INSTRUCTIONS
and
PARTS MANUAL
STAND ALONE
CDS LINEAR WEAVER
Please record your equipment identification information below for future reference. This information can be
found on your machine nameplate.
Model Number
Serial Number
Date of Purchase
Whenever you request replacement parts or information on this equipment, always supply the information
you have recorded above.
LIT-SALW-IPM-0409
A DIVISION OF WELD TOOLING CORPORATION
280 TECHNOLOGY DRIVE CANONSBURG, PENNSYLVANIA 15317-9564 USA
PHONE: 1-412-331-1776 http://www.bugo.com FAX: 1-412-331-0383
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
connectors covered with the supplied
protective panels. Operation of the
machine without the protective panels
may result in injury .
3. Never open the equipment without
first unplugging the power cord or
serious injury may result.
4. Verify the customer-supplied power
connections are made in accordance
with all applicable local and national
electrical safety codes. If none exist,
use International Electric Code (IEC)
950.
5. Never remove or bypass the equipment
power cord ground. Verify the
equipment is grounded in accordance
with all applicable local and national
electrical safety codes. In none exist,
use International Electric Code (IEC)
950.
EQUIPMENT DAMAGE
POSSIBLE.
1. Do not plug in the power cord without
first verifying the equipment is OFF
and the cord input voltage is the same
as required by the machine or serious
damage may result.
2. Always verify both the pinion and
wheels are fully engaged before
applying power or equipment damage
may occur .
3. Do not leave the equipment
unattended.
4. Remove from the worksite and store
in a safe location when not in use.
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.
READ INSTRUCTIONS.
Read the instruction manual before
installing and using the 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.
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
Read the precautions below before installing and using the equipment.
OPERATION AND THEREFORE, WELD QUALITY
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 weldingcables.
3) Strictly follow the grounding procedures specified for the plasma or welding unit.
NOTE: Some plasma and welding units produce exceptionally large amounts of
high frequency noise. They may require a grounding rod be driven into the earth
within six feet (2 meters) of the plasma or welding unit to become compatible
with an automatic cutting or welding process.
4) If the high frequency is produced using a spark gap, adjust the points so the gap
is as small as possible. The larger the gap, the higher the voltage and the higher
the interference.
5) Some plasma or welding units will inject high frequency interference into the AC
power line. Use separate power line branches whenever possible to power the
plasma or welding source and the machine. Do not plug them into the same
outlet box.
6) High frequency noise may enter the machine through the plasma or welding
supply remote contactor leads. Some plasma and welding sources can produce
noise spikes of up to several thousand volts. These sources are not compatible
with automated cutting and welding equipment. It is recommended that the
remote contactor leads on these plasma or welding sources not be connected to
the machine. An alternate solution is to purchase a separate remote contactor
isolation box.
3
STAND ALONE CDS LINEAR WEAVER
INSTRUCTIONS AND P ARTS MANUAL
TABLE OF CONTENTS
PAGE
5 ........ Introduction / Features
6........Major Components / Pictorial
6........Technical Data / Weaver Unit
7 ........CDS-1210 Dimensions
8........CDS-1210 Weaver Unit / Parts List
9 ........ CDS-1215 Weaver Unit Motor Plate Assembly / Parts List
10 ...... CDS-1210 Weaver Unit / Wiring Diagram
11 ...... BUG-6330 / Control Box
1 2 ...... BUG-6330 / Control Box / Exploded View
1 3 ......BUG-6330 / Control Box / Parts List
1 4 ......BUG-6330 / Control Box / Wiring Diagram
15 ...... BUG-5475 / Exploded View
1 6 ...... Connector Wiring Harness
1 7 ......Timer and Weave Wiring Harnesses
1 8 ......BUG-5570 Power Circuit Box / Exploded View
1 9 ......Power Circuit Box / Wiring Diagram
20 ......Warranty
THIS PRODUCT IS COVERED BY ONE OR
MORE PATENTS WORLD WIDE.
4
CDS-6350 STAND ALONE LINEAR WEAVER
INTRODUCTION
The S tand Alone CDS Linear Weaver is a self cont ained machine used for weave welding.
It can be installed as part of a welding fixture, or mounted on a drive carriage running on a
track.
The CDS Linear Weaver is particularly useful for weaving v-groove welds in a butt joint.
The Weaver box is attached on the end of an adjustable rack, held by a rackholder that
can be mounted on the front of the drive carriage, or directly on the welding fixture.
FEATURES
• High torque, low inertia motor for precise starts and stops.
• Heavy duty planetary gear box with powerful output shaft.
• Uniform linear motion with independent control of right and left dwell times.
• Closed loop speed control for adjustable and repeatable control of critical welding
parameters.
• Closed loop position control to prevent drift from the center position.
• Gun mounting group with adjustable linkage for accurate positioning of the gun.
• Weld Contactor ON/OFF switch.
5
CDS-6350: STAND ALONE LINEAR WEAVER
MAJOR COMPONENTS
BUG-6330
Control Box
BUG-5571
Power Cable
CDS-1210
Linear Weaver
BUG-5571
Power Cable
BUG-5295 Rod Mount Assy &
BUG-9180-6 Rod
BUG-5570, BUG-5572, BUG-5574
Power Circuit Box
TECHNICAL DATA / WEAVER UNIT
Power Requirement: CDS-6350 120 VAC/50-60/1
CDS-6352 240 V AC/50-60/1
CDS-6354 42 V AC/50-60/1
Weave Speed: 4 to 100 ipm (100 to 2540 mm/min)
Dwell: 0-3 seconds
Each side, calibrated
Weave Width: 0 to 2'' (0 to 50 mm)
Steering: 2'' (50 mm) left and right of center
4'' (100 mm) total
Dimensions: 6.75''L x 5.00''W x 4.88''H
(171 x 127 x 124 mm)
Net Weight: 20 lbs. (9.07 kg)
Shipping Weight: 25 lbs. (11.34 kg)
6
CDS-1210 DIMENSIONS
5''
(127 mm)
10''
(254 mm)
18.25''
(464 mm)
4.88''
(124 mm)
6.75''
(171 mm)
7
CDS-1210 WEAVER UNIT/PARTS LIST
12
6
4
7
10
1 2 BUG-5661 Stop Plate
2 1 BUG-9856 Panel Connector, 2-T, Female
3 1 BUG-9909 Panel Connector, 6-T, Male
4 1 CDS-1215 Motor Plate Assembly
5 1 CDS-1217 Panel, Control End
6 1 CDS-1218 Panel
7 1 CDS-1221 Cover
8 14 FAS-0114 Pan Hd Scr 6-32 x 3/8 Lg
9 8 FAS-0204 Rnd Hd Scr 4-40 x 3/8 Lg
1 1 8 FAS-1305 Hex Nut 4-40
10 2 FAS-0357 Hex Hd Cap Scr 1/4-20 x 3/4 Lg
ITEM QTY PART NO. DESCRIPTION
12
2
8
3
1 2 9, 11
1
5
8
12 1 BUG-5475 Weaver Racking Group
CDS-1215 WEAVER UNIT MOTOR PLATE ASSEMBLY/PARTS LIST
ITEM QTY PART NO. DESCRIPTION
1 1 BUG-5590 Gear Motor
2 1 BUG-5591 Pinion
3 2 BUG-5592 Spacer
4 4 BUG-5594 Pan Hd Scr 3mm x .5
5 1 BUG-5595 Pot/Gear Assembly
6 2 BUG-5670 Adj Leg & Wheel Assembly
7 2 BUG-5675 Fixed Leg & Wheel Assembly
8 1 CDS-1216 Mounting Plate
9
CDS-1210 WEAVER UNIT / WIRING DIAGRAM
ELECTRICAL COMPONENT CHART
ITEM DESCRIPTION PART NUMBER
M Gear Motor BUG-5590
P Servo Potentiometer BUG-5240
PS Power Supply Connector BUG-9909
TR Tractor Connector BUG-9856
10
BUG-6330 / CONTROL BOX
STEERING
CONTROL
WEAVE
SPEED
DWELL
LEFT
WELD
CONTACT
AMPLITUDE
DWELL
RIGHT
POWER
ON/OFF
WEAVE / NO WEAVE
TO PENDULUM GEAR BOX
POWER SUPPLY
11
BUG-6330 / CONTROL BOX / EXPLODED VIEW
2
7
10
3
6
1
18
10
17
10
16
4
10
13
15
9
10
19, 21
10
10
12
11
5
8
20
14
12
BUG-6330 CONTROL BOX / PARTS LIST
ITEM PART NO. Q TY DESCRIPTION
1 BUG-1770-PW 1 Motor Control Board
2 BUG-5757 1 Knob
3 BUG-5760 1 Control Board
4 BUG-6331 1 Front Panel
5 BUG-6332 1 Rear Panel
6 BUG-6333 1 Mounting Bracket
7 BUG-9621 4 Knob
8 CDS-1068 1 Mounting Bracket
9 FAS-0104 8 Pan Hd. Scr . 4-40 x 3/8 Lg.
10 FAS-0114 14 Pan Hd. Scr . 6-32 x 3/8 Lg.
11 F AS-0224 2 Pan Hd. Scr. 10-32 x 3/8 Lg.
12 FAS-0824 2 Flat Hd. Slt. Scr. 8-32 x 3/8 Lg.
13 FAS-1305 8 Hex Nut 4/40
14 SFX-1292 4 Bumper
1 5 WAS-0201-4 4 #4 Internal S tar Lock W asher
16 BUG-1869 1 SW-3 T oggle Switch, SPDT
17 BUG-5761 1 SW-2 T oggle Switch, DPST
18 ARM-2279 1 SW-1 T oggle Switch, DPST
19 BUG-9677 3 Potentiometer - 10k
20 BUG-5054 2 Potentiometer - 500k
21 BUG-5759 5 Pot Shaft Seal
* BUG-6336 1 Connector Wiring Harness
* BUG-6318 1 Weave Wiring Harness
* BUG-6337 1 Timer Wiring Harness
* not shown
13
BUG-6330 CONTROL BOX /
WIRING DIAGRAM
ELECTRICAL COMPONENTS
ITEM P ART NO. DESCRIPTION
CN-2 BUG-9909 Panel Connector , 6-T , M
CN-3 BUG-9902 Panel Connector, 6-T, F
P-1,2,3 BUG-9677 Pot, 10 K
P-4,P-5 BUG-5054 Pot, 500 K
PCB-1 BUG-5760 Control Board
PCB-2 BUG-1770-PW Motor Control Board
SW-1 ARM-2279 Toggle Switch, DPST
SW-2 BUG-5761 Toggle Switch, SPDT
SW-3 BUG-1869 Toggle Switch, SPDT
14
BUG-5475 / EXPLODED VIEW
5
1
2
3
4
ITEM Q TY PART NO. DESCRIPTION
1 1 BUG-5462 Right Angle Clamp
2 1 BUG-2708 Clamp
3 1 BUG-1853 Machined Rack 7-1/2''
4 1 BUG-2714 Rackrider w/Post
5 1 BUG-5695 Cross Arm
15
CONNECTOR WIRING HARNESS
BUG-6336
CNN-022A 10-PIN HOUSING
INCLUDES:
(1) CNN-022A-P 10 PIN HOUSING
(MOLEX P/N 09-50-8101)
(10) CNN-0220 PIN .156
(MOLEX P/N 08-50-0106)
CNN-0128 8-PIN HOUSING
INCLUDES:
(1) CNN-0128-P 8 PIN HOUSING
(MOLEX P/N 22-01-3087)
(8) CNN-0120 PIN .100
(MOLEX P/N 08-05-0114)
ARM-2279
TOGGLE
SWITCH,
ON-OFF,
DPST (EATON
P/N 7310K38)
BUG-9902
PANEL CONNECTOR 6-T, F
(DESC: DMS3102A14S(D235))
BUG-9909
PANEL CONNECTOR 6-T, M
(DESC: DMS3102A14S-6P(D235))
16
TIMER WIRING HARNESS
BUG-6337
WEAVE WIRING HARNESS
BUG-6318
CNN-012A
10-PIN HOUSING
ORG
RED
GRY
GRN
BLK
BLU
YEL
W/GN
WHT
(3) BUG-9677 10 K-Ohm POT
RED
GRY
BLU
BLUBLU
TEL
GRN
WHT
W/GN
GRN
RED RED
ORG
BLK
BUG-5761 SWITCH
TOGGLE SPDT ON-OFF-ON
17
BUG-5570 POWER CIRCUIT BOX / EXPLODED VIEW
4
5
11
17
15
7
6
14
2
13
3
1
10
16
BUG-5570 POWER CIRCUIT BOX 120 V / PARTS LIST
ITEM QTY PART NUMBER DESCRIPTION
1 1 ARM-2279 Toggle Switch
*2 1 BUG-2923 Circuit Breaker .7A
3 1 BUG-2924 Reset Button Seal
*4 1 BUG-5218 Transformer
5 1 BUG-5573 Enclosure
*6 1 BUG-9445 Power Cord
7 1 BUG-9446 Cord Grip
8 1 BUG-9486 Panel Connector, 2-T, M
9 1 BUG-9487 Cable Connector, 2-T, F
10 1 BUG-9884 On-Off Switch Plate
11 1 BUG-9902 Panel Connector, 6-T, F
12 8 FAS-0204 Rnd Hd Scr 4-40 x 3/8
13 1 FAS-1224 But Hd Soc Hd Scr 8-32 x 3/8
14 8 FAS-1305 Hex Nut 4-40
15 1 FAS-1320 Hex Nut 8-32
16 4 SFX-1292 Bumper
17 1 WAS-0221 #8 Star Lockwasher
* See Electrical Component Chart for 240 VAC and 42 VAC Part Numbers
9
8
12
18
POWER CIRCUIT BOX / WIRING DIAGRAM
CN 1
A
F
E
D
B
C
WHT/BLK/GR
WHT/BLK/GR
TAN
BLU
TAN
RED
BLU
YEL
GY
A
B
ELECTRICAL COMPONENT CHART
S
T
CN 2
CB
BLK
WH
GRN
PCVT
BUG-5570 BUG-5572 BUG-5574
ITEM DESCRIPTION 120 VAC 240 VAC 42 VAC
PART NO. PART NO. PART NO.
CB Circuit Breaker BUG-2923 BUG-2952 BUG-2933
PC Power Cord BUG-9445 GOF-3115 BUG-9442
T Transformer BUG-5218 BUG-5231 BUG-5232
VT Volt Trap BUG-1393 BUG-1563 BUG-1393
CN-1 Panel Connector BUG-9902
CN-2 Panel Connector BUG-9486
S Toggle Switch ARM-2279
19
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.
Distributor’s Warranty:
Serial No. __________________________
Date Purchased: ____________________
Where Purchased:___________________
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
difculty you have experienced. BE SURE to mention the MODEL and SERIAL numbers.
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