INSTRUCTIONS
AND
PARTS MANUAL
UNI-BUG III
THE UNIVERSAL BUG-O
WITH STITCH
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-UNI3-IPM-1114
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.
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
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
rst unplugging the power cord or
serious injury may result.
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.
POSSIBLE.
4) Verify the customer-supplied power
connections are made in accor-
dance with all applicable local and
national electrical safety codes. If
none exist, use International Electric
Code(IEC) 950.
5) Never remove or bypass the equiment 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.
Read the instruction manual before
installing and using the equipment.
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 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
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
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
UNI-BUG III
THE UNIVERSAL BUG-O WITH STITCH
INSTRUCTIONS AND PARTS MANUAL
TABLE OF CONTENTS
PAGE
5 .............Introduction / Setup
6 .............Setup Diagram
7 .............Operation
8-9 ..........Controls
10 ...........Technical Data / Dimensions UNI-BUG-III
11 ............Technical Data / Dimensions UNI-BUG III Bulb
12 ...........Technical Data / Dimensions UNI-BUG III “T”
13 ...........Technical Data / Dimensions UNI-BUG III “L”
14 ...........UNI-BUG III Wiring Diagram / Parts List
15 ...........UNI-BUG III Single Gun Welding Kit
16 ...........UNI-BUG III Dual Gun Welding Kit
17 ...........UNI-BUG III Bulb Dual Gun Welding Kit
18-19 ......UNI-BUG III “T” Dual Gun Welding Kit
20 ...........UNI-BUG III “L” Dual Gun Welding Kit
21 ...........UNI-2400 UNI-BUG III / Exploded View / Parts List
22 ...........UNI-2410 Cover Assembly / Exploded View
23 ...........UNI-2410 Cover Assembly / Parts List
24 ...........UNI-2720 UNI-BUG III Bulb / Exploded View / Parts List
25 ...........UNI-2820 UNI-BUG III “T” / Exploded View / Parts List
26 ...........UNI-2840 UNI-BUG III “T” / Exploded View / Parts List
27 ...........UNI-2920 UNI-BUG “L” / Exploded View / Parts List
28 ...........UNI-1020 Base Assembly / Exploded View
29 ...........UNI-1020 Base Assembly / Parts List
30 ...........UNI-2020 “L” Base Assembly / Exploded View
31 ...........UNI-2020 “L” Base Assembly / Parts List
32 ...........UNI-2120 “T” Base Assembly / Exploded View
33 ...........UNI-2120 “T” Base Assembly / Parts List
34 ...........UNI-2140 “T” Base Assembly / Exploded View
35 ...........UNI-2140 “T” Base Assembly / Parts List
36 ...........UNI-2220 Bulb Base Assembly / Exploded View
37 ...........UNI-2220 Bulb Base Assembly / Parts List
38 ...........UNI-1350 Dual Welding Group / Exploded View / Parts List
39 ...........UNI-1355 Dual Cable Anchor / Exploded View / Parts List
40 ...........BUG-1855 Welding Group / Exploded View / Parts List
41 ...........BUG-1875 Cutting Group / Exploded View / Parts List
42 ...........Troubleshooting Guide
44 ...........Warranty
4
Patents Pending
INTRODUCTION
The UNI-BUG III is small enough to carry a cutting torch or welding gun into tight work areas or
around very tight curves without the use of a track. The built in carrying handle allows for easy
mounting and removal at any point along the work piece. The UNI-BUG III can weld or cut both
straight line and on an inner radius as small as 6" (152mm). It will travel at speeds of 4-75 ipm
(102-1905 mm/min) with a 50 lb. (22.7 kg) horizontal pulling capacity. The UNI-BUG III is designed
to run on the edge of a bar or stiffener up to 2" (51 mm) wide, with a minimum height of 2" (51mm).
SETUP
The UNI-BUG III operates without a track as shown in the set-up diagram. A gear motor turns the
two Drive Wheels on one side of the work piece. On the opposite side of the work piece the Idler
Wheel Bracket supports four Idler Wheels. An Idler Screw Knob is used to move the Idler Wheel
Bracket into the work piece, clamping the work piece between the two Drive Wheels and the four
Idler Wheels. The Support Rollers support the machine and tilt it forward for optimal control and
traction. This also sets the working direction. The machine is to be tilted in the direction of travel
and should be turned around to weld or cut on the opposite side of the work piece. (See Set-Up
Diagram page 6)
1. Loosen the Idler Screw Knob to open the gap between the Idler Wheels and the Drive
Wheels. When the gap is large enough, position the machine on the work piece.
2. The machine should be rmly resting on the front and rear Support Rollers and tilted
forward, in the direction of travel.
3. Engage the Idler Screw Knob until the Drive Wheels and the Idler Wheels are rmly in
contact with the work piece.
4. Adjust the racking group so that the cutting torch, or welding gun is in the proper position.
The arc should always be placed below the center of the machine so that the gun or torch
can hold the same relative position as the machine moves from a straight to a curved
work section.
5
SETUP DIAGRAM
Note: Torch holding devices not shown for clarity.
CARRYING
HANDLE
IDLER SCREW KNOB
SUPPORT
ROLLER
SUPPORT ROLLERS
DRIVE WHEELS
IDLER WHEEL BRACKET
BEAM
6
IDLER WHEELS
IDLER SCREW
KNOB
OPERATION
Always set the Travel Direction switch to the “Off” position before powering up the machine. If the
machine is powered up and the Travel Direction switch is in the left or right position, the controls
will be inactive and not be able to be programmed until the Travel Direction switch is turned to
the “Off” position.
1. When the machine Power “On/Off switch is in the “On” position the LCD Display shows
the set travel speed. The travel speed can be pre-set or adjusted with the Travel Speed
Control.
2. Use the Enter button to enter into programming mode, accept parameter values, or
toggle to the next setting. Utilizing the Increase and Decrease buttons to adjust the
settings. LED lights above the symbols for Skip Length, Crater Fill, and Weld Length
will light up to indicate which parameter is being programmed, or edited.
The parameters to be set for stitch welding are:
A. Weld Length .1'' (.1 cm) increments
B. Crater Fill .1 second increments
C. Skip Length .1'' (.1 cm) increments
NOTE: 120 VAC machines are factory set to inches per minute. 42 VAC and 240 VAC
machines are factory set to centimeters per minute.
NOTE: Load, heat or application may affect actual travel speed or distance. Minor
adjustments to speed or distance settings may be necessary to obtain desired travel.
3. Set the appropriate Weld Contact switches to the “ON” position.
(Welding Operations Only) See machine wiring diagram to wire cable connector for
weld contacts.
NOTE: Weld contacts will not close until the travel direction switch is thrown.
The Uni-bug II comes with a power cord only and the amphenol for connecting the
contactor to the machine.
Weld Contact - There are two contact cables available: UNI-1085-25 or UNI-1085-50
(sold separately). The other option is to build your own using a heavy lamp type cord and
wire it into the 4-pin amphenol. You only need four wires as you connect pin A & B then C
& D together to make it work.
4. Turn the Travel Direction switch to the desired direction to begin the welding or cutting
operation.
7
CONTROLS
SKIP
LENGTH
CRATER FILL
WELD
LENGTH
LCD DISPLAY
TRAVEL SPEED
CONTROL
INCREASE
BUTTON
DECREASE
BUTTON
ENTER
BUTTON
TRAVEL
DIRECTION
SKIP /
CONTINUOUS
WELD CONTACT II
WELD CONTACT I
POWER
ON / OFF
CIRCUIT
BREAKER
8
CONTROLS, CONT’D.
LCD DISPLAY: Displays the programming parameters such as travel speed, skip
length, crater ll, and weld length.
TRAVEL SPEED: Used to adjust the travel speed of the machine.
INCREASE BUTTON: Increases the numerical value of the selected parameter.
DECREASE BUTTON: Decreases the numerical value of the selected parameter.
ENTER BUTTON: Enters the set value into memory and toggles you to the next parameter.
SKIP LENGTH: When selected enter the value of the length of the skip distance.
CRATER FILL: When selected enter the value of the crater ll time.
WELD LENGTH: When selected enter the value of the length of the weld.
TRAVEL DIRECTION: Dictates which direction the machine will travel. Must be in the “OFF”
position to program parameters.
SKIP / CONTINUOUS: Used to select either the skip or continuous welding operation.
CIRCUIT BREAKER: Provides overload protection for the machine.
POWER ON / OFF: Turns power on and off to the machine.
WELD CONTACT I: If using one welding gun, switch weld contact 1 to the “ON” position.
WELD CONTACT II: If using two welding guns, both weld contact 1 and 2 should be switched
to the “ON” position.
9
TECHNICAL DATA / UNI-BUG III
Power Requirement: UNI-2400 120 VAC/50-60/1
UNI-2402 240 VAC/50-60/1
UNI-2404 42 VAC/50-60/1
Speed Range: 4 ipm to 75 ipm (102 to 1905 mm/min)
Maximum Stiffener Size: 2'' (50.8 mm)
Net Weight: 18 lb. (8.16 kg)
Shipping Weight: 30 lb. (13.61 kg)
DIMENSIONS
11.5''
(292 mm)
7''
(178 mm)
2''
(51 mm)
2''
(51 mm)
8''
(203 mm)
6.25''
(159 mm)
7''-9''
(178-229 mm)
10
TECHNICAL DATA: UNI-BUG III BULB
Power Requirement: UNI-2720 120 VAC/50-60/1
UNI-2722 240 VAC/50-60/1
UNI-2724 42 VAC/50-60/1
Speed Range: 4 ipm to 75 ipm (102 to 1905 mm/min)
Maximum Stiffener Size: 2'' (50.8 mm)
Net Weight: 13 lbs. (5.9 kg)
Shipping Weight: 40 lbs. (18.14 kg)
DIMENSIONS
11.5''
(292 mm)
7.75''
(197 mm)
2''
(51 mm)
2''
(51 mm)
6.88''
(175 mm)
8''
(203 mm)
11
TECHNICAL DATA / UNI-BUG III “T”
Power Requirement: UNI-2820 120 VAC/50-60/1 UNI-2840 120 VAC/50-60/1
UNI-2822 240 VAC/50-60/1 UNI-2842 240 VAC/50-60/1
UNI-2824 42 VAC/50-60/1 UNI-2844 42 VAC/50-60/1
Speed Range: 4 ipm to 75 ipm Maximum Stiffener Size: 2" (50.8 mm)
(102 to 1905 mm/min)
Net Weight: 13 lbs. (5.9 kg) Shipping Weight: 40 lbs. (18.14 kg)
DIMENSIONS
13''
(330 mm)
7.75''
(197 mm)
2.65''
(67 mm)
UNI-2820, UNI-2822 & UNI-2824
10.06''
(256 mm)
10.67''- 13.37''
(271 - 339.6 mm)
UNI-2840, UNI-2842 & UNI-2844
8.25''
(210 mm)
12
13''
(330 mm)
7.75''
(197 mm)
2.65''
(67 mm)
7.69''
(195 mm)
8.32''- 10.94''
(211 - 278 mm)
8.25''
(210 mm)
TECHNICAL DATA: UNI-BUG III “L”
Power Requirement: UNI-2920 120 VAC/50-60/1
UNI-2922 240 VAC/50-60/1
UNI-2924 42 VAC/50-60/1
Speed Range: 4 ipm to 75 ipm (102 to 1905 mm/min)
Maximum Stiffener Size: 2" (50.8 mm)
Net Weight: 13.5 lbs. (6.12 kg)
Shipping Weight: 40 lbs. (18.14 kg)
DIMENSIONS
12.89''
(327 mm)
(178 mm)
7''
3.31''
(84 mm)
9''
(229 mm)
9.69'' - 15.12''
(229 - 384 mm)
8''
(203 mm)
13
UNI-BUG III WIRING DIAGRAM / PARTS LIST
14
ITEM QTY PART NO. DESCRIPTION
1 1 ARM-2279 Toggle Switch
2 1 BUG-1034 Panel Connector
3* 1 BUG-1393 Volt Trap 120 VAC
3** 1 BUG-1563 Volt Trap 240 VAC
3*** 1 BUG-1393 Volt Trap 120 VAC
4 1 BUG-1550 Gear Motor 150:1
5 1 BUG-1735 Speed Control
6* 1 BUG-2923 .7 Amp Circuit Breaker
6** 1 BUG-2952 .5 Amp Circuit Breaker
6*** 1 BUG-2933 2 Amp Circuit Breaker
7* 1 BUG-9445 Power Cord
7** 1 GOF-3115 Power Cord
7*** 1 BUG-9442 Power Cord
8* 1 BUG-9675 Transformer
8** 1 GOF-3112 Transformer
8*** 1 BUG-1466 Transformer
9 1 BUG-9677 Potentiometer
10 1 MUG-1258 Rotary Switch
11 1 PCB-2400 Stitch Board
12 3 SWT-7101 Toggle Switch
13 1 SWT-1111 NOR. Open Push Button
14 2 SWT-3502 NOR. Open Push Button
15 1 BUG-1035 Cable Connector
* 120 VAC Part Number
** 240 VAC Part Number
*** 42 VAC Part Number
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