BUG-O Systems BUG-6550 - Manual (Page 6)

6
DETAILED SETUP
1. Secure the Rail to the Workpiece
The Universal Bug-O-Matic with AHC is designed for use with most BUG-O rails. Descriptions of the
various BUG-O rails and their applications are provided on pages 23-26. Select a rail appropriate to your
application. Install rail to workpiece.
2. Secure the Carriage on the Rail
Select a BUG-O carriage that is compatible with the rail being used. Descriptions of the various BUG-O
carriages are provided on pages 27-29. Declutch the drive pinion prior to installing carriage. Verify wheel
alignment and adjust wheels as needed, then engage the drive pinion.
3. Position and Clamp Welding Gun
Secure welding gun in the all-position clamp located on the end of the height control mechanism. Arrange
cables so that they do not interfere with the movement of the machine before securing cables in the cable
anchor at the back of the machine.
4. Connect Control Cables
The Universal Bug-O-Matic with AHC includes four control cables that must be properly connected for
the machine to function.
A. Connect the Control Pendant (BUG-5755) to the Drive Unit (BUG-5980).
B. Connect the weld contact outlet, pins A & B, on the Drive Unit (BUG-5980) to the wire feeder contact
circuit.
C. Connect the Height Slide Assembly (CAS-1500) to the CAS Electronics Box (CAS-1555).
D. Connect the control cable from the Current Sensor (CAS-1550) to the CAS Electronics Box (CAS-1555).
5. Install Current Sensor
Connect the Hall Effect Current Sensor “in-line” on welding power source ground cable. The positive lead
and the input cable are located on the same side of the enclosure. For a positive electrode, this lead
should be connected to the work piece.
6. Plug in Universal Bug-O-Matic with AHC
Inspect the power cord before each use. Do not use if damaged. Plug in the machine to a power receptacle
of the appropriate voltage.
7. Power ON Universal Bug-O-Matic with AHC
CAUTION: Machine may start moving as soon as it is powered on.
Use the toggle switch on the back of the drive unit to turn power on and off to the machine. For operator
safety, set weld pattern to “NO WEAVE” and tractor to “OFF” before turning on the machine.
8. Position Welding Gun
Proper setup of the welding gun is critical to a successful weld. In addition to manually positioning the
welding gun within the clamp, the welding gun must also be properly set with respect to three mechanical
controls: The cross arm, the height controller and the tractor position.
A. Cross Arm: The cross arm offers a weave up to 1" (25 mm) left and right, 2" (50 mm) total. Center the
cross arm before placing the welding gun over the work area. This will ensure maximum oscillation
amplitude. See “Centering the Cross Arm” on page 9.
B. Height Slide Assembly: The slide assembly has 4" (100 mm) of vertical travel available. For best results,
position the slide assembly in the middle of its travel range before setting the welding gun. Use the
torch manual jog switch to raise or lower the height controller to the desired height.
C. Tractor position: Use the tractor Forward/Off/Reverse switch to position the Universal Bug-O-Matic
with AHC at the start of the weld. The operator can increase or decrease the tractor travel speed at
any time using the speed controller.