INSTRUCTIONS
AND
PARTS MANUAL
PROGRAMMABLE
GANTRY SYSTEM
Please record your equipment identication 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-PGS-IPM-0314
Bug-O Systems is guided by honesty, integrity and
ethics in service to our customers and in all we do.
A DIVISION OF WELD TOOLING CORPORATION
280 TECHNOLOGY DRIVE CANONSBURG, PENNSYLVANIA 15317-9564 USA
PHONE: 412-331-1776 http://www.bugo.com FAX: 412- 331- 0383
SAFETY
PROTECT YOURSELF AND OTHERS FROM SERIOUS INJURY OR DEATH.
KEEP CHILDREN AWAY. BE SURE THAT ALL INSTALLATION, OPERATION,
MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY
QUALIFIED INDIVIDUALS.
ELECTRIC SHOCK can kill.
1) The equipment is not waterproof. Using
the unit in a wet environment may result
in serious injury. Do not touch equipment
when wet or standing in a wet location.
2) The unused connectors have power on
them. Always keep the unused connec tors covered with the supplied protective
panels. Operation of the machine without
the protective panels may result in injury.
3) Never open the equipment without rst
unplugging the power cord or serious
injury may result.
4) Verify the customer-supplied power
connections are made in accordance
with all applicable local and national
electrical safety codes. If none exist,
use International Electric Code (IEC)
950.
5) Never remove or bypass the equipment
power cord ground. Verify the equipment
is grounded in accordance with all appli cable local and national electrical safety
codes. If none exist, use International
Electric Code (IEC) 950.
EQUIPMENT DAMAGE
POSSIBLE.
1) Do not plug in the power cord without rst
verifying the equipment is OFF and the
cord input voltage is the same as required
by the machine or serious damage may
result.
2) Always verity both the pinion and wheels
are fully engaged before applying power
or equipment damage may occur.
3) Do not leave the equipment unattended.
4) Remove from the work site and store in
a safe location when not in use.
FALLING EQUIPMENT
can cause serious
personal injury and
equipment damage.
Faulty or careless user installation is
possible. As a result, never stand or
walk underneath equipment.
MOVING PARTS can
cause serious injury.
READ INSTRUCTIONS.
1) Never try to stop the pinion from moving
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 equipment.
2
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 specied for the plasma or welding unit.
NOTE: Some plasma and welding units produce exceptionally large amounts of high
frequency noise. They may require a grounding rod be driven into the earth within six
feet (2 meters) of the plasma or welding unit to become compatible with an automatic
cutting or welding process.
4) If the high frequency is produced using a spark gap, adjust the points so the gap is as
small as possible. The larger the gap, the higher the voltage and the higher the inter ference.
5) Some plasma or welding units will inject high frequency interference into the AC
power line. Use separate power line branches whenever possible to power the
plasma or welding source and the machine. Do not plug them into the same outlet
box.
6) High frequency noise may enter the machine through the plasma or welding supply
remote contactor leads. Some plasma and welding sources can produce noise spikes
of up to several thousand volts. These sources are not compatible with automated
cutting and welding equipment. It is recommended that the remote contactor leads on
these plasma or welding sources not be connected to the machine. An alternate
solution is to purchase a separate remote contactor isolation box.
3
PROGRAMMABLE GANTRY SYSTEM
INSTRUCTIONS AND PARTS MANUAL
TABLE OF CONTENTS PAGE
PAGE
5.............. Setup and Operating Instructions
6,7........... Introduction: Program Control Description and Operation
7.............. Shape Programming
8.............. Segment Type and Quadrant Chart #1
9-11 ......... Programming Data Requirements
12............ Setting Measurement Units: Metric or Inches
13-14 ...... Shape Programming Examples
15............ Hand Held Pendant
16............ PGS-1000 Programmable Gantry System / Exploded View
17............ Programmable Gantry System / Parts List / Technical Data
18............ MUG-1680 Control Box Functions
19............ MUG-1680 Control Box Wiring Diagram
20............ MUG-1680 Control Box Electrical Component Chart
21............ MUG-1590-E Drive Unit / Parts List
22............ MUG-1595 Encoder Assembly / Parts List
23............ Drive Unit / Encoder Assembly Wiring Diagram
24............ Pendant Cable Wiring
25............ Plasma Cutting
26............ Aluminum Rigid Rail
27............ PRS-1010 Power Racker Introduction / Technical Data
28............ PRS-1050 Motorized Block Assembly / Parts List
29............ Power Racker Wiring Diagram / Electrical Component Chart
30............ Accessories
31-32 ...... Suggested Bed Designs for Burning Table
33............ Operation Checklist and Troubleshooting
34............ Keypad Character / Map Direct and Shifted Characters
35............ Program Diagnostics for Gantry
36............ Warranty
------CAUTION------
DO NOT LEAVE EQUIPMENT
UNATTENDED WITH POWER ON.
BE CERTAIN POWER IS OFF WHEN
4
NOT IN USE!
SETUP
The GANTRY is shipped in major assemblies, ready to assemble on your burning table. It is very important to
construct the burning table carefully; two suggested bed designs are shown on pages 31 and 32. Whichever design is
used, it is critical that:
1. The ARR-1080 Rails are mounted on strong supports, independent of the burning bed. By using a 6" (150 mm)
beam, the rails may be mounted in a straight line, by using the ARR-1050 mounting system, even though the steel
may not be perfectly straight. USE A TRANSIT when setting the rails to ensure they are both LEVEL AND
STRAIGHT.
2. After the rails are installed and checked, put the carriages one at the time on the rails. The LEFT carriage is the
one with the Controls.
3. Insert the 2 vertical columns (MUG-1053) into the column bases (MUG-1050). Place the Crossing Rail on the
columns, and bolt on loosely. With the drives disengaged, square up the gantry, level the crossing rail, and then
tighten the Crossing Rail clamps. Slide the cross drive on to the rail.
4. Connect the cables between various components, referring to diagrams on page 16.
5. Rotate the clutches on the 3 drive units to engage the pinions with the racks. The machine can now be plugged in
and run.
OPERATING INSTRUCTIONS
1. Check that the cross-beam is square to the main track. Adjust the torch position, and connect the required gas
hoses or plasma trigger connection.
2. Plug the machine into the power line of correct voltage, and push the RESET button.
3. Push the red STOP/PAUSE button and use the toggle switches to move the machine and cross drive to the
starting position. Press the RESET button to make this the starting point.
4. Set the speed knob for correct speed. Speed can be checked by moving the machine manually using the toggle
switches.
5. It the required shape has not been programmed, refer to Shape Programming, and enter the program. If the
shape has been programmed, turn on the preheat gases, set the torch height and ignite the torch.
6. When the work piece is heated enough, press the black RUN button. The solenoid will turn on the cutting oxygen,
the machine will start moving along the programmed shape, and at the end of the shape it will stop and turn off
the, solenoid. Manually turn off the preheat gases. The machine is now ready for the next cut. Note: For Plasma
Cutting, see page 25.
5
INTRODUCTION
This is a 2-axis gantry that has 2 synchronized drives running on parallel tracks, and a second axis drive carrying a
cutting torch that runs on a cross beam. It can be used for ame or plasma cutting, or welding, of a variety of shapes
programmed and stored in memory.
PROGRAM CONTROL DESCRIPTION
The machine has 20 storage areas in memory for different programmed shapes, numbered 0 to 19. At any time, one of
these shape numbers is the current one, and will stay current even when power is shut off and turned back on, until the
shape number is changed by the operator.
All programming is done with the hand-held terminal provided; this may be plugged into the connector on the rear of the
machine or unplugged at any time. The terminal is not needed to run the machine once programmed; it is recommended
it be disconnected when cutting.
Shapes are built up only from the segments provided: circular arcs and straight lines, square or inclined, by selecting
type and quadrant for each segment. A shape can have up to 50 segments. Some other operations, like solenoid On/
Off, time delay, or repeat another shape a number of times, also count as one segment each if used.
OPERATION
When rst plugged in, the position of the machine becomes the reference Start (Home) position. Now there are 3
options (the pendant terminal is not needed for the rst two).
1. MOVE
To change the Start position, push and release the STOP/PAUSE button, move the machine manually to the
required position using the manual X and Y jog switches, and push the RESET button.
2. RUN
Push the RUN button to cut a shape.
3. PROGRAM using the Hand Held Terminal
The Programming operation is selected by pressing keys A, B, C, D, E.
A: ALL SEGMENTS; data entry for new shape consists of Total number of segments
Data for each: Type (arc, x/y line or slope)
Quadrant 1-4
Size (radius, or x/y dimension) See Shape programming for details.
For example, a 2 inch diameter circle could be 4 Segments:
1. 2 1 100 Counterclockwise arc quadrant 1 1.00 inch rad
2. 2 2 100 Counterclockwise arc quadrant 2 1.00 inch rad
3. 2 3 100 Counterclockwise arc quadrant 3 1.00 inch rad
4. 2 4 100 Counterclockwise arc quadrant 4 1.00 inch rad
The data should be tabulated on paper from a diagram before entering.
B: PROGRAM SEGMENT
Press B on terminal to re-program a single segment. This is useful if there is an error in data for just one
segment, so the whole shape does not have to be re-entered.
C: CHANGE Shape Number
Press C on terminal to change the current shape number. Enter the new shape number. The program
switches to the new number in memory, and to whatever shape is stored there.
6
OPERATION, CONT’D.
D: DISPLAY Shape Data
Press D to display the data for the current shape. The terminal display shows Total No. of segments, and
data for each segment one by one each time you press Enter.
E: END of segment Slowdown.
Press E to set Deceleration value for the shape, when the machine approaches the end of each segment.
This is useful when the shape has sharp corners, to prevent overshoot. 99 is maximum slowdown, 0 is no
slowdown.
IMPORTANT:
1. Once the HOLD button is pressed, computer control is halted until the RUN or the RESET button is pressed.
Therefore the programming cannot be done with the handheld terminal in this state; the RESET button should
be pressed rst.
2. After pushing A and programming a new shape, End of segment Slowdown will still have the old value unless
reprogrammed. To set-new value, push E.
SHAPE PROGRAMMING
1. Draw the required shape on paper to some scale.
2. Refer to the Segment Chart (Chart #1) and divide the shape into straight line and arc segments.
3. Decide on the operation sequence and mark any other operations such as turning torch on or off, or delay.
4. Number all the segments in sequence, including other operations if any, and make a table with required data.
Example for a clockwise circle starting from the top:
(Dimensions described for metric version)
Seg. No. Type Quadrant Dimensions
1. 1 1 300 (30 mm)
2. 1 4 300
3. 1 3 300
4. 1 2 300
5. With the machine powered up and pendant plugged in, select which shape number this will be.
Push C : display reads Shape No.
Push 3 for No. 3, press Enter key (backward arrow) .The program is now in Shape No. 3
6 . Push A : display reads “Total segments?”
Push 4 for 4 segments and Enter.
Display reads “1. Type?” waiting for Segment 1 data.
7. Push 1 for type, clockwise arc. (Refer to Chart #1).
Display reads “Quadrant?”
Push 1 for quadrant 1.
Display reads “mm x 10”
Push 3, 0, 0, Enter, for 300, which is 30.0 mm.
Segment 1 has now been entered, display reads “2. Type?”, asking for data for segment 2.
8. Repeat above steps to enter data for all segments, in sequence. Display will read “Ready” after all segments
are entered.
The shape program is now stored in memory as shape No. 3, and the machine is ready to cut the shape.
7
SEGMENT TYPE AND QUADRANT CHART
SEGMENT TYPES: QUADRANT:
#1 #2 #3 #4
1. CLOCKWISE 900 ARC
0
2. COUNTERCLOCKWISE 90
3. X OR Y AXIS LINE
ARC
4. OBLIQUE LINE
5. FUNCTIONS
6. FUNCTIONS
7. CLOCKWISE PARTIAL ARC
8. COUNTERCLOCKWISE
PARTIAL ARC
WELD/OXY
ON
REPEAT
ANOTHER
SHAPE
WELD/OXY
OFF
WAIT FOR
START BUTTON
AUXILIARY
MODES
TIME
DELAY
PERCENT
SPEED
CHART #1
8
PROGRAMMING DATA REQUIREMENTS
To program a complete new shape (press “A”):
Count the number of segments or operations and enter the total.
For each segment (refer to DIMENSIONS REQUIRED Chart #2, Page 10)
Enter TYPE : Select from 1 through 8
QUADRANT: 1,2,3 or 4; refer to Chart #1.
SIZE: One or more dimensions per segment as described below; 100 per inch or 10 per mm
(Depending on machine version); or for time, 100 per second of delay.
Eg. 150 = 1.5", or for metric 375 = 37.5 mm
NOTE: Maximum distance per segment is 72" (1829 mm)
DETAILED DESCRIPTION OF TYPES
Type 1. Clockwise, 900 arc segments.
Quadrant determined by which quarter of a full circle makes the arc. (See Chart #1).
Dimensions required: Radius only.
Type 2. Counterclockwise , 900 arc segments.
Quadrant determined by which quarter of a full circle makes the arc. (See Chart #1).
Dimensions required: Radius only.
Type 3. Line along X or Y axis.
Quadrant determined by direction of movement. (See Chart #1) (East: 1, North: 2, West: 3, South:4).
Dimensions required: Length only.
Type 4. Angled straight line.
Quadrant determined by direction of movement. (See Chart #1) (NE: 1, NW: 2, SW: 3, SE: 4 ).
Dimensions required: (1) X-dimension; movement along X axis
(2) Y-dimension; movement along Y axis
Type 5. Functions or other operations.
Quadrant by selecting function. (See Chart #1)
1. Weld/oxygen ON: turn ON weld contact-relay or cutting oxygen solenoid.
Dimensions required: None.
2. Weld/oxygen OFF.
Dimensions required: None.
3. Pause: Machine stops and waits until START/RUN button is pushed again.
Dimensions required: None.
4. Delay: Machine stops and holds position for a programmed time period, up to 99.99 seconds.
Dimensions required: time in .01 second units.
(eg. 2.5 seconds = 250)
Type 6. Special functions.
Determine quadrant by selecting function.
1. Repeat: Another complete shape will be repeated the specied number of times.
Shape No. of the repeated shape MUST BE LOWER than the Shape No. of the current
shape being programmed. Therefore it CANNOT BE USED IN SHAPE No. 0.
Data required: (1) Shape No. to be repeated
(2) Number of times.
2. Ellipse: This is provided for making a complete true ellipse, always starting from the left
(West extremity) and moving clockwise.
Dimensions required: (1) diameter along X-axis.
(2) diameter along Y-axis.
9
PROGRAMMING DATA REQUIREMENTS, CONT’D.
Type 7. Clockwise arc, must be less than 1800.
Quadrant determined by direction of end point of arc relative to the start point. (See Chart #2).
Dimensions required:
(1) X-dimension; offset along X-axis from start to end point.
(2) Y-dimension; offset along Y-axis from start to end point.
(3) Radius of arc.
Type 8. Counterclockwise arc, must be less than 1800.
Quadrant determined by direction of end point of arc relative to the start point. (See Chart #2).
Dimensions required:
(1) X-dimension; offset along X-axis from start to end point.
(2) Y-dimension; offset along Y-axis from start to end point.
(3) Radius of arc.
R R
L
1
X
4
Y
2
3
X
Y
6-2
10
X
R
7
Y
Y
R
X
8
CHART #2
PROGRAMMING DATA REQUIREMENTS, CONT’D.
AUXILIARY MODES: TYPE 6, QUADRANT 3
This function allows the 2 internal Solid State Relay outputs to be independently turned ON and OFF, providing
control of 2 output signals; and also to switch the machine between Rapid Traverse mode and Set Speed.
The machine is shipped with OUTPUT (1) wired to the amphenol connector for the external relay or solenoid,
using pins A and C. By default, this Output turns ON when the Start button is pressed to run a shape, and
turns OFF at the end of the shape. Both the contact relay and cutting solenoid use only Output (1).
OUTPUT (2) is present across pins A and D on the amphenol connector, but is not used by the standard relay
box - a custom box has to be made to use this output. By default the output is OFF when a shape is started,
until specically turned ON by the Solenoid/Weld ON command Type 5, Quad 1.
Subsequently while running, the Type 5 ON and OFF commands turn both Outputs On and Off together, and
both turn Off at the end.
When programming Type 6 Quad 3, a Mode Number is required to be entered. The 8 auxiliary modes, numbered
0 through 7, allow the setting of a mode with any combination of Outputs On or Off, and choice of Set Speed
by the speed knob, or maximum speed regardless of setting. The combinations are listed in the table below:
AUXILIARY MODES CHART
Mode
No.
Output 1 Output 2 Speed
0 Off Off Set
1 Off On Set
2 Off Off Hi
3 Off On Hi
4 On Off Set
5 On On Set
6 On Off Hi
7 On On Hi
11
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