BUG-O Bug-O-Matic BUG-5700 Instructions Manual Download

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INSTRUCTIONS

AND

PARTS MANUAL

UNIVERSAL

BUG-O-MATIC

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-BUG-O-MATIC-IPM-0415

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

Bug-O Systems is guided by honesty, integrity and

ethics in service to our customers and in all we do.

Summary of Contents for Bug-O-Matic BUG-5700

Page 1: ...ate of Purchase Whenever you request replacement parts or information on this equipment always supply the information you have recorded above LIT BUG O MATIC IPM 0415 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 Bug O Systems is guided by honesty integrity and ethics in service to our custom...

Page 2: ...r 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 READ INSTRUCTIONS Read the instruction manual before installing and using the equipment 1 Never try to stop the pinion from moving except by removing power or by using the STOP control ...

Page 3: ...ounts 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 pla...

Page 4: ... Assembly 12 Drive Unit Wiring Diagram 13 Electrical Component Chart Drive Unit 14 Wiring Harness BUG 5726 Diagram 15 PCB 5700 Drive Unit Interconnect PC Board 16 PCB 5700 Wiring Diagram 17 BUG 5775 Control Pendant Exploded View 18 BUG 5775 Control Pendant Parts List 19 Control Pendant BUG 5775 Wiring Diagram 20 BUG 5751 Pendant Cable Wiring Diagram 21 Rail Options 25 Carriage Options 28 Accessori...

Page 5: ...carriage the machine will run on any BUG O rail Aluminum Rigid Semi Flex Bent Rigid or Hi Flex The chart below shows which types of rail are compatible with each carriage See pages 21 27 for details CARRIAGES BUG 5910 Tube Carriage X X X FMD 1100 Hi Flex Carriage X MPD 1055 18 Carriage X MPD 1065 Releasable Carriage X X A l u m i n u m R i g i d R a i l A R R 1 0 8 0 A R R 1 0 8 5 B e n t R i g i ...

Page 6: ... Steering 2 50 mm left or right from center C Amplitude 0 2 50 mm D Dwell Left 0 3 sec E Dwell Right 0 3 sec F Weld Contact Switch G Mode Selector Switch H Digital Display Tractor Speed I Forward Off Reverse Tractor Travel J Tractor Speed PENDANT CONTROL FUNCTIONS ...

Page 7: ...ngle Clamp 3 1 BUG 5710 Drive Box 120 V 1 BUG 5712 Drive Box 240 V 1 BUG 5714 Drive Box 42 V 4 1 BUG 5751 Pendant Cable 5 1 BUG 5775 Pendant Control 6 1 BUG 9180 6 Rod 6 152 mm 7 1 BUG 1853 Machined Rack 7 5 8 1 BUG 5455 Gun Mounting Group 9 1 BUG 5965 Handle Assembly UNIVERSAL BUG O MATIC BUG 5700 PARTS LIST ...

Page 8: ... DESCRIPTION 1 1 BUG 5707 Left Side Panel 2 1 BUG 5708 Right Side Panel 3 1 BUG 5715 Base Assembly 4 1 BUG 5720 Cover Assembly 120 V 5 1 BUG 5725 Cross Drive Assembly 6 6 FAS 0114 Pan Hd Scr 6 32 x 3 8 7 12 FAS 0124 Pan Hd Scr 8 32 x 3 8 BUG 5710 DRIVE BOX ASSEMBLY ...

Page 9: ...eset Button Seal 6 1 BUG 5218 Transformer 117 VAC 7 1 BUG 5721 Cover panel anodized N S 1 BUG 5726 Wire harness 8 1 BUG 9445 Power Cord 9 1 BUG 9446 Cord Grip 10 1 BUG 9487 Cable connector 2 T 11 1 BUG 9884 On Off switch plate 12 1 CAS 1770 Speed Control 13 8 FAS 0114 Pan Hd Scr 6 32 x 3 8 14 1 FAS 0124 Pan Hd Scr 8 32 x 3 8 15 8 FAS 0205 Rnd Hd Scr 4 40 x 1 2 16 8 FAS 1305 Hex nut 4 40 17 1 FAS 1...

Page 10: ...bly 3 2 BUG 5723 Attachment Bar 4 4 FAS 0557 Soc Hd Cap Scr 1 4 20 x 3 4 5 4 FAS 0825 Flt Hd Slot Scr 8 32 x 1 2 6 8 FAS 0923 Flt Hd Soc Scr 8 32 x 5 16 7 1 GOF 3014 Drive Pinion w Key Set Scr 8 1 MPD 1015 Gear Motor 60 1 9 1 WPD 1013 Rubber Ring Gasket 10 1 WPD 1045 Brake Assembly BUG 5715 BASE ASSEMBLY ...

Page 11: ... Hd Scr 3mm x 18mm 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 BUG 5728 A Cross Drive Support 9 1 WPD 1164 Arm Stop 10 1 FAS 0539 Screw 10 24 x 1 11 1 WPD 1150 Cross Arm 15 50 12 2 WAS 0230 10 SAE Flat Washer 13 2 FAS 0537 Screw 10 24 x 3 4 14 1 WPD 1177 Post BUG 5725 CROSS DRIVE ASSEMBLY ...

Page 12: ...12 BUG 655X DRIVE UNIT WIRING DIAGRAM ...

Page 13: ...mer BUG 5218 BUG 5231 BUG 5232 SW Toggle Switch ARM 2279 IB Interconnect Board PCB 5700 CN1 Connector to Pendant BUG 5527 CN2 Connector to Weld Contact BUG 1034 MT Tractor Motor MPD 1015 BR Brake WPD 1045 MW Weave Motor BUG 5590 MC1 Motor Control Tractor BUG 1770 UB MC2 Motor Control Weave CAS 1770 SVP Servo Pot BUG 5240 BUG 655X DRIVE UNIT ELECTRICAL COMPONENT CHART ...

Page 14: ...14 BUG 5726 WIRING HARNESS WIRING DIAGRAM ...

Page 15: ...15 PCB 5700 DRIVE UNIT INTERCONNECT PC BOARD ...

Page 16: ...16 PCB 5700 WIRING DIAGRAM ...

Page 17: ...17 BUG 5775 CONTROL PENDANT WIRING DIAGRAM ...

Page 18: ...18 11 16 17 1 9 11 11 16 17 10 13 4 10 15 12 24 3 5 20 14 20 8 21 22 25 20 1 11 16 2 19 23 6 11 16 18 11 7 6 11 16 BUG 5775 CONTROL PENDANT EXPLODED VIEW ...

Page 19: ...Large 10 2 BUG 5758 Toggle Switch Seal 11 7 BUG 5759 Pot Shaft Seal 12 1 BUG 5760 Control Board 13 1 BUG 5761 Toggle Switch SPDT On On 14 1 BUG 5772 Rear Panel 15 1 BUG 5773 Front Panel 16 5 BUG 9621 Knob 17 2 BUG 9677 Potentiometer 10 K 18 1 BUG 9694 Knob Pointer 19 4 FAS 0104 Pan Hd Scr 4 40 x 3 8 L 20 8 FAS 0114 Pan Hd Scr 6 32 x 3 8 L 21 4 FAS 0205 Rnd Hd Scr 4 40 x 1 2 L 22 4 FAS 1305 4 40 He...

Page 20: ...D___________________ B Osc Speed E___________________ P Osc Dir F___________________ D Brake Release G___________________ E Tractor Speed H___________________ L Weld Contact J____________________ M Weld Contact K___________________ H Gear Pot BUG 5751 PENDANT CABLE WIRING DIAGRAM ...

Page 21: ...250 93 1 2 1 18 m called 8 2 37 m rail ARR 1200 46 1 2 1 18 m called 4 1 18 m rail PARTS LIST ITEM PART NO DESCRIPTION 1 ARR 1006 Rack 2 ARR 1027 Splicer Bar 3 ARR 1028 Carriage Bolt 4 ARR 1081 Rail Extrusion 5 FAS 0375 Screw Hex Hd Cap 5 16 18 6 FAS 1370 Hex Nut 5 16 18 RAIL OPTIONS With a simple carriage change the Universal Bug O Matic with AHC can be made compatible with any BUG O rail A brief...

Page 22: ...dering specify the work diameter inside or outside method of mounting and if a complete ring is required On larger diameters rail can be leapfrogged around the vessel to reduce the quantity needed Maximum section length is 80 2 m Note Adjustable magnet support legs ARM 2480 shown above are sold separately PARTS LIST PART NO QTY DESCRIPTION ARR 1002 1 Rack ARR 1027 2 Splicer Bar ARR 1028 2 Carriage...

Page 23: ...with every two 2 rails for moving the rack on the rail Available in 8 2 37 m lengths Use at least four 4 attachments vacuum cups or magnets on each section of Semi Flex Rail PARTS LIST ITEM PART NO DESCRIPTION 1 AFR 1015 Spacer Washer 2 AFR 2001 Rack Adjuster Tool 3 AFR 3002 Splice Plate 4 AFR 3006 Rack 5 AFR 3009 Extrusion Punched 6 FAS 0955 Screw Flt Hd Soc 1 4 20 7 FAS 1446 HW S T Slt Hx 10 32 ...

Page 24: ... down to 40 1 m radius in or out Hi Flex rail can be used on compound curvatures and can be twisted 10o per 24 600 mm of length PARTS LIST ITEM PART NO DESCRIPTION 1 FAS 0376 Screw Hex Hd Cap 5 16 18 2 FAS 1370 Hex Nut 5 16 18 3 FAS 1444 Screw Phil Pan Hd 10 32 4 FMD 1051 Track 5 FMD 1052 Rack Section 3 Teeth 6 FMD 1053 Flex Rail Splice Plate 7 WAS 0250 Washer SAE 5 16 A B C A 3 995 102 mm B 0 080...

Page 25: ...ob located on the side of the carriage which engages or disengages the wheels from the rail Use with BUG O Aluminum Rigid or Semi Flex Rails ITEM QTY PART NO DESCRIPTION 1 2 BUG 1984 External Adj Leg Wheel Assembly 2 2 FAS 0545 Screw Soc Hd Cap 10 32 x 1 2 3 2 MPD 1045 Fixed Leg Wheel Assembly 4 1 MPD 1049 Handle Black 5 1 MPD 1059 Knob Screw Included w carriage 6 1 MPD 1066 Carriage MPD 1055 CARR...

Page 26: ...wheel brackets in selected holes Tighten the bolts until the brackets are snug but still free to rotate 2 Open the cam handle to separate the carriage On the drive unit loosen and turn the clutch knob counterclockwise to declutch the drive pinion 3 Place the carriage on the rail with the wheels in the rail grooves Close the cam handle and move the carriage back and forth a few inches The wheels on...

Page 27: ...e knob on the side of the carriage to engage disengage the wheels from the track Use with BUG O Hi Flex Rails ITEM QTY PART NO DESCRIPTION 1 1 BUG 2708 Clamp 2 1 FMD 1060 FMD Clamp Block 3 1 FMD 1062 Carriage Includes Items 4 5 6 4 1 FMD 1068 Fixed Wheel Mounting Block 5 1 FMD 1069 Adj Wheel Mounting Block 6 1 FMD 1072 Knob 3 4 2 5 1 6 ...

Page 28: ... gun accordingly Controls for the AHC are self contained and its drives are independent from those of the drive unit AHC features a built in time delay after the arc is struck and automatically shuts off when current drops too low generally below 60 amp The operator can tempo rarily override AHC using the manual jog switch while welding AHC resumes as soon as the jog switch is released To disable ...

Page 29: ...nion also Run the Cross Arm until it is centered align reference mark C with face of side plate Make sure the brass gear teeth and the V guide teeth do not skip 9 If necessary connect the Pendant Control BUG 5755 to the Drive Unit BUG 5980 using the Pen dant Control Cable BUG 5551 10 10 On the control pendant center steering control 1 1 2 turns from either extreme 11 Connect the machine to a power...

Page 30: ...e harness leading from Potentiometer 7 Using Ohmmeter measure resistance across Node 1 and Node 3 refer to figure 9 This should measure approximately 5000 ohms 8 Rotate potentiometer until resistance across Node 1 and Node 2 is equal to resistance across Node 2 and Node 3 This should be approximately 2500 ohms The potentiometer is now centered 9 While being careful not to move the potentiometer se...

Page 31: ...her 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 ...

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