Bug-o-systems Modular Drive System Bedienungsanleitung

INSTRUCTIONSANDPARTS MANUALMODULAR DRIVESYSTEMA DIVISION OF WELD TOOLING CORPORATION280 TECHNOLOGY DRIVE CANONSBURG, PENNSYLVANIA 15317-9564

10MASTER DRIVE WIRING DIAGRAM MPD-1000/ MPD-1002/ MPD-1004NOTES:Encoder card and brake are mounted on the motor.18 pin connectors are not wired 1:1.Th

11AC POWER WIRING DIAGRAMPEM BLK RFIREDGRNGRNPCJ1 ACPOWEROUTBLK REDRED BLK 115 VAC&240 VACBLK RED42 VACBLK BLU REDBLU PS PSBLU DC OUTDC OUTELECTR

12SIGNAL WIRING PSWHT/REDWHT/BLKWHT/ORWHT/REDWHT/BLKWHT/OR+ 15 VGND- 15 V+ 15 VGND- 15 VFREDBLKCONTACTAPURPURYELYELABCD1234CICONTACTBMOTOR OUTCKCHOKEG

13MDS-1002 STRAIGHT LINE MODULE MDS-1003 STITCH MODULE MDS-1004 PROGRAMMABLE MODULEMDS-1005 WEAVER CONTROL MODULE Dimensions: 7.50" L x

14SPEED CONTROL: Sets the tractor speed from 2-120 in/min (5.1-304.8 cm/min). CARRIAGE TRAVEL SWITCH: Provides FORWARD/STOP/REVERSE direction control.

15SPEED CONTROL: Sets the tractor weld speed from 2-120 in/min (5.1-304.8 cm/min).CARRIAGE TRAVEL SWITCH: Provides FORWARD/STOP/REVERSE direction cont

16STITCH/CONTINUOUS: Selects between cyclic (Stitch) welding and continuous welding or cutting. a) CONTINUOUS - Selects continuous welding or cutting.

17MDS-1004 PROGRAMMABLE MODULEThe MDS-1004 PROGRAMMABLE MODULE provides stitch controls for welding or cutting with the Modular Drive System. All sti

18MDS-1005 WEAVER CONTROL MODULEThe MDS-1005 Weaver Control Module provides weave welding control functions.TRACTOR SPEED CONTROLMODE SELECTOR SWITCH

19AMPLITUDE (WEAVE): Continuously adjustable up to a 2" (51 mm) maximum weaver stroke. CARRIAGE TRAVEL SWITCH: Provides FORWARD/STOP/REVERSE dir

2SAFETYPROTECT YOURSELF AND OTHERS FROM SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR

20MDS-1005 / MDS-1005-DIAL WEAVER CONTROL MODULE REPLACEMENT PARTSREPLACEMENT POTS AND SWITCHES MDS-1005 MDS-1005-DIALWELD CONTACT:Switch and Spacer M

21DIGITAL READOUT CALIBRATIONInternal Control Module adjustments enable the user to change between cm/min and in/min. The display can also be recalibr

22WPD-1100 LINEAR WEAVERThe Linear Weaver and Weaver Control Module add weave welding capability to the Modular Drive System. The Linear Weaver bolts

23TECHNICAL DATADIMENSIONSWPD-1100 LINEAR WEAVER Power Receives power from Master Drive. Requirements: Uses 70 additional watt

24LINEAR WEAVER SETUP1) WEAVER CONTROL MODULE AND LINEAR WEAVER INSTALLATIONSet the weave amplitude to maximum. Use the steering knob on the control m

25LINEAR WEAVER SETUP, CONT’D.4) REMOTE CONTACTOR WIRING Connect the remote weld contactor on the Master Drive to the welding source as shown below.

26WPD-1100 LINEAR WEAVER / EXPLODED VIEW41401132236382939373354448474645432427313028101715146,587,5893342182526161634212518192332311211208524121152515

27WPD-1100 LINEAR WEAVER / PARTS LIST ITEM QTY PART NO. DESCRIPTION 1 1 BUG-1590-KM Gear Motor (80:1) 2 1

28WPD-2100 PENDULUM WEAVER IIINTRODUCTIONThe Pendulum Weaver and Weaver Control Module add a pendulum-type weaving motion to the Modular Drive System

29PENDULUM WEAVER II SETUPINSTALLATION The Weaver Control Module plugs into the Master Drive Unit. Use a at blade screwdriver to rmly secure the fo

3 PRECAUTIONS: 1) Some plasma or welding cables are strong sources of high frequency interference. NEVER lay a plasma or welding cable across

30SETUP AND ALIGNMENTAttach the rail parallel to the weld joint, with magnet bars or vacuum cups. Position the drive carriage on the rail - see Modula

31TECHNICAL DATAWPD-2100 PENDULUM WEAVER IIPower Uses 70 watts, Requirements: received from Master Drive Unit. Dimensions: Electron

32WPD-2100 PENDULUM WEAVER II / EXPLODED VIEW / PARTS LISTPARTS LIST ITEM QTY PART NO. DESCRIPT

33PARTS LIST ITEM QTY PART NO. DESCRIPTION 1 4 FAS-0104 Pan Hd Scr 4-40 x 3/8 Lg 2 8 FAS-01

34WPD-2115 PENDULUM GEAR BOX / EXPLODED VIEW / PARTS LISTPARTS LIST ITEM QTY PART NO. DESCRIPTION 1 3 FAS-0104 4-40 x 3/8 P

35WPD-1100 LINEAR WEAVER, WPD-2100 PENDULUM WEAVER WIRING DIAGRAM***Notes:* The encoder section outlined is for the WPD-1000 Linear Weaver only.** The

36CARRIAGESFOR ALUMINIUM RIGID RAIL AND SEMI-FLEX RAILMPD-1065 RELEASABLE CARRIAGE 12" (305 mm)100 lb (45 kg) Carrying CapacityPARTS LIST / EXPLO

2. Secure Carriage on RailA. Select the correct pair of holes on each side of the carriage for the rail diameter being used (see chart, below). If the

38MDS-1055 UNIVERSAL LIMIT KITThe MDS-1055 Universal Limit Kit is an accessory that installs between the Master Drive Unit and any of the three contro

39MDS-1060-10 10' (3 m) REMOTE CONTROL CABLEMDS-1060-25 25' (7.6 m) REMOTE CONTROL CABLEThe optional Remote Control Cable allows the opera

45... Introduction / Standard Features6... Additional Features7... Setup 8... Master Drive Unit / Technica

40MODULAR DRIVE ACCESSORIESFOR STRAIGHT LINE CUTTING: MDS-98983-HoseQuick-ActingManifoldMUG-1119-323-HoseAssembly 32" (813 mm)CIR-1010-3Twin Hose

41ALUMINUM RIGID RAILALUMINUM RIGID RAIL is a high quality alloy, rigid section made to the machine tool tolerance shown in the sectional view below.

42SEMI-FLEX RAILSEMI-FLEX RAIL can be bent inside or outside to a minimum radius of 15' (4.6 m) or 30' (9.1 m) diameter without permanent de

43HI-FLEX RAIL The FMD Hi-Flex Rail can ex from a straight to a 30" (760 mm) radius inside or outside. The rail is made from a tempered, wear r

44STANDARD MAGNET ASSEMBLIESHi-Flex Magnet w/ ReleaseFMD-2325Holding Power 250 lbs. (113 kg)For Hi-Flex RailSwivel Magnet w/ ReleaseARM-2325Holding Po

45ITEM QTY PART NO. DESCRIPTION 1 2 ARR-9008 Spacer Tube 2 2 ARV-1034 Choke Nipple 3 2 ARV-1107 3/8 Hose Barb x 1/4 NPT-M 4 2 A

46ARV-2020 VACUUM PUMP KIT, 120VAC 60HZ/1PH ARV-2030 VACUUM PUMP KIT, 240 VAC 50 HZ/1PHVACUUM PUMP / EXPLODED VIEW / PARTS LIST21432156787691011131415

47MODULAR DRIVE SYSTEM TROUBLESHOOTING GUIDEThe Modular Drive System allows the user to mix and match components to custom build a machine for an appl

48TROUBLESHOOTING GUIDE, CONT’D.PROBLEM POSSIBLE CAUSE TEST BASE SYSTEM TEST PROCEDURE / REMEDYSpeed display is not lit and tractor does not run. Pow

49TROUBLESHOOTING GUIDE, CONT’D.PROBLEM POSSIBLE CAUSE TEST BASE SYSTEM TEST PROCEDURE / REMEDYBad power supply. 1G Turn on the main power. The green

5The Modular Drive System is the only product in the industry that allows the user to custom congure one machine for various applications. The system

50TROUBLESHOOTING GUIDE, CONT’D.PROBLEM POSSIBLE CAUSE TEST BASE SYSTEM TEST PROCEDURE / REMEDYFaulty motor. 2E Disconnect the motor leads. Apply 2 to

51TROUBLESHOOTING GUIDE, CONT’D.PROBLEM POSSIBLE CAUSE TEST BASE SYSTEM TEST PROCEDURE / REMEDYLinear Weaver does not move.Bad control card or bad wea

52TROUBLESHOOTING GUIDE, CONT’D.PROBLEM POSSIBLE CAUSE TEST BASE SYSTEM TEST PROCEDURE / REMEDYPendulum shaftdoes not move.Bad control module,damaged

53TROUBLESHOOTING GUIDE, CONT’D.PROBLEM POSSIBLE CAUSE BASE SYSTEM TEST PROCEDURE / REMEDYChatter from main drive unitClutch improperly engagedKnob sh

54TROUBLESHOOTING GUIDE, CONT’D.The Modular Drive System is equipped with internal fault diagnostic LEDs and test Points 10 Speed troubleshooting as s

55TROUBLESHOOTING GUIDE, CONT’D.CAUTION: UNPLUG THE POWER CORD BEFORE OPENING OR CLOSING THE CASE OR SERIOUS INJURY MAY RESULT.1. Unplug the power

56UNIVERSAL LIMIT KIT TROUBLESHOOTINGThis Troubleshooting section details troubleshooting the Universal Limit Kit. See the Modular Drive System Troubl

57WARRANTYLimited 3-Year WarrantyModel _____________________________Serial No. __________________________Date Purchased: ____________________Where

61. Control Module that is easily remoted or changed. 2. Master Power Drive Module that is recongurable by the user, for different applications, by

71) WHEEL ADJUSTMENT AND ALIGNMENT Always check for proper carriage wheel adjustment before using the machine. Turn the wheel engagement knob (A) on t

8CAUTION: The Speed Control Card in the Master Drive is NOT interchangeable with the speed card in the Linear or Pendulum Weavers.Power Requirements:

9MPD-1000 MASTER DRIVE UNIT / EXPLODED VIEW / PARTS LIST2061554411112141214546114410435155522391453438403019281354323534295016312554718633363713111726