PENDULUM WEAVER II

Power Uses 70 watts, Requirements: received from Master Drive Unit.

Dimensions: Electronics Box: 6.0"W x 4.38"H x 2.38"L (152 x 111 x 60.3 mm)

Gearbox: 3.31"W x 4.10"H x 5.66"L (84 x 104 x 144 mm)

Net Weight: 12.88 lbs (5.84 kg)

Speed:* 0 - 200 ipm (0-5080 mm/m)

Cycles:* 3.7 cycles per second at 1/8" (3 mm) stroke

3.0 cycles per second at 1/4"(6 mm) stroke

2.0 cycles per second at 1/2" (12 mm) stroke

1.3 cycles per second at 1.0"(25 mm) stroke (at maximum speed and 0 dwell)

Stroke:* 2"(51 mm)

Steering:* 4"(101 mm) to 2" (51 mm), each side of center

Dwell Time: 0 - 3 seconds, left and right

Load Capacity: 10 lbs (4.5 kg)

*all measured at a 6" (152mm) radius

DIMENSIONS

6.00"

(152 mm)

4.38"

(111 mm)

2.38"

(60.3mm)

Electronics Box

4.10"

(104 mm)

19.00"

(483 mm)

5.66"

(144 mm)

3.31"

(84 mm)

7.25"

(184 mm)

7.50"

(191 mm)

14.00"

(356 mm)

WPD-2100 PENDULUM WEAVER II / EXPLODED VIEW / PARTS LIST

PARTS LIST

ITEM QTY PART NO. DESCRIPTION

1 1 MUG-1634-3 Power Cable, 3' (914 mm) 2 1 MDS-1029 Mounting Plate w/Screws 3 1 WPD-2110 Pendulum Gear Box (Includes items 4, 5, 6) 4 1 WPD-2115 Gear Box 5 1 WPD-2041 Clamp Block 6 1 WPD-2050 Gun Mounting Group (Includes items 7 thru 10) 7 2 BUG-2234 Adjustable Clamping Lever 8 1 WPD-2044 Shaft Adaptor w/Collar

9 1 WPD-2052 Gun Clamp

10 1 WPD-2053 Link 11 1 WPD-2120 Pendulum Weaver Electronics Box 12 1 WPD-2040 Pendulum Mounting Group (Includes items 13 thru 17) 13 1 BUG-1796 Machined Rack 14" (355 mm) 14 1 BUG-1853 Machined Rack 7-1/2" (191 mm) 15 1 BUG-5462 Right Angle Clamp 16 1 MDS-1031 3.5" (89 mm) Rackholder w/Long Handle 17 1 UNI-1036 Rackrider w/Post

WPD-2120 PENDULUM WEAVER II / ELECTRONICS / EXPLODED VIEW

PARTS LIST

ITEM QTY PART NO. DESCRIPTION

1 4 FAS-0104 Pan Hd Scr 4-40 x 3/8 Lg 2 8 FAS-0114 Pan Hd Scr 6-32 x 3/8 Lg 3 1 FAS-0225 Rnd Hd Scr 8-32 x 1/2 Lg 4 10 FAS-0905 Flt Hd Soc Scr 4-40 x 1/2 Lg 5 8 FAS-1305 Hex Nut 4-40 6 2 FAS-1320 Hex Nut 8-32 7 2 FAS-1322 Hex Nut 8-32 Nylock 8 2 FAS-2127 Pan Hd Scr 8-32 x 2 3/4 Lg 9 2 MDS-1034 Spacer Washer .125 ID x .255 OD x .06 Thick 10 1 PCB-1009 Speed Board for Pendulum Weaver

11 1 PCB-1021 Capacitor Card

12 1 WAS-0221 #8 Internal Star Lockwasher

13 1 WPD-1001 Ground Harness

14 1 WPD-1023 Connector, 50-Pin, Male

15 1 WPD-2005 Wiring Harness 16 1 WPD-2006 Wiring Harness-Capacitor Bd to Speed Bd 17 1 WPD-2011 Front Panel 18 1 WPD-2012 Rear Panel

WPD-2115 PENDULUM GEAR BOX / EXPLODED VIEW / PARTS LIST

PARTS LIST

ITEM QTY PART NO. DESCRIPTION

1 3 FAS-0104 4-40 x 3/8 Pan Head, Black 2 12 FAS-0124 8/32 x 3/8 Pan Hd, Di-Chrome 3 3 FAS-1305 Hex Nut 4-40 4 4 MET-0053 Pan Hd. Phillips M4 x .7 x 10 5 4 MET-0063 Pan Hd. Phillips M5 x .7 x 10 6 6 MET-1033 Flt Hd Phil M2.5 x 10 7 3 WAS-0201 #4 Internal Star Lockwasher 8 1 WPD-1037 Pot w/Wiring

9 1 WPD-2027 Motor Mounting Plate

10 1 WPD-2028 Pot Mounting Plate w/Inserts

11 1 WPD-2123 Rear End Plate 12 1 WPD-2124 Output End Plate

13 1 WPD-2125 Enclosure Exclusion 14 1 WPD-2130 125:1 Gear Reduction Unit 15 1 WPD-2131 Timing Belt, 3MM Pitch 16 1 WPD-2132 Timing Pulley, 60 Grooves 17 1 WPD-2133 Timing Pulley, 22 Grooves 18 1 WPD-2134 Pulley, 14 Teeth, 32 Pitch 19 1 WPD-2135 Drive Belt, 32 Pitch 20 1 WPD-2136 Pulley, 72 Teeth, 32 Pitch

21 1 WPD-2137 Flanged Clip Bearing 12 MM ID

22 1 WPD-2140 Motor w/Wires

23 1 WPD-2141 Wiring Harness

WPD-1100 LINEAR WEAVER, WPD-2100 PENDULUM WEAVER WIRING DIAGRAM***

Notes: * The encoder section outlined is for the WPD-1000 Linear Weaver only.

** The PC Card to lter power is only used in WPD-2000 Series Pendulum Weavers.

***Wiring diagram will also work for older WPD-1000 and WPD-2000 Weavers.

CARRIAGES

The MPD-1065 Releasable 12" (305 mm) and FMD-1105 12" (305 mm) Hi Flex Carriages can be placed anywhere on the track by using the knob located on the side of the carriage, which engages or disengages the wheels from the rail. The MPD-1055 18" (457 mm) Carriage provides an extended deck for mounting accessories, wire feeder, etc. The pinion from the drive unit engages the rack on the rail, providing positive drive in all positions. On each carriage, one set of wheels is adjustable to allow for smooth, accurate travel. All wheels contain permanently lubricated, sealed bearings and their steel components are plated to resist corrosion.

FOR HI-FLEX RAIL

FMD-1105 12" HI FLEX CARRIAGE 100 lb (45 kg) Carrying Capacity

The Hi-Flex Carriage can be placed anywhere along the track using the quick release knob on the side of the carriage to engage/disengage the wheels from the track. Use with BUG-O Hi-Flex Rails.

FMD-1105 HI-FLEX CARRIAGE / PARTS LIST / EXPLODED VIEW

FOR ALUMINIUM RIGID RAIL AND SEMI-FLEX RAIL

MPD-1065 RELEASABLE CARRIAGE 12" (305 mm) 100 lb (45 kg) Carrying Capacity

PARTS LIST / EXPLODED VIEW

ITEM QTY PART NO. DESCRIPTION

1 2 BUG-1984 External Adj Leg & Wheel Assembly 2 2 FAS-0545 Soc Hd Cap Scr 10-32 x 1/2 Lg 3 2 MPD-1045 Fixed Leg & Wheel Assembly 4 1 MPD-1049 Handle, Black 5 1 MPD-1059 Knob Screw (Included w/carriage)

6 1 MPD-1066 Carriage

ITEM QTY PART NO. DESCRIPTION

1 4 BUG-2841 Washer 5/8" O.D. X 5/16" I.D. Teon 2 2 FAS-0659 Soc Hd Shr 5/16-18 X 1" 3 2 FMD-1093 Standoff .875 Dia. .688 Lg. 4 1 MPD-1035 Handle W / Cable Anchor 5 4 FAS-0956 Screw, Flat Hd Cap 5/16-24 x 5/8 6 1 FMD-1022 Carriage For Flex Rail

*A 1 FMD-1068 Fixed Wheel Mounting Block *B 1 FMD-1069 Adj. Wheel Mounting Block *C 1 FMD-1081 Bearing Block *D 8 FAS-0386 Screw, Hex Hd Cap 5/16-24 x 5/8 *E 8 BUG-2012 Bearing *F 8 CON-1029 Washer, 5/16 x 0.015 *G 2 FMD-1083 Dowel Pin, 1/2 x 2" *H 1 FMD-1071 Threaded Shaft *J 2 BUG-2848 Cam Spacer *K 1 FMD-1072 Knob *L 1 FMD-1026 Carriage Base

*Part of Item 6 (FMD-1022)

MPD-1055 CARRIAGE 18" (457 mm) 150 lb (68 kg) Carrying Capacity

PARTS LIST / EXPLODED VIEW

ITEM QTY PART NO. DESCRIPTION

1 3 BUG -1984 External Adj Leg & Wheel Assembly 2 3 BUG-2956 Fixed Leg & Wheel Assembly 3 4 FAS-0545 Soc Hd Cap Scr 10-32 x 1/2 Lg 4 2 MPD-1049 Handle, Black 5 1 MPD-1055-PNT Carriage 18" (457 mm), Painted

DETAILED SETUP

1. Install Rail

The Tube Carriage is designed for use with Bent Rigid Rail (BRR) or Ring Rail. The exact outside diameter (OD) of the work piece, including coating, must be known when ordering rail. Minimum pipe OD is 9 inches (229 mm). Rail is custom bent for each OD and features adjustable feet to accommodate pipe ovality and deviations in coating thickness.

2. Secure Carriage on Rail

A. Select the correct pair of holes on each side of the carriage for the rail diameter being used (see chart,

below). If the wheels are not attached to the correct set of holes, remove the wheel brackets and bolt them in selected holes. Tighten the bolts until the brackets are snug but still free to rotate.

B. Loosen the adjustment knob to separate the two halves of the split carriage. Loosen and turn the clutch

knob counterclockwise to put the drive in the declutched position.

C. Place the carriage on the ring rail with the wheels in the rail grooves. Close the cam handle and move

the carriage back and forth a few inches. The wheels on their mounting brackets will align themselves correctly with the rail grooves.

D. Verify that wheels are properly aligned, then tighten the wheel mounting bolts to lock them in position.

Rotate the clutch knob clockwise to engage the drive pinion with the rack.

E. Verify that pinion is properly engaged in rack. The correct wheel position will provide a minimum of 1/8"

(3.175 mm) engagement between the drive pinion and the gear rack.

Pipe OD

Carriage

Wheel

Hole Set

BRR-1210

Rail ID

in mm in mm

A 20 - 25 500 - 635 9 - 21 230 - 530 B 23 - 35 585 - 890 12 - 31 300 - 790

C 30 - 44 760 - 1120 18 - 40 455 - 1015 D 41 - 60 1040 - 1525 29 - 54 735 - 1375 E 75 - 174 1905 - 4420 64 - 170 1625 - 4320 F at rail at rail

Notes: 1. Chart values are for reference only

2. Pinion height may need to be adjusted for some rail or pipe sizes.

3. Position and Clamp Welding Gun

Secure welding gun in the all-position clamp located on the end of the height control mechanism. Arrange cables so that they do not interfere with the movement of the machine and secure in the cable anchor at the back of the machine.

MDS-1055 UNIVERSAL LIMIT KIT

The MDS-1055 Universal Limit Kit is an accessory that installs between the Master Drive Unit and any of the three control modules: the *MDS-1002 Straightline, the MDS-1003 Stitch and the MDS-1005 Weaver Control Module. This limit kit adds the ability to CYCLE between limits, STOP AT LIMIT, or RAPID RETURN. All existing functions of the control modules are maintained.

CYCLE MODES:

a) CYCLE - Cycles between two limits. Limit contact does not turn off the weld contactor.

b) STOP AT LIMIT - Limit contact in the direction of travel set by the control module Carriage Travel

Switch will stop motion and turn off the weld contactor. The Carriage Travel Switch will reverse the travel direction and start motion away from the contacted limit. The weld contactor will not automatically turn back on when the machine exits a limit.

c) RAPID RETURN - The machine will run at the preset welding speed in the direction set by the

Carriage Travel Switch on the control module until it hits a limit. When this limit is hit, the machine will turn off the weld contactor, reverse direction, and travel at full speed to the opposite limit. Upon reaching the limit, the machine stops.

*FMD-1055 For use on Hi-Flex Rail Only.

MASTER

DRIVE UNIT

TO REAR LIMIT

CONTROL MODULE

UNIVERSAL

LIMIT KIT

TO FRONT LIMIT

CARRIAGE

MDS-1060-_ REMOTE CONTROL CABLE

MDS-1060-10 10' (3 m) REMOTE CONTROL CABLE MDS-1060-25 25' (7.6 m) REMOTE CONTROL CABLE

MOUNTS TO

MASTER DRIVE

MOUNTS TO

CONTROL MODULE

The optional Remote Control Cable allows the operator to perform work in conned areas where it is difcult to reach the controls. To use the remote cable, detach the control module from the master drive. Fasten the Master Drive Adaptor Plate to the drive unit using the four 8-32 x 3/8 long captive screws provided with the remote cable. Attach the Control Module Adaptor Plate to the control module using the control module’s captive screws. The Master Drive Unit is now ready for remote control.

CAS-20__ AUTOMATIC HEIGHT CONTROL

CAS-2050 AUTOMATIC HEIGHT CONTROL / Linear Weaver

The CAS-2050 is an Automatic Height Control (AHC) for the Linear Weaver (WPD-1100) that controls the welding tip to work distance and maintains a constant weld current, helping to provide uniform weld penetration. The CAS-2050 senses the actual weld current, compares this value to the set point, and raises or lowers the welding gun accordingly.

CAS-2060 AUTOMATIC HEIGHT CONTROL / Pendulum Weaver

The CAS-2060 is an Automatic Height Control (AHC) for the Pendulum Weaver (WPD-2100) that controls the welding tip to work distance and maintains a constant weld current, helping to provide uniform weld penetration. AHC senses the actual weld current, compares this value to the set point, and raises or lowers the welding gun accordingly. It features a built-in time delay after the arc is struck, and automatically shuts off when the current drops too low (generally below 60 amps).

CAS-2050

AUTOMATIC HEIGHT CONTROL / Linear Weaver

AUTOMATIC HEIGHT CONTROL / Pendulum Weaver

CAS-2060

MODULAR DRIVE ACCESSORIES

FOR STRAIGHT LINE CUTTING:

MDS-3025

2-Hose

Quick-Acting Manifold

MDS-1050

Machined Rack

Cutting Group

CIR-1010-3

Twin Hose Assembly 32" (813 mm)

FOR STRAIGHT LINE AND STITCH WELDING:

MDS-9898

3-Hose

Quick-Acting Manifold

MUG-1119-32

3-Hose

Assembly 32" (813 mm)

MDS-1040

Machined Rack

Welding Group

FOR ALL APPLICATIONS:

MPD-1065

Releasable

Carriage

12"

(305 mm)

MPD-1055

Carriage

18"

(457 mm)

BUG-2205

Carriage

Trailer with Hitch

MDS-1045

Extended

Mounting Plate

FMD-1105 Drive Carriage

with cable anchor for MDS Master Drive or Universal Bug-O-Matic on High-Flex Rail

MPD-1035

Handle with Cable Anchor

FMD-1090 Long Trailer For use w/ FMD-1100

• Used to carry accessories, wire feeder, etc.

FMD-1150 Hi-Flex Carriage

for DC-III Drive

FMD-1095 Short Trailer For use w/ FMD-1100

• Used to carry accessories, wire feeder, etc.

FMD-1100 Drive Carriage

• Used when oscillation is not required

ALUMINUM RIGID RAIL

ALUMINUM RIGID RAIL is a high quality alloy, rigid section made to the machine tool tolerance shown in

the sectional view below. The carriage drive pinion meshes with a machined gear rack that is mounted on the rail. The wheels of the carriage travel in opposed grooves at either side of the rail, locking the carriage to the rail. Heavy duty [H.D.] aluminum four-legged rigid rail is supplied in two lengths: ARR-1080 [93-1/2" (2.37 m)] called 8' (2.37 m) rail and ARR-1085 [46-1/2" (1.18 m)] called 4' (1.18 m) rail - see insert below. Extra heavy duty aluminum four-legged rigid rail: ARR-1250 [93-1/2' (2-37 m)] called 8' (2.37 m) rail and ARR-1200 [46-1/2" (1.18 m)] called 4' (1.18 m) rail, is also available.

NOTE: 8' Rails accept up to 8 supports, 4' Rails accept up to 4 supports.

RAIL FOR LONGER SPANS:

When unsupported rail paths longer than 93-1/2" (2.37 m) nominal 8' (2.37 m) rail are required, multiple sections of standard rail are mounted on plate, channel or box sections.

ARR-1080 / H.D. ALUMINUM RIGID RAIL 8' (2.37 m)

A 2.75" (70mm)

B 4.0" (102 mm) C .375" (9.5 mm) D .875" (22 mm)

PARTS LIST

ITEM QTY PART NO. DESCRIPTION

1 1 ARR-1006 Rack

2 2 ARR-1027 Splice Bar

3 2 ARR-1028 Carriage Soft 4 1 ARR-1081 Rail-Extrusion 5 2 FAS-0375 Hex Hd Cap Scr 5/16-18 x 1/2 6 2 FAS-1370 Hex Nut 5/16-1 8 7 16 FAS-1445 S.T. Pan Hd Scr 10-32 x 1/2

SEMI-FLEX RAIL

MIN. RADIUS

15' (4.6 m)

SEMI-FLEX RAIL can be bent inside or

outside to a minimum radius of 15' (4.6 m) or 30' (9.1 m) diameter without permanent deformation.

(2.37 m)

AFR-3000 SEMI-FLEX RAIL replaces the old AFR-1000, 1010, 1020 and the later AFR-2000 rails. All the rack-mounting holes on the AFR-3000 Semi-Flex Rail are slotted so that the rack can slide along the rail. The length of the slots has been increased so that the rails can now be leapfrogged around a complete circle. The tension of the screws holding the rack on the rail is adjusted so that the rack can be moved along the rail with the AFR-2001 Rack-Adjusting Tool.

NOTE: Use at least four attachments (magnets or vacuum cups) on each SEMI-FLEX RAIL.

AFR-3000 / SEMI-FLEX RAIL

A 2.75" (70mm) B 4.0" (102 mm) C .33" (8.5 mm) D .500" (12.7 mm)

CAUTION: Bending beyond the recommended 15'-0" (4.6 m) radius may put

a permanent bend in the rail and break off some of the rack screws.

PARTS LIST

ITEM QTY PART NO. DESCRIPTION

1 16 AFR-1015 Spacer Washer 2 1 AFR-2001 Rack Adjusting Tool

3 1 AFR-3002 Splice Plate

4 1 AFR-3006 Rack 5 1 AFR-3009 Extrusion, Punched 6 2 FAS-0855 Flt Hd Soc Scr 1/4-20 x 1/2 7 2 FAS-0955 Flt Hd Soc Scr 1/4-20 x 1/2 8 16 FAS-1446-HW S.T. Slotted Hex w/Washer 10-32 x 5/8 9 16 WAS-0230 #10 Washer

HI-FLEX RAIL

The FMD Hi-Flex Rail can ex from a straight to a 30" (760 mm) radius inside or outside. The rail is made from a tempered, wear resistant, stainless steel with a steel rack. It is designed for use with the FMD Hi-Flex Carriage. The rail comes in 57.7" (1.47 m) lengths and can be held in place with magnets or vacuum cups. An optional stiffener can be installed behind the rail for heavy duty, straight line applications.

R 30"

(760 mm)

FMD-1050 Hi-Flex Rail Without Magnet Assemblies

3.995"

(102 mm)

.080"

(2 mm)

.250"

(6.4 mm)

FMD-2155 Hi-Flex Rail

with 8 Permanent magnets

FMD-2170 Hi-Flex Rail with 8 Rare Earth On/Off magnets

57.722" (1.47 m) Actual Length

R 30"

(760 mm)

FMD Hi-Flex Rail can

ex inside or outside

to a minimum radius of 30" (760 mm).

ITEM QTY PART NO. DESCRIPTION

1 4 FAS-0376 Hex Hd Cap Scr 5/16-18 x 5/8" 2 4 FAS-1370 Hex Nut 5/16-18 3 196 FAS-1444 Phil Pan Hd Scr 10-32 x 3/8" 4 1 FMD-1051 Track 5' 17-4 Stainless .077 5 98 FMD-1052 Rack Section, 3 Teeth 6 1 FMD-1053 Flex Rail Splice Plate 7 4 WAS-0250 5/16 Sae Washer

STANDARD MAGNET ASSEMBLIES

MAGNET PLATE ASSEMBLIES mount ARR rail quickly and conveniently right on the work surface.

Magnets cannot exert maximum pull on dirty material. Remove excessive paint, scale and rust from the area on which the magnets will be placed.

KEEP MAGNETS CLEAN - before positioning, wipe off magnetic particles which adhere to the poles.

For MAXIMUM HOLDING POWER on swivel magnets, press down on top of each side of magnet.... then

rotate until it holds rmly. The magnet will retain its magnetism indenitely - to preserve the magnet casing, keep torch 4" (101 mm) away from magnets when burning/welding. Use various thicknesses of keepers to decrease the magnetic pull when required.

R.E. On/Off Magnets

The New, Bug-O/ Mag-switch, Switchable On/Off Rare-Earth magnet assembly provides for quick rail positioning without ghting the magnet. The lighter weight, at just 1.7 lb. (.77 kg), less than all other magnet assemblies, improves handling. 200 lb (90 kg) holding capacity.

*All XXX-2010-HH are “High Heat” models and are rated at 180°C (356°F) for high temperature applications.

For Aluminum Rigid Rail

R.E. On/Off Magnet ARM-2010 ARM-2010-HH*

Holding Power 250 lb. (113 kg)

Swivel Magnet w/ Release ARM-2325

Holding Power 250 lbs. (113 kg)

Magnet Plate, Short ARM-2248

Holding Power 200 lbs. (91 kg)

Spacer ARM-2015

Use with

ARM-2010 only

Swivel Magnets

Magnet bar, swivel with release; recommended for all applications, combines maximum strength and versatility. This assembly holds up to 250 lbs. (113 kg) on a at, clean steel surface.

Short Swivel Magnets

Magnet bar, short; compact for positioning in hard-to-reach or restricted areas. This assembly holds up to 200 lbs. (91 kg) on a at, clean steel surface.

Fixed Magnet w/ Release ARM-2265

Holding Power 200 lbs. (91 kg)

For Semi-Flex Rail

R.E. On/Off Magnet AFR-2010 AFR-2010-HH*

Holding Power 250 lb. (113 kg)

For Hi-Flex Rail

R.E. On/Off Magnet, Hi-Flex FMD-2010 FMD-2010-HH*

Holding Power 250 lb. (113 kg)

Hi-Flex Magnet w/ Release FMD-2325

Holding Power 250 lbs. (113 kg)

Spacer Bar FMD-2015

Use with

FMD-2010 only

Fixed Magnet w/ Release ARM-2465

Holding Power 200 lbs. (91 kg)

Swivel Magnet w/ Release ARM-2425

Holding Power 250 lbs. (113 kg)

VACUUM SUPPORT KIT

The standard Vacuum Support Kit, ARV-1080 consists of four (4) bars (with 8 cups) and associated hose and ttings. Some applications may require additional ARV1036 Vacuum Support Bar assemblies.

ARV-1051

ARV-2020 Vacuum Pump Kit 120V

ARV-1036

ARV-2030 Vacuum Pump Kit 240V

ARV-1036 VACUUM SUPPORT BAR / EXPLODED VIEW / PARTS LIST

VACUUM CUPS are used for mounting the rail to the work piece when magnet bars will not hold.

EXAMPLE: Stainless steel or nonferrous surfaces. The surface must be smooth and nonporous.

Each vacuum bar is tted with two (2) cups and will exert a maximum pull of 100 lbs. (45 kg).

ITEM QTY PART NO. DESCRIPTION

1 2 ARR-9008 Spacer Tube 2 2 ARV-1034 Choke Nipple 3 2 ARV-1107 3/8 Hose Barb x 1/4 NPT-M 4 2 ARV-1109 Protective Cap

5 1 ARV-1111 Support Bar 6 2 ARV-1116 Vacuum Cup (Silicone)

7 2 FAS-0252 Rnd Hd Scr 1/4-20 x 1/4 8 2 FAS-2372 Hex Hd Cap Scr 5/16-18 x 1-1/4

NOTE: Keep ame or arc at least 4"(101 mm) away from vacuum cups. Vacuum cups can be used on preheated material to 6000 F (3150 C). Each vacuum cup exerts a maximum pull of 50 lbs. (22.6 kg).

VACUUM SUPPORT KIT, CONT’D.

VACUUM PUMP / EXPLODED VIEW / PARTS LIST

ARV-2020 VACUUM PUMP KIT, 120VAC 60HZ/1PH ARV-2030 VACUUM PUMP KIT, 240 VAC 50 HZ/1PH

The VACUUM PUMP KITS are 1/6 HP units that provide 15" (381 mm) Hg on continuous duty. The ARV-2020/2030 Pump will support

30 vacuum cups. A Repair Kit ARV-1029 is available for the ARV-2020 and ARV-2030 pumps. The kit con-

tains (4) vanes, (1) body gasket, lter felts for the mufer, oiler lter, and oiler wick, a cover gasket and separator felt for the oiler lter.

ITEM QTY PART NO. DESCRIPTION

1 1 ARV-2017 1/4'' Brass Vacuum Relief Valve

2 1 ARV-2014 Vacuum Gage

3 1 ARV-2018 1/4'' NPT Union Cross, Female 4 2 ARV-2012 1/4'' NPT Nipple 5 1 ARV-2016 1/4'' NPT Brass Check Valve, F 6 2 ARV-1107 3/8'' Hose Barb x 1/4'' NPT-M 7 2 ARV-1005 11/16'' x .112 Thk Clamp 8 1 ARV-1004-P Hose 3/8'' ID x 11/16'' OD 9 1 ARV-1012 Female Quick Connector

10 1 ARV-2019 Pump

11 1 ARV-1999 Foot Support w/Fasteners 12 1 ARV-2021 120 VAC Power Cord w/Switch *

†

240 VAC Replacement Power Components

13 1 ARV-2013 Handle 14 1 ARV-2011 Body 15 4 ARV-2010 Vane

16 1 ARV-2009 Shroud

17 2 ARV-2003 End Cap 18 2 ARV-2004 Felt 19 2 ARV-2005 O-ring

20 2 ARV-2002 End Cap Assembly (Includes parts 17, 18, 19) 21 1 ARV-2001 Filter/Mufer 22 1 ARV-2006 Mufer Box 23 1 ARV-2007 Gasket

24 1 ARV-2008 End Plate

†

240 VAC requires the items below

* 1 BUG-9233 Label, 240 VAC * 1 BUG-9593 240 VAC Twist Plug * 1 BUG-9594 240 VAC Connector Body * 1 ARV-2021 120 VAC Power Cord w/Switch * Not Shown

MODULAR DRIVE SYSTEM TROUBLESHOOTING GUIDE

The Modular Drive System allows the user to mix and match components to custom build a machine for an application. The resulting ability to replace and remove individual components while troubleshooting signicantly reduces the time and effort required to troubleshoot the system. The recommended troubleshooting procedure is as follows:

1) Verify that there are no loose electrical or mechanical connections.

2) Verify that the welding power source is properly grounded and its ground clamp is attached to

the workpiece.

3) Ensure the High Frequency Warnings in the front of this IPM are not being violated.

4) When possible, swap out each component in the system one at a time with a known good

component. For example, replace the Control Module on a defective machine with the Control Module from a working machine. Often, this will pinpoint the defective component quickly. If the defective component is a Weaver Drive or a Master Drive, troubleshoot the drive to a circuit board level using step 5 and/or 6 below.

5) Remove all attached components. This includes the Remote Control Cable and Universal Limit Kit. All attached components are removed to limit the number of components affecting the operation and complexity of the system. Assemble a base system composed of a Control Module and a Master Drive. Test the base system. If the base system does not work, troubleshoot the base system to a circuit board level using the Base System Test Procedure. If possible, test the Control Module by swapping it with a known good Module.

6) If the system had a Weaver Drive, install it and retest the system. If the system does not work, troubleshoot the system to a circuit board level using the Base System Test Procedure. NOTE: The weaver failure can result from a faulty Control Module, Master Drive or Weaver Drive because they all interact. Use the Base System Test Procedure to nd the faulty component.

7) Some components require special attention when troubleshooting and have their own trouble shooting section. These components are:

Universal Limit Kit (MDS-1055)

Perform any relevant troubleshooting section as required before proceeding to the base system

test procedure. The special troubleshooting sections are located after the Base System Test Procedure.

8) Finish installing the components one at a time. Test the system after each installation in order to identify the problem components.

TROUBLESHOOTING GUIDE, CONT’D.

PROBLEM POSSIBLE CAUSE TEST BASE SYSTEM TEST PROCEDURE / REMEDY

Speed display is not lit and tractor does not

run.

Power switch is OFF.

No power to machine.

Blown fuse. 1C Unplug the power cord. Check the machine’s power input fuse(s).

1A Turn ON the main ON/OFF switch located in the power entry

module. (see Figure 1)

1B Verify the power cord is OK and the correct voltage exists at the

outlet.

The fuse(s) is located in the power entry module and is accessible without opening the case.

Faulty accessory

attached to the master drive accessory port.

Faulty power entry module.

1D Remove any accessory plugged into the master drive accessory

port (see gure 2). Plug in the power cord and turn on the main power.

a) If the speed display does not light, proceed with test 1E

b) If the speed display lights, install the connector cover on

the accessory port. NOTE: FAILURE TO INSTALL THE

CONNECTOR COVER ON THE ACCESSORY PORT AFTER COMPLETING THIS TEST MAY CAUSE SERIOUS INJURY

FROM ACCIDENTAL ELECTRICAL SHOCK.

Set the tractor for continuous forward motion at full speed. If the control module has any type of motion enable switch, turn it to enable.

1) If the tractor does not work properly, proceed with step 2A.

2) If the tractor operates correctly, the accessory removed from the accessory port is defective.

1E Remove the connector cover or any attached accessory from the

master drive accessory port (see Figure 2). Verify the power line voltage is on the two outer pins of the three pin connector (see Figure 2). The center pin is chassis ground.

NOTE: INSTALL THE CONNECTOR COVER ON THE

ACCESSORY PORT AFTER COMPLETING THIS TEST.

FAILURE TO INSTALL THE COVER MAY CAUSE SERIOUS

INJURY FROM ACCIDENTAL ELECTRICAL SHOCK.

If the voltage is not present, rerun tests 1A, 1B, 1C, 1D and 1E. A second failed 1E test indicates bad internal AC wiring or a defective power entry module. Open the master drive case (see Figure 3). Examine the AC wiring and rewire at fault or replace the power entry module assembly. NOTE: The replacement power entry module is provided with the accessory port’s three pin AC connector prewired.

Defective RFI lter. 1F Disconnect the two RFI lter output wires (see Figure 1). Turn on

the main power. Verify the power line voltage exists on the two output wires. Reconnect the wires. Replace the RFI lter if the power line voltage is not present.

TROUBLESHOOTING GUIDE, CONT’D.

PROBLEM POSSIBLE CAUSE TEST BASE SYSTEM TEST PROCEDURE / REMEDY

Bad power supply. 1G Turn on the main power. The green LEDs L1 and L2 (see Figure 1)

will light if the power supply is OK.

If the LEDs are off, unplug the power supply output connector (see Figure 1). The connector wiring is: White & RED is +15 V DC (+/-2V). White & Black is DC ground. White & Orange is -15V DC (+/-2V). Measure the voltages at the connector.

a) A bad voltage indicates a defective supply. Replace the supply.

b) Correct voltages indicate the power supply is OK, however,

there is a short in the equipment. Plug in the power supply output connector. Perform test 1H.

Short circuit. 1H The Green LEDs L1 and L2 will light when the short is removed.

Unplug the following and monitor the LEDs to see if the short is removed: 1) The control module 2) The speed card input power connector (see Figure 1). 3) All connectors attached to the interconnect card (see Figure 1), except the connector from the supply.

No tractor speed control and

display is lit.

If L1 and/or L2 never turned on, the interconnect card is bad. Replace the board.

Operator Error

(Stitch Control Module).

Operator Error

(Weaver Control Module).

Bad DC power. 2C Open the master drive case (Figure 3). Unplug the power supply

2A Set the MODE switch to CONTINUOUS WELD and the CARRIAGE

TRAVEL switch to STOP. Turn the SPEED CONTROL clockwise. Proceed to step 2C if the display does not increase. If the display does increase, then turn the CARRIAGE TRAVEL switch to FORWARD. Open the master drive case (Figure 3) and proceed to step 2D if the tractor does not move forward.

2B Set the MODE switch to RUN , the CARRIAGE TRAVEL switch to

STOP and the START/STOP switch to START. Turn the SPEED CONTROL clockwise. Proceed to step 2C if the display does not increase. If the display does increase, then turn the CARRIAGE TRAVEL switch to FORWARD. Open the master drive case (Figure

3) and proceed to step 2D. If the tractor does not move forward.

output connector (see Figure 1). The connector wiring is: White & Red is +15 V DC (+/-2 V). White & Black is ground. White & Orange is -15 V DC (+/-2 V). Measure the voltages at the connector.

A missing or bad voltage indicates a bad supply. Replace the supply.

Faulty motor wiring. 2D Check the wires from the speed card to the motor for faults.

Rewire if needed.

TROUBLESHOOTING GUIDE, CONT’D.

PROBLEM POSSIBLE CAUSE TEST BASE SYSTEM TEST PROCEDURE / REMEDY

Faulty motor. 2E Disconnect the motor leads. Apply 2 to 8 volts DC across the motor

leads. Verify that the motor spins.

Faulty control

module, speed card, or motor.

2F Install one voltmeter lead on TP4 and the other lead on TP5. Turn

on the main power. Set the control module for continuous forward tractor motion. If the control module has any type of motion enable switch, turn it to enable. Rotate the tractor speed control knob while observing the voltmeter output. It is possible to vary this voltage between 0 and 8 Volts DC using a good control module.

a) If the voltage does not vary, replace the control module card.

b) If the voltage does vary, turn the machine OFF and then ON

using the main power switch. Observe LED L5. L5 should light for a moment or two during power-up while safety circuits hold the tractor OFF until full power is reached. L5 should then turn off indicating power has been applied to the motor and motion should start.

1) If the L5 never lights, replace the speed card.

2) If the L5 turns on, turns off, and then turns on again, check for shorted motor connections. If none are found, replace the speed card.

3) If the L5 turns on and then stays on, check that the control module is set up as dened above and retest 2F. A second failure indicates a bad speed card.

Stitch mode on

control module

does not work.

Tractor moves a short distance and then stops.

4) If L5 turns on and then off and the motor doesn’t start turning, turn the tractor speed up. If the motor does not begin to turn, check the motor to speed card wiring for faults and repair as needed. If the motor still fails to turn, replace the speed card.

Bad control module

or bad tractor speed card.

High Frequency Interference.

Carrying too much weight.

Brake is dragging. 4C Remove the unit from the track and set the controls to forward

3A If the speed and direction work in CONTINUOUS mode, then the

control module is bad.

If the speed and direction do not work in CONTINUOUS mode, go to test 2A.

4A Turn off the welder or plasma unit. The unit should operate normally.

4B Verify the load placed on the carriage does not exceed the factory

rating.

tractor motion. If the pinion motion stops after a short time, or a check shows that the weight placed on the machine is not excessive, then the problem is most likely brake related. Return the machine for repair.

TROUBLESHOOTING GUIDE, CONT’D.

PROBLEM POSSIBLE CAUSE TEST BASE SYSTEM TEST PROCEDURE / REMEDY

Linear Weaver

does not move.

Bad control card or

bad weaver.

5A Set the weaver control module MODE SELECT switch to NO

WEAVE and the START/STOP switch to START. Turn the weave speed up to max. Continuously move the STEERING CONTROL knob clockwise and then counter clockwise. This should cause the weaver arm to move back and forth.

a) If the arm moves, proceed to step 6A.

b) Unbolt and disconnect the weaver box from the modular drive

accessory port (see Figure 2). Open the master drive case (see Figure 3). Install one voltmeter lead on TP6 and the other lead on TP7 (see Figure 1). Turn on the unit.

Set the weaver control module MODE select switch to RUN (no weave) and the START/STOP switch to START. If the voltage reading is less than 2 V DC, adjust the STEERING pot on the control module until the reading is greater than 2 V DC.

1) If the pot adjustment will not produce at least 2 V DC on the voltmeter, replace the control module card.

Linear Weaver moves in one

direction only or

moves erratically.

Pendulum Weaver moves

in one direction

only or moves erratically.

Bad control card, bad weaver speed card, or loose set screws on the servo pot’s exible

coupling (coupling is used on WPD-1000

only).

Bad control card or

bad speed card.

2) If the voltmeter displays above two volts, with or without pot adjustment, replace the weaver speed card.

6A On the WPD-1000 linear weaver only, tighten the set screws on

the servo potentiometer’s exible coupling. This part can be accessed by removing the WPD-1000 linear weaver’s side panel that is located closest to the clutch screw.

Set the weaver control module MODE SELECT switch to NO WEAVE and the START/STOP switch to START. Turn the WEAVE SPEED up to max. Continuously move the STEERING CONTROL knob clockwise and then counter clockwise. This should cause the weaver arm to move back and forth.

a) If the weaver moves in one direction only, the weaver speed

card is bad.

b) If the arm weaves but the control module does not function

correctly, the control module is bad.

7A Set the weaver control module MODE SELECTOR switch to NO

WEAVE and the START/STOP switch to START. Turn the WEAVE SPEED up to max. Continuously move the STEERING CONTROL knob clockwise and then counter clockwise. This should cause the weaver arm to move back and forth.

a) If the weaver moves in one direction only, the weaver speed

card is bad.

b) If the arm weaves but the control module does not function

correctly, the control module is bad.

TROUBLESHOOTING GUIDE, CONT’D.

PROBLEM POSSIBLE CAUSE TEST BASE SYSTEM TEST PROCEDURE / REMEDY

Pendulum shaft does not move.

Bad control module, damaged power cable, bad speed board or bad capacitor board.

8A Set the weaver control module MODE SELECT switch to RUN

(no weave) and the START/STOP switch to START. Turn the WEAVE SPEED to maximum. Move the STEERING CONTROL knob clockwise and counter-clockwise. This should cause the pendulum shaft to move back and forth.

a) If the pendulum output shaft moves, then proceed to step 8A.

b) Listen very closely to the Pendulum Gearbox to see if the motor

is turning. The gearbox is bad if the motor is turning but the output shaft does not turn.

c) Remove the cable from between the electronics box and the

pendulum gearbox. Use a meter to verify the connections through the cable. For example, verify pin A to pin A continuity, pin B to pin B, etc.

d) Remove the pendulum weaver electronics box from the modular

drive accessory port by removing 4 pan head screws (see Figure 2). Open the master drive case (see Figure 3). Install one voltmeter lead on TP6 and the other on TP7 (see Figure 1). Turn on the unit, set the weaver control module MODE SELECT switch to RUN (no weave) and the START/STOP switch to START.

If reading is less than 2 V DC, adjust the STEERING pot on the control module until the reading is greater than 2 V DC. Replace the control module if the pot adjustment will not produce at least 2 V DC on the voltmeter.

e) Reassemble the master drive case (see Figure 3). Open the

pendulum electronics box by removing the 4 pan head screws. Install the back of the electronics box onto the master drive unit. Locate the 2 pin connector on the speed board. Place the voltmeter probes in the connector from the back. Set the control module as follows.

1) Set the MODE switch to any mode except RUN (no weave)

2) Set the WEAVE SPEED to 3.

3) Set the WEAVE AMPLITUDE to maximum.

4) Set the RIGHT and LEFT DWELL to minimum.

5) Turn on the main power. Set the STOP/START switch to START to enable weaver motion.

If the voltmeter reads 1.5 V DC or more, replace the gear motor box.

f) If the voltmeter reading is less than 1 V DC, unplug connector J1

from the speed board. Unplug connector JP1 from the capacitor board and plug it into J1 on the speed board. Redo test 7D.

TROUBLESHOOTING GUIDE, CONT’D.

PROBLEM POSSIBLE CAUSE BASE SYSTEM TEST PROCEDURE / REMEDY

Chatter from main drive unit

Clutch improperly

engaged

Wheel engagement knob improperly

engaged

Carriage wheels out of

adjustment

Worn or damaged rail Visually inspect for damage or worn part. Replace if necessary.

Worn or damaged pinion gear

Clutch assembly

improperly adjusted

Knob should be seated rmly against drive unit. Turn drive clutch knob fully clockwise while gently rocking the machine forward and backward to fully engage the drive pinion. The rocking motion is necessary to help ensure proper gear mesh (see page 6).

Wheel support bar should seat rmly against carriage rib. Turn the wheel engagement knob (A) on the side of the carriage until the wheels are fully moved towards the center of the carriage (engaged) (see page 6).

Follow setup procedure for Wheel Adjustment and Alignment (page 7).

Visually inspect for damage or worn part. Replace if necessary. See Master Drive Unit / Technical Data (page 8).

Note: This is factory set. Examine all other possibilities rst. For proper pinion adjustment, allow 1/16th back lash in drive carriage movement on rail. To increase or decrease pinion engagement, increase or decrease the overall length of the clutch adjustment mechanism by adjusting items #32 and #37 on the MPD-1000 Master Drive Unit Exploded View / Parts List (page 9).

TROUBLESHOOTING GUIDE, CONT’D.

The Modular Drive System is equipped with internal fault diagnostic LEDs and test Points 10 Speed troubleshooting as shown below. Test point evaluation should be performed by a qualied technician using a volt meter. If a qualied technician is not available, return the unit to the factory for repair. Always unplug the power cord before opening the case.

RFI FILTER OUTPUT

POWER

SUPPLY

SPEED CARD

INPUT POWER

CONNECTOR

POWER SUPPLY

OUTPUT CONNECTOR

Figure 1. Troubleshooting Test Points

TP8

TP6

TP4

TP3

RFI FILTER

SPEED CARD

TP9

TP1

TP5

POWER ENTRY MODULE

TP2

INTERCONNECT CARD

TEST POINTS

TP1 -15V TP2 GND TP3 +15V TP4 Tractor + Speed Command TP5 Tractor - Speed Command TP6 Weaver + Speed Command TP7 Weaver - Speed Command TP8 Height + Speed Command TP9 Height - Speed Command

L1 -15v L2 +15V L3 Height Off L4 Weaver Off L5 Tractor Off

TROUBLESHOOTING GUIDE, CONT’D.

ACCESSORY PORT

CHASSIS GROUND

Figure 2. Master Drive Accessory Port

Figure 3. Procedure for Opening the Master Drive Case:

1. Unplug the power cord.

3. Remove ONLY the seven screws as shown.

2. Unbolt the Master Drive from the carriage.

4. Open the case.

CAUTION: UNPLUG THE POWER CORD BEFORE OPENING OR CLOSING

THE CASE OR SERIOUS INJURY MAY RESULT.

UNIVERSAL LIMIT KIT TROUBLESHOOTING

This Troubleshooting section details troubleshooting the Universal Limit Kit. See the Modular Drive System Troubleshooting Guide for troubleshooting all other components.

Recommended Troubleshooting Procedure:

1) If using the Universal Limit Kit with the MDS-1001 Straight Module, the CYCLE SELECTION switch on the Control Module must be in the BASIC FORWARD/REVERSE position for the machine to operate property.

2) Perform steps 1 through 6 in the Modular System Troubleshooting Guide, The Master Drive, Control Module and Weaver Drive must be functioning correctly before proceeding.

3) Check for loose or damaged wires both internal and external to the Universal Limit Kit.

4) If the machine does not move at all, measure the voltage across each limit switch on the PC board

while cycling the switch on and off. The voltage should toggle between 0 and 12V DC. If it does not, the limit switch or limit switch wiring is damaged. CAUTION: If using the MDS-1001 Straight Module with the Universal Limit Kit, the CYCLE SELECTION switch on the Control Module must be in the BASIC FORWARD/REVERSE position or the machine may not move.

5) If the machine turns around, stops, or starts unexpectedly, the Universal Limit Kit may be picking up RF noise from the welder. Move all of the welder cables away from the Universal Limit Kit, the limit switch wires and the Control Module.

6) If the previous steps did not x the Universal Limit Kit, the PCB-1030 card is probably defective. Replace the card.

WARRANTY

Model _____________________________

Limited 3-Year Warranty

For a period ending one (1) year from the date of invoice, Manufacturer warrants that any new machine or part is free from defects in materials and workmanship and Manufacturer agrees to repair or replace at its option, any defective part or machine. HOWEVER, if the invoiced customer registers the Product Warranty by returning the Warranty Registration Card supplied with the product within 90 days of the invoice date, or by registering on-line at www.bugo.com, Manufacturer will extend the warranty period an additional two (2) years which will provide three (3) total years from the date of original invoice to customer. This warranty does not apply to machines which, after Manufacture’s inspection are determined by Manufacturer to have been damaged due to neglect, abuse, overloading, accident or improper usage. All shipping and handling charges will be paid by the customer.

The foregoing express warranty is exclusive and Manufacturer makes no representation or warranty (either express or implied) other than as set forth expressly in the preceding sentence. Specifically, Manufacturer makes no express or implied warranty of merchantability or fitness for any particular purpose with respect to any goods. Manufacturer shall not be subject to any other obligations or liabilities whatsoever with respect to machines or parts furnished by Manufacturer.

Manufacturer shall not in any event be liable to Distributor or any customer for any loss of profits, incidental or consequential damages or special damages of any kind. Distributor’s or customer’s sole and exclusive remedy against Manufacturer for any breach of warranty, negligence, strict liability or any other claim relating to goods delivered pursuant hereto shall be for repair or replacement (at Manufacturer’s option) of the machines or parts affected by such breach.

Serial No. __________________________ Date Purchased: ____________________ Where Purchased:___________________

Distributor’s Warranty:

In no event shall Manufacturer be liable to Distributor or to any customer thereof for any warranties, representations or promises, express or implied, extended by Distributor without the advance written consent of Manufacturer, including but not limited to any and all warranties of merchantability or fitness for a particular purpose and all warranties, representations or promises which exceed or are different from the express limited warranty set forth above. Distributor agrees to indemnify and hold Manufacturer harmless from any claim by a customer based upon any express or implied warranty by Distributor which exceeds or differs from Manufacturer’s express limited warranty set forth above.

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 they cannot give you the necessary

service, write or phone us to tell us exactly what difculty you have experienced. BE SURE to

mention the MODEL and SERIAL numbers.

BUG-O Systems Modular Drive System User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual