BUG-O Systems Side Beam System User Manual

INSTRUCTIONS

AND

PARTS MANUAL

SIDE BEAM 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-SBC-4555-IPM-1014

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

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.

Read the instruction manual before
installing and using the equipment.

2

1) Never try to stop the pinion from moving
except by removing power or by using the
STOP control.

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

HIGH FREQUENCY WARNINGS

SPECIAL PRECAUTIONS ARE REQUIRED WHEN USING PLASMA,

TIG OR ANY WELDING PROCESS THAT USES HIGH FREQUENCY

TO STRIKE AN ARC.

WARNING: HIGH FREQUENCY CAN EFFECT MACHINE

OPERATION AND THEREFORE, WELD QUALITY.

Read the precautions below before installing and using the equipment.

PRECAUTIONS:

1) Some plasma or welding cables are strong sources of high frequency interference.

NEVER lay a plasma or welding cable across the controls of the machine.

2) Always physically separate the plasma or welding cable leads from the machine
cables. For example, the plasma or welding cable leads should NEVER be bundled
with a pendant cable or the machine power cord. Maximize the separation between
any machine cables and the plasma or welding cables.

3) Strictly follow the grounding procedures specied for the plasma or welding unit.
NOTE: Some plasma and welding units produce exceptionally large amounts of high
frequency noise. They may require a grounding rod be driven into the earth within six
feet (2 meters) of the plasma or welding unit to become compatible with an automatic
cutting or welding process.

4) If the high frequency is produced using a spark gap, adjust the points so the gap is as
small as possible. The larger the gap, the higher the voltage and the higher the inter­ ference.

5) Some plasma or welding units will inject high frequency interference into the AC
power line. Use separate power line branches whenever possible to power the
plasma or welding source and the machine. Do not plug them into the same outlet
box.

6) High frequency noise may enter the machine through the plasma or welding supply
remote contactor leads. Some plasma and welding sources can produce noise spikes
of up to several thousand volts. These sources are not compatible with automated
cutting and welding equipment. It is recommended that the remote contactor leads on
these plasma or welding sources not be connected to the machine. An alternate
solution is to purchase a separate remote contactor isolation box.

3

SIDE BEAM SYSTEM

INSTRUCTIONS AND PARTS MANUAL

TABLE OF CONTENTS

PAGE

5.......Introduction / Mounting

6.......SBC-4555 Motorized Carriage / Exploded View

7.......SBC-4555 Motorized Carriage / Parts List

8.......CWO-3918-MH Carriage Assembly Motorized Horizontal / Exploded View

9.......CWO-3918-MH Carriage Assembly Motorized Horizontal / Parts List

10.....SBC-1065 Floating Car w/ Follower / Exploded View / Parts List

11 .....SBC-1020-DS Dual Side ABR 62"

12.....MUG-1145 Carriage Spotter Sub Assy. / Exploded View / Parts List

13.....MUG-1145 Carriage Spotter Sub Assy. / Exploded View / Parts List

14.....CWO-1690 Large Horizontal Racker / Exploded View / Parts List

15.....SBC-6110 M-14 Rotational Control / Wiring Diagram

16.....SBC-5997 Bodine Motor w/ Connector / Wiring Diagram

16.....SBC-1635-10-2 Remote Weld Starter (Two Guns) / Wiring Diagram

17.....Warranty

4

INTRODUCTION

Bug-O Side Beam Systems are custom designed assemblies that are used in a variety of applications

such as automated seam welding, beam and stiffener fabrication as well as cutting applications such as
stripping and edge preparation. A wide range of gantry and side beam carriage designs are available and
can be used to suite a specic application. Systems are available in programmable or manually operated
versions. Consult your Bug-O distributor for more information.

MOUNTING

You will need the following:

Side View

• Standard allen keys

• Standard wrench set

• Large C clamps 8-10 inch range

1) Loosen bolts (1). There are two bolts per carriage. The
slide bolts to the back of the carriage towards the U slot
of the motor mount.

1

2) Install the carriage onto the monorail. Using the large C
clamps, tighten the carriage to the monorail. Tighten the
C clamps which will bring the face of the carriage toward
the monorail, this will bring the face of the carriage into
place. These wheels are (2) on the drawing.

3) Bring the bolts (1) to the monorail and tighten. This will
secure the carriage to the monorail. Loosen clamps and
slide carriage. This should move easily on the beam.
Repeat process for the second carriage.

2

5

SBC-4555 MOTORIZED CARRIAGE / EXPLODED VIEW

23

14

12

2

6

5

4

25

11

26

20

24

27

22

17

8

28

16

21

15

13

3

19

1

9

18

7

10

6

SBC-4555 MOTORIZED CARRIAGE / PARTS LIST

ITEM QTY PART NO. DESCRIPTION
1 1 CWO-3918-MH Carriage Assy. Motorized Horiz.

2 1 CWO-5997 Bodine Motor 156 w/connector
3 1 CWO-4884 McGill Cyr 1/45
4 1 CWO-5768 Pinion Gear w/ Key
5 1 SBC-4551 Shaft Extender

6 1 CWO-5802 Motor Mount Plate
7 1 CWO-5804 Guard
8* 1 SBC-6110 Rotation Control Modied
9 1 CWO-9006 Wheel & Clamp Mount (left)
10 1 FAS-0357 Hex Hd Cap Scr 1/4-20 x 3/4"
11 2 FAS-0359 Hex Hd Cap Scr 1/4-20 x 1"
12 1 FAS-0455 Set Scr 1/4-20 x 1/2" Cup Point
13 2 FAS-0558 Soc Hd Cap Scr 1/4-20 x 7/8
14 1 FAS-0593 Soc Hd Cap Scr 3/8-16 x 1-1/2
15 1 FAS-0679 Soc Hd Shr 3/8" x 1" x 5/16-18
16 2 FAS-0955 Flt Hd Soc Scr 1/4-20 x 1/2"
17 2 FAS-0957 Flt Hd Soc Scr 1/4-20 x 3/4"
18 2 FAS-0999 Flt Hd Soc Scr 3/8-16 x 1"
19 2 FAS-1350 Hex Jam Nut 1/4-20
20 4 FAS-2556 Soc Hd Cap Scr 1/4-20 x 2-1/2
21 1 SBC-1014 Control Mount Angle
22 1 SBC-4540 Side Beam Clutch Assembly
23 2 SBC-4547 Cot Extension Spring
24 1 SBC-4548 Stabilizer Block
25 1 SBC-4549 Stabilizer / Stop Block
26 2 WAS-0240 1/4" SAE Washer
27 2 WAS-0243 1/4" Split Lockwasher
28 1 SBC-1635-10-2 Pendant Control (2 guns) (Part of SBC-6110)

* 240 VAC requires SBC-6110-240 Rotation Control

7

CWO-3918-MH CARRIAGE ASSEMBLY MOTORIZED HORIZONTAL /
EXPLODED VIEW

8

CWO-3918-MH CARRIAGE ASSEMBLY MOTORIZED HORIZONTAL / PARTS LIST

ITEM QTY PART NO. DESCRIPTION

1 1 CWO-9001 Carriage Front Plate
2 1 CWO-9002-MT Carriage Top Plate Motorized
3 1 CWO-9003 Carriage End Plate (L.H.)
4 1 CWO-9004 Carriage Reinforcement Bar
5 1 CWO-9005 Wheel & Clamp Mounting Block, Right
6 1 CWO-9006 Wheel & Clamp Mounting Block, Left
7 3 CWO-9007 Cam Roller Spacer
8 4 CWO-9008 Wheel Mount Block
9 1 CWO-9011 Carriage Back-up Bar
10 1 CWO-9194 Carriage End Plate (R.H.)
11 9 CWO-4884 Cam Roller Spacer
12 2 FAS-0557 Soc Hd Cap Scr 1/4-20 x 3/4"
13 6 FAS-0679 Soc Hd Cap Scr 3/8 x 1 x 5/16-18
14 19 FAS-0959 Flt Hd Soc Scr 1/4-20 x 1"
15 22 FAS-0999 Flt Hd Soc Scr 3/8-16 x 1"
16 11 FAS-1390 Hex Nut 3/8-16
17 3 FAS-2397 Hex Hd Cap Scr 3/8-16 x 2-1/2"
18 4 FAS-2399-FT Hex Hd Cap Scr 3/8-16 x 3-1/2" Full Thread
19 7 WAS-0260 3/8" Washer
20 7 WAS-0262 3/8" Split Lockwasher
21 2 CWO-9490 Lower Cam Roller Assembly
* 2 CWO-9492 Metric Spacer Plate

* Not Shown

9

SBC-1065 FLOATING CAR W/ FOLLOWER / EXPLODED VIEW / PARTS LIST

10

ITEM QTY PART NO. DESCRIPTION

1 1 CWO-1690 Large Horizontal Racker
2 1 MUG-1145 Carriage Spotter Sub-Assy
3 1 ABR-1060 V-Guide Ways 33"

SBC-1020-DS DUAL SIDE ABR 62"

ITEM QTY PART NO. DESCRIPTION

1 1 SBC-1021-DS Dual Side Abr Box 65"
2 2 SBC-1022 Rack 62"
2 2 SBC-1023 Spacer 62"
3 4 SBC-1024 T-3 Guide Way 62"
4 1 SBC-1025 Gusset Assembly
5 2 SBC-1029 Mtg. Angle
6 10 FAS-0399-SS Hex Hd Cap Scr 3/8-16 x 1"
6 10 WAS-0260-SS 3/8 Washer
7 44 FAS-0535-SS Soc Hd Cap Scr #10-24 x 1/2"
8 22 FAS-0545-SS Soc Hd Cap Scr #10-32 x 1/2"
8 22 WAS-0232-SS #10 Split Lock Washer

11

MUG-1145 CARRIAGE SPOTTER SUB ASSY. / EXPLODED VIEW / PARTS LIST

12

ITEM QTY PART NO. DESCRIPTION

1 1 BUG-2032 Knob, Black w/ Set Scr 1/4-20 x 3/8" (FAS-0454)
2 1 FAS-0357 Hex Hd Cap Scr 1/4-20 x 3/4"
3 1 FAS-0557 Soc Hd Cap Scr 1/4-20 x 3/4"
4 1 FAS-1307 Hex Jam Nut 3/4-16
5 1 MUG-1141 Bearing, Collet
6 1 MUG-1142 Knob, Locking
7 1 MUG-1143 Positioning Plate
8 1 MUG-1502 Gear Assembly
9 1 MUG-1579 Retaining Ring For 3/4" Shaft

MUG-1145 CARRIAGE SPOTTER SUB ASSY. / EXPLODED VIEW / PARTS LIST

NOTE: WHEN USED FOR MUG-1148 (TORCH
SPOTTER), CUT MUG-1143 (POSITIONING PLATE) TO

2.5" LONG AND INVERT IN ASSEMBLY AS SHOWN.

ITEM QTY PART NO. DESCRIPTION

1 1 BUG-2032 Knob, Black w/ Set Scr 1/4-20 x 3/8" (FAS-0454)
2 1 FAS-0357 Hex Hd Cap Scr 1/4-20 x 3/4"
3 1 FAS-0557 Soc Hd Cap Scr 1/4-20 x 3/4"
4 1 FAS-1307 Hex Jam Nut 3/4-16
5 1 MUG-1141 Bearing, Collet
6 1 MUG-1142 Knob, Locking
7 1 MUG-1143 Positioning Plate
8 1 MUG-1502 Gear Assembly
9 1 MUG-1579 Retaining Ring For 3/4" Shaft

13

CWO-1690 LARGE HORIZONTAL RACKER / EXPLODED VIEW / PARTS LIST

F = FIXED WHEEL PLACEMENT
A = ADJUSTABLE WHEEL PLACEMENT

14

ITEM QTY PART NO. DESCRIPTION

1 1 BUG-2032 Knob, black w/ Set Scr 1/4-20 x 3/8" (FAS-0454)
2 1 CWO-1678 Racker Plate
3 1 CWO-1679 Pinion 11T
4 2 CWO-1680 W2 Fixed Leg & Wheel Assembly
5 2 CWO-1681 W2 Adj. Leg & Wheel Assembly
6 1 CWO-1687 Mount Plate (Large Racker)
7 2 CWO-4326 Fixed Leg & Wheel Assembly
8 2 CWO-4327 Adj. Leg & Wheel Assembly
9 2 FAS-0557 Soc Hd Cap Scr 1/4-20 x 3/4"
10 1 FAS-1307 Hex Jam Nut 3/4-16
11 1 MUG-1141 Bearing Collet
12 1 MUG-1142 Knob, Locking
13 1 MUG-1144 Shaft
14 2 MUG-1453 Stand-off
15 1 MUG-1579 Retaining Ring
16 3 WAS-0240 1/4" SAE Washer
17 1 CWO-1671 Racker Shield
18 2 FAS-0559 Soc Hd Cap Scr 1/4-20 x 1"

SBC-6110 M-14 ROTATIONAL CONTROL / WIRING DIAGRAM

BLK

ACCEL

WHT

L1

L2

RED

RED

A-

CLIR

FH1

3 AMP

BLK

BLK

BLK

SW

WHT

WHT

BLK

WHT

BLKBLK

GRN

LMP

GRY

C

LT BLU
GRY

WHT

D

E

PC4
LS1

RED

LT BLU

WHT

A

F

B

C

E

D

BLK

PC4
LS2

F

E

D

VIO

VIO

K1

GRN/YEL

DRIVE MOTOR

D

A

B

C

FH2

1.5 AMP

GRY GRY

K1A

GRY

WHT

PC3

WELD CONTACT

DCBA

GRN

PC1

WHT

K1B

GRY

A+

P2

CB

YEL

P3 P1

RED

MAX MIN

BRN

GRN/YEL

GRN

ORG

BRN

GRNBLU

WHT
YEL

RED

PC2

A

B

M

N

L

T

P

K

S

R

J

H

F

G

GRN

WHT

GRN

BLU

RED

LT BLU

A

B

C

WHT

COIL

A B C D

WIRING CONNECTIONS

FOR K1

LS2

N.C.

N.O.
N.C.

N.O.

LS1

N.C.

WHT

N.O.
N.C.

N.O.

COM
N.O.
N.C.

CORD

A

B
C
D

E
F

A

B
C
D

E
F

CBC1

CBC1

ITEM PART NO. DESCRIPTION 120V 240V

CB CWO-6525 0-90Dc Speed Control W/Reset 1 1

CORD

BUG-9445 Power Cord 16/3 Type, So, 10 Amp 1

GOF-3115 Line Cord 240Vac 1

FH1 FHO-0188 Fuse Holder 1 1

FUS-0257 3 Amp 1 1

FH2 FHO-0188 Fuse Holder 1 1

FUS WTE 0190 1.5 Amp 1 1

LMP CWO-6206 Red Neon Lamp 125V 1

BUG-1428 Pilot Light 240V 1

PC1 BUG-1034 Panel Connector 4-T, M 1 1
PC2 BUG-5527 Panel Connector 17-T, F 1 1
PC3 MUG-1156 Panel Connector 4-T, F 1 1
PC4 BUG-9902 Panel Connector 6-T, F 2 2

CBC1 BUG-9906 Cable Connector 6-T, M 2 2

SW ARM-2279 Toggle Switch 1 1

K1 BUG-1383 Relay, 4Pdt, 3A 120V Plug In 1 1
LS1 BUG-9274 Micro Switch in Housing 1 1
LS1 BUG-9274 Micro Switch in Housing 1 1

15

SBC-5997 BODINE MOTOR W/ CONNECTOR / WIRING DIAGRAM

QTY PART NO. DESCRIPTION

1 MUG-1616 Cable Connector 4-T, M

SBC-1635-10-2 REMOTE WELD STARTER (TWO GUNS) / WIRING DIAGRAM

16

ITEM QTY PART NO. DESCRIPTION

CC 1 BUG-5552 Cable Connector 17-T, M
SW1 1 ABP-1069 Toggle Switch, ON-NONE-ON
SW2 1 ABP-1069 Toggle Switch, ON-NONE-ON
SW3 1 CWO-6525 0-90 VDC Speed Control w/ Reset, Pot Only
SW4 1 MUG-1258-1 Rotary Switch Assembly
R1 1 CWO-6213 50 OHMS, 10W, 5% Wire Wound

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 DIFFICULTY YOU HAVE EXPERIENCED. BE SURE TO MENTION THE MODEL
AND SERIAL NUMBERS.

17