INSTRUCTIONS
AND
PARTS MANUAL
SPEED WEAVER II
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-SPWV-IPM-0114
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
PHONE: 412-331-1776 http://www.bugo.com FAX: 412-331-0383
280 TECHNOLOGY DRIVE CANONSBURG, PENNSYLVANIA, 15317-9564 USA
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.
EQUIPMENT DAMAGE
ELECTRIC SHOCK can kill.
1.The equipment is not waterproof.
Using the unit in a wet environment
may result in serious injury. Do not
touch the equipment when wet or
standing in a wet location.
2.Never open the equipment without rst
unplugging the power cord or serious
injury may result.
3. 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.
4.Never remove or bypass the equipment
power cord ground. Verity the equip ment is grounded in accordance with all
applicable local and national electrical
safety codes. If none exist, use lnterna-
tional Electrical Code (IEC) 950.
READ INSTRUCTIONS
Read the instruction manual before installing
and using the equipment.
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. Do not leave the equipment unattended.
Remove from the worksite 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
moving except by removing power or
by using the STOP control.
2. Do not remove any protective panels,
covers or guards and operate equipment.
POSSIBLE.
CAUTION
DO NOT LEAVE EQUIPMENT UNATTENDED
WHEN NOT IN USE!
Remove from work site and store in a safe location.
2
SPEED WEAVER II
INSTRUCTION AND PARTS MANUAL
BUG-5300 120 VAC/50-60/1
BUG-5302 240 VAC/50-60/1
BUG-5304 42 VAC/50-60/1
TABLE OF CONTENTS
PAGE
5............INTRODUCTION / FEATURES
6............TECHNICAL DATA / ASSEMBLY / OPERATION
7............WHEEL ADJUSTMENT / WELD CONTACTS
8, 9........FUNCTIONS AND CONTROLS / WELD PATTERNS
10..........BUG-5300 SPEED WEAVER II / PARTS LIST
11 .......... BUG-5300 SPEED WEAVER II / EXPLODED VIEW
12..........WIRE LIST / WIRING DIAGRAM
13..........ELECTRICAL COMPONENT CHART
13..........TROUBLESHOOTING GUIDE
14..........KITS
15..........WARRANTY
THIS PRODUCT IS COVERED BY ONE OR
MORE PATENTS WORLD WIDE.
3
INTRODUCTION:
The SPEED WEAVER II is a compact, precision, all-position machine,
designed for maximum versatility in oscillation. Its solid-state controls with
graduated dials provide adjustable and readily repeatable control of critical
weld parameters.
The unit will oscillate up to 160 cycles per minute at a stroke of .125" (3 mm).
A stroke adjustment of .125 to 2" (3 to 51 mm), a wide speed range of 6 to
152 ipm (152 to 3810 mm/m), and independently adjustable left and right
dwell time of 0 to 3 seconds will cover any commonly encountered welding
requirements.
The Speed Weaver II is designed to mount on any BUG-O carriage or xture.
Its lightweight permits easy movement of the machine from one welding
location to another.
FEATURES:
• All Solid-state control circuitry
• Non-contact proximity sensors for end of stroke limits
• Minimum stroke .125" (3 mm) to 2" (51 mm) maximum
• High speed oscillation - 160 cycles/min at .125" (3 mm) stroke
• Wide speed range, 6-150 ipm (152-3810 mm/m)
• New welding mode: tractor stop during dwell
• Positive holding torque during dwell
• Independent dwell control, each side, 0-3 seconds
• Digital dial control with lock for weave amplitude
• Straight line mode: (stringer pass)
5
TECHNICAL DATA
Power
Requirement - 60 watts at rated voltage:
BUG-5300 120 VAC/50-60/1
BUG-5302 240 VAC/50-60/1
BUG-5304 42 VAC/50-60/1
Dwell Time: 0 to 3 secs. each side
Dimensions: 6.5"H x 8.5"L x 8.75"W
(165 mm x 216 mm x 222 mm)
not including rail and torch
mounting
Net Weight: 19 lbs. (8.6 kg)
Shipping Weight: 22 lbs. (10 kg)
Linear Speed: 6 to 150 ipm
(152-3810 mm/m)
Stroke: .125" to 2" (3 to 51 mm)
Cycles / Minute: (Maximum speed, zero dwell left and right)
Stroke: (in.) .125 .25 .50 1.0 2.0
(mm) 3 6 12 25 51
Cycles: 160 120 85 60 37
ASSEMBLY AND
OPERATION ASSEMBLY:
MOUNTING:
The Weaver is normally mounted on a BUG-O drive carriage; bolt the mounting
bar on the Weaver to the front end of the carriage or xture (Fig. 1).
8.75"
(222mm)
6.5"
(165mm)
8.5"
(216mm)
Figure 1
(Fig. 2) A swivel mount is available for mounting the Weaver so that it can
pivot around 2 axis. This enables it to make llet weld or other angled-weave
welds. The swivel mount bolts to the carriage and the Weaver in turn bolts
to the swivel mount.
Mounts to
Weaver
Mounts to
Carriage
BUG-5195 Weaver Swivel Mount
6
Figure #2
WHEEL ADJUSTMENT
The gauge of the wheels is adjusted to the supplied rail
before being shipped. The wheels on the forward side of
the Weaver are externally adjustable - they have stainless shim washers under them. If it is ever necessary to
readjust them, rotate the Hex Head Bolt (K) with a 1/2"
wrench until the wheels are snug in the rail groove but
can still be forced to slip with nger pressure.
CROSS-RAIL INSERTION:
To insert the rail, turn the mode selector switch to any of the three weave
positions, with the power off. Plug in the Weaver power cord.
Insert the rail from the right, guiding the rail into each pair of wheels successively, until the rack meshes with the drive pinion, then throw the power switch
on. The rail will start oscillating automatically.
WELD CONTACTS:
For weld contact control, remove the trigger-switch leads from the welding
gun and connect them to the “amphenol” plug provided, that mates with the
connector on the Weaver panel.
OPERATION:
1. Setup the rail on the work, parallel to, and at a suitable distance from the
weld joint, using magnet bars, vacuum cups, or other fastening means.
2. De-clutch the drive on the BUG-O carriage and slide it along the rail
to the desired location with the Weaver mounted on it. Engage the drive
clutch.
3. Rack the welding gun into position, set the nozzle angle and clamp in
place. Run the welding cable through the cable anchor and clamp
in place.
K
4. Set the weave speed and dwell left and right by the control knobs on
the panel, set the weave amplitude on the dial counter, and rotate the
MODE selector switch to the weave position for the welding mode desired.
5. Set the speed and direction of travel of the tractor drive, and plug the
BUG-O power cord into the Weaver outlet.
6. Plug the Weaver cord into the power outlet and throw the power switch
on. After checking all settings and operations, push the weld contact switch
to the “On” position to start welding.
The machine will now travel down the track weaving a perfectly uniform
weld precisely to the parameters set until shut off.
7
FUNCTION AND CONTROLS
1. The Speed Control Knob (A) sets the traverse speed of the cross rails:
turn clockwise to increase speed. Common weaving speeds are from
“20” to “30” on the graduated dial.
2. Two Dwell Control Knobs (B, C) set the time interval that the torch
dwells at each end of the stroke - one control for each side. Dwell time can
be set from 0 to 3 seconder independently for left and right side of weave.
3. The Amplitude Control Knob (D) on the side of the machine sets the
length of the weave stroke between .125 and 2" (3 to 51 mm). The dial counter
reads 100 for every .125" (3 mm) of stroke, eg. a reading of 0300 would give
a .375" (9.5 mm) weave. The dial counter has a lever on the bottom that locks
the amplitude setting.
4. Power Controls.
Toggle Switch (E) is used to turn power ON and OFF to the machine.
Circuit Breaker (F) is rated at 0.7A (.5A for 240V) and provides protection
against overloads. If it pops up it can be reset by pushing down.
CAUTION: Find and correct the cause of overload before resetting.
5. Weld Contact Controls.
Toggle Switch (G) turns the Weld contacts ON when momentarily
pushed forward and released, and turns them OFF when pushed back.
The Weld Contacts are wired into the terminals on the “Amphenol”
Connector (H); the leads from the trigger switch on the welding gun should
be connected to the mating connector provided.
NOTE: The Weld Contacts will also shut off if the power to the Weaver is
interrupted or turned off for any reason.
B, C
D
A
J
F
G
E
H
8
6. Mode Selector Switch.
The 5-position Switch (J) is used to select any one of four welding
modes, described below, or to eject the cross rail.
A. RUN: In this mode, power to the tractor is always on, and the
tractor travels continuously both during weave and dwell.
Weave speed and dwell time both affect the weld patterns.
B. STEP: The tractor travels only during dwell, and stops during
the oscillator cross stroke. Changing weave speed does not
affect the weld pattern, dwell time does.
C. TRACTOR STOP ON DWELL: This is a new mode that has
proven very advantageous in certain cases. The tractor and
oscillator travel simultaneously during the weave stroke, both
stop during dwell. Dwell time thus does not affect the weld
pattern, it controls the weld deposit on each side.
D. NO WEAVE: In this mode oscillation is stopped and only the
tractor moves, to make stringer passes.
E. Switchingtothefthpositionwillejecttherail.
WELD PATTERNS:
A
B
C
D
When mounted on a tractor plugged into its panel, the Weaver
produces the above weld patterns; shown for increasing dwell time or
tractor speed from left to right.
9
BUG-5300 SPEED WEAVER II / PARTS LIST
ITEM QTY PART NO. DESCRIPTION
1 1 ARM-2279 Toggle Switch (Power)
2 1 ARR-1150 Cross Rail Assembly
* 3 1 BUG-1393 Volt Trap 120 VAC
4 1 BUG-1548 Rotary Switch (Mode Select)
5 1 BUG-1577 Short Arm Hex Key
6 1 BUG-1600 Gear Motor (50:1)
7 1 BUG-1770 Motor Control Board
8 2 BUG-1982-N Nylon Ext Adj Leg & Wheel Assembly
* 9 1 CIR-5247 Circuit Breaker 0.7 Amp
10 1 BUG-2924 Reset Button Seal
11 2 BUG-2956-N Nylon Fixed Leg & Wheel Assembly
* 12 1 BUG-5001 Transformer 120 VAC
13 2 BUG-5054 Potentiometer, 500K (Dwell)
14 1 BUG-5308 Rackholder Adaptor Plate
15 1 BUG-5309 Spacer
16 1 BUG-5311 Base
17 1 BUG-5312 Screw
18 1 BUG-5313 Side Panel
19 1 BUG-5314 Side Panel
20 1 BUG-5319 Cover
21 1 BUG-5321 Power Receptacle
22 1 BUG-5323 Toggle Switch (Weld Contact)
23 1 BUG-5385 Sensor Assembly (includes both sensors)
24 1 BUG-5333 Tractor Switch
25 1 BUG-5335 Weaver Circuit Board
26 1 BUG-5339 Mounting Bar
27 1 BUG-5451 3.5" Rackholder
28 1 BUG-5455 Gun Mounting Group
29 1 BUG-9198 Right Angle Rack
30 1 BUG-9444 Tool Kit
* 31 1 BUG-9445 Power Cord 120 VAC
32 1 BUG-9446 Cord Grip
33 1 BUG-9486 Panel Connector, 2-T, M
34 1 BUG-9487 Cable Connector, 2-T, F
35 1 BUG-9603 Pillow Block
36 2 BUG-9621 Knob
37 1 BUG-9628 Cap & Chain Assembly
38 1 BUG-9676 Dial Counter
39 1 BUG-9686 Potentiometer Control
40 1 BUG-9694 Knob
41 14 FAS-0114 Pan Hd Scr 6-32 x 3/8 Lg
42 3 FAS-0124 Pan Hd Scr 8-32 x 3/
43 2 FAS-0155 Pan Hd Scr 1/4-20 x 1/2
44 4 FAS-0204 Rnd Hd Slt Scr 4-40 x 3/8 Zinc
45 4 FAS-0527 Soc Hd Cap Sor 8-32 x 314 Lg
46 2 FAS-0559 Soc Hd Cap Scr 1/4-20 x 1" Lg
47 2 FAS-0735 Fil Hd Scr 10-24 x 1/2 Lg
48 4 FAS-1305 Hex Nut 4-40
49 3 FAS-1320 Hex Nut 8-32
50 2 FAS-2351 Hex Hd Cap Scr 1/4-20 x 1 1/4 Lg
51 4 GOF-3012 Stand-off
52 1 GOF-3014 Pinion
53 3 WAS-0221 # 8 Internal Star Lockwasher
See Electrical Component Chart for 240 VAC and 42 VAC part numbers.
10 11
BUG-5300 / EXPLODED VIEW
41
18
32
38
7
42
28
14
27
29
25
21
39
2
40
4
36
13
36
13
41
43
0
3
12
10
9
22
34
44
37
33
48
1
20
31
5
50
30
26
46
16
11
8
8
24
49
23
17
51
47
15
35
53
52
6
19
45
41
ITEM DESCRIPTION
W/BLK Switched line power, weave board to tractor outlet
W/BRN Speed signal voltage, weave to speed board, 0-8 V
W/RD Weld contact switch control to weave board, 8 or -5 V
W/OR Made select switch to weave board
W/GRN Stop on dwell, weave board to selector switch
W/BLU Fwd/Rev signal, 0 or 8 V, weave board to speed board
W/GY Step, 0 or 8 V, weave board to selector switch
W/B/OR Delay left, pot to weave board
W/B/GRN-1 Weld contact, weave board to amphenol
W/B/GRN-2 Weld contact, weave board to amphenol
W/B/BLU Delay right, pot to weave board
BLK-1 Input line to power switch, hot side
BLK-2 Power line, switch to circuit-breaker
BLK-3 Power line to weave board, for tractor switch
BLK-4 Power line from circuit-breaker to transformer
BRN Speed signal fr om speed pot to weave board, 0-8 V
RED Motor current
OR-1 Weld switch to selector switch, 8 V line
OR-2 Selector switch to dwell pot-right
OR-3 Dwell pot-right to dwell pot-left
OR-4 Dwell pot-left to speed pot
OR-5 Speed pot to 8 V supply from weave board
YEL-1 -5 V from speed board to weld switch
YEL-2 Weld contact switch to mode select switch, -5 V
YEL-3 Select switch to sensor connector, -5 V
YEL-4 Select switch to sensor connector, -5 V
GRN-1 Power line ground, line cord to machine case
GRN-2 Ground, case to tractor power socket
LT.BLU Circuit common (O V), speed board to speed pot
BLU-1 Common (O V), selector switch to motor
BLU-2 Common, speed board to selector switch
BLU-3 Common, transformer C.T. to speed board
BLU-4 Transformer C.T. to weave board, O-V ref.
VIO Sensor input, left, sensor to weave board
GY-1 Sensor input, right
WHT-1 Power input line
WHT-2 Line power, on-off switch to outlet
WHT-3 Line power, outlet to 20 V.C.T. transformer
TN-1 Transformer sec., supply to speed board
TN-2 Transformer sec., supply to weave board
TN-3 Transformer sec., supply to speed board
TN-4 Transformer sec., supply to weave board
PINK Motor current, speed board to selector switch
WIRING DIAGRAMWIRE LIST
12
ELECTRICAL COMPONENT CHART
ITEM
120 VAC 240 VAC 42 VAC
BUG-5300 BUG-5302 BUG-5304
VT Volt Trap BUG-1393 BUG-1563 BUG-1393
PC Power Cord BUG-9445 GOF-3115 BUG-9445
CB Circuit Breaker CIR-5247 BUG-2952 BUG-2933
PO Power Socket BUG-5321 BUG-9595 BUG-5321
T Transformer BUG-5001 BUG-5002 BUG-5003
MCB Motor Control Board BUG-1770
TCB Tractor Switch BUG-5333
WCB Weaver Circuit Board BUG-5335
SW1 Power ON-OFF Switch ARM-2279
WT Connector-Weld Contact BUG-9486
SW2 Toggle Sw.-Weld Cont. BUG-5323
SW3 Rotary Sw.-Mode Select BUG-1548
Pl Speed Pot., 1 OK BUG-9686
P2,P3 Dwell Pot. L&R BUG-5054
SN Sensor Assy. L&R BUG-5385
M Gear Motor BUG-1600
DESCRIPTION
FUNCTION
PART NUMBER
TROUBLESHOOTING GUIDE
PROBLEM CAUSE REMEDY
Machine dead. No Power. Check supply line for power
Plug power cord in rmly.
Circuit-breaker Find cause of overload
popped. correct and reset breaker.
Weaver runs, Bad tractor switch. Replace tractor switch BUG-5333
tractor dead. (plug in on Weaver board).
Weaver does not Faulty speed board. Replace speed board BUG-1770.
stop in dwell.
13
KITS
BUG-1916 DC SPEED WEAVING KIT
(120/50-60/1)
Includes:
1 BUG-0343 BUG-O DC-IV
1.5-30 ipm (38-762 mm/min)
Includes:
1 BUG-9444 Tool Kit
1 BUG-5300 Speed Weaver II
1 BUG-5195 Weaver Swivel Mount
1 BUG-2975 Cable Mounting Assembly
1 ARR-1080 H.D. Rigid Rail 93-1/2" (2.37 m)
1 ARR-1085 H.D. Rigid Rail 46-1/2" (1.18 m)
5 ARM-2325 Magnet Bar, Swivel w/Release
BUG-1917 Same as above, except with
240 VAC BUG-O DC-IV BUG-0443
and Speed Weaver II BUG-5302
BUG-1918 Same as above, except with
42 VAC BUG-O DC-IV BUG-0543
and Speed Weaver II BUG-5304
14
BUG-5195
Weaver Swivel Mount
WARRANTY
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.
MODEL ____________________________
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.
15
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