Bug-O Systems MDS-1004 User manual

INSTRUCTION
MANUAL
MDS-1004
PROGRAMMABLE
STITCH MODULE
FOR THE MODULAR DRIVE SYSTEM
Pleaserecordyourequipmentidentificationinformationbelowforfuturereference.Thisinformationcanbefound
onyour machine nameplate.
ModelNumber
SerialNumber
DateofPurchase
Wheneveryou request replacement parts or informationon this equipment, always supply theinformation you
haverecordedabove.
A DIVISION OF WELD TOOLING CORPORATION
280 TECHNOLOGY DRIVE CANONSBURG, PENNSYLVANIA USA 15317-9564
PHONE: [phone] http://www.bugo.com FAX: [phone]
LIT-MDS-1004-IPM-0419
Bug-O Systems is committed to empowering our customers by providing operator
controlled mechanized solutions for their welding, cutting and custom applications.

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MOVING PARTS can
cause serious injury.
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) Theequipment isnotwaterproof. Using
theunitinawetenvironment may resultin
seriousinjury.Donottouch equipment
whenwetor standingin a wetlocation.
2) Theunused connectors have poweron
them.Alwayskeeptheunused
connectorscoveredwith the supplied
protectivepanels.Operation ofthe
machinewithouttheprotectivepanels
mayresult ininjury.
3) Neveropen theequipmentwithoutfirst
unpluggingthepower cordor serious
injurymayresult.
4)Verifythe customersupplied power
connectionsare madein accordance
withallapplicable localand national
electricalsafetycodes. If noneexist,use
InternationalElectricCode (IEC)950.
5) Neverremove orbypassthe equipment
powercordground. Verify theequipment
isgrounded in accordance with all
applicablelocal and nationalelectrical
safetycodes.Innoneexist, use
InternationalElectricCode (IEC)950.
READ INSTRUCTIONS.
Readtheinstructionmanual before
installingandusingtheequipment.
1) Donot plugin thepower cordwith out
firstverifying the equipmentis OFFand
thecord inputvoltage isthe sameas
requiredby the machineor serious
damagemayresult.
2) Alwaysverify boththepinionand wheels
arefullyengaged beforeapplying power
orequipment damage mayoccur.
3) Donot leavetheequipmentunattended.
4)Remove fromthe worksiteand storein a
safelocationwhen not inuse.
1) Nevertryto stopthepinion from moving
exceptby removing poweror by using
theSTOPcontrol.
2) Donot removeanyprotective panels,
coversor guardsand operate
equipment.
FALLING EQUIPMENT
can cause serious
personal injury and
equipment damage.
Faultyor careless user installationis
possible.As a result, never standor
walkunderneathequipment.
EQUIPMENT DAMAGE
POSSIBLE.
SAFETY

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HIGH FREQUENCY WARNINGS
WARNING: HIGHFREQUENCYCANEFFECTMACHINE
OPERATIONAND THEREFORE, WELD QUALITY.
SPECIAL PRECAUTIONS ARE REQUIRED WHEN USING PLASMA,
TIG OR ANY WELDING PROCESS THAT USES HIGH FREQUENCY
TO STRIKE AN ARC.
Read the precautions below before installing and using the equipment.
PRECAUTIONS:
1) Someplasma or weldingcables arestrong sources ofhigh frequencyinterference.
NEVERlay aplasma or welding cable across the controls of themachine.
2) Alwaysphysically separate theplasma orweldingcable leadsfrom the machine
cables.For example,the plasmaor weldingcable leadsshould NEVERbe bundled
witha pendant cableor themachine powercord. Maximize theseparation between
anymachine cables andthe plasmaor weldingcables.
3) Strictlyfollowthe groundingproceduresspecified fortheplasma orweldingunit.
NOTE:Someplasma andweldingunits produce exceptionallylarge amounts ofhigh
frequencynoise.They may requirea grounding rodbedriven intotheearth within six
feet(2 meters)of theplasma orwelding unitto becomecompatible withan automatic
cuttingor welding process.
4) Ifthe highfrequency isproduced usinga sparkgap, adjustthe pointsso the gap is as
smallas possible. Thelarger the gap,the higherthevoltage andthe higher the
interference.
5) Someplasmaor weldingunitswill injecthighfrequency interferenceintothe ACpower
line.Use separatepower line branches whenever possibleto powerthe plasmaor
weldingsourceand themachine.Do notplugthem intothesame outletbox.
6) Highfrequencynoisemay enter themachinethroughthe plasma orweldingsupply
remotecontactor leads.Some plasmaand weldingsources canproduce noise
spikesof up toseveral thousandvolts.These sourcesare not compatiblewith
automatedcuttingand welding equipment.It is recommendedthatthe remote
contactorleads on theseplasma orwelding sources notbe connectedto themachine.
Analternate solution is to purchasea separateremote contactorisolation box.

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TABLE OF CONTENTS
PROGRAMMABLE STITCH MODULE
INSTRUCTIONS MANUAL
Patents Pending
PAGE
5 ..........Introduction
5 ..........Features
6 ..........GettingStarted
7 ..........Basic Setup
7 ..........Stitch Program Setup
9 ..........Modes of Operation
10 ..........Enabling Contactor
10 ..........Motion Control
12 ..........Stitch Program Example
13 ..........Warranty

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INTRODUCTION
The MDS-1004 PROGRAMMABLE MODULE provides stitch controls for welding or cutting
with the Modular Drive System. The graphic display interface allows the user to view the exact
valueofeach stitch parameterfor precise andrepeatable configuration. The ProgrammableModule
contains an extra weld contactor output which can be enabled or disabled independent of the
Modular Drive Unit contactor.
FEATURES
• Exact, repeatable stitch configuration. Each stitch parameter is displayed while being set;
allowing each parameter to be exactly set each time a job is set up.
• Two contactor outputs. Programmable Module includes a 2-pin contactor output which can
be enabled or disabled independent of the Modular Drive Unit contactor.
• User defined home position. Module can be configured to return the machine to a position
beforethe weld startlocation forwork piece change-outwithout guninterference. One button
will start the whole welding program again.
• No external limit switches. User defines whether module will stop the machine or return it to
the home position upon completion of the last weld of the program.
• Resume mode. Stitch welds stopped mid-job can be restarted without interrupting the weld
pattern.
• Independent timers for Puddle-buildup and Crater-fill.
• Closed loop feedback ensures the traveled distances match the set distances.
Display
Controls
2-PinContactorOutput

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GETTING STARTED
The MDS-1004 PROGRAMMABLE MODULE is a controller for the Modular Drive Unit, and
mustbe installedon aModular Drive Unit. Please refer to the Modular DriveUnit instructionmanual
for further instructions on setting up the Modular Drive Unit.
NOTE: BUG-O Systems recommends becoming familiar with the controls through
programminganddry-running the machineseveraltimes before weldingorcutting.
Begin by powering up the Modular Drive Unit. During power-up, a boot screen similar to figure
1 is displayed. This screen provides software and hardware version information.
Figure 1: Boot Screen.
The boot screen is promptly followed by the Main Operating Screen (figure 2). This screen is
divided in two sections, with machine status information displayed in the upper section and control
functions displayed in the lower section. These functions change from screen to screen and vary
depending on machine status. When the machine is stopped, its position is displayed on the left
side of the lower section. The status information shown on the Main Operating screen includes
tractor speed during welding, the weld contactor status (not shown in figure 2), and the mode of
operation.
Figure 2: Main Operating Screen.

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BASIC SETUP
From the Setup Menu (figure 3), the User will select measurement units and which weld
contactors to use, as well as configure the stitch parameters.
From the Main Operating Screen, use button to access the Setup Menu.
Figure 3 Setup Menu.
The following controls are available in the Setup Menu:
Unit selector. Select between English (in) and Metric (mm) units.
Contact selector. Choose which contactor(s) will be used - Drive unit contactor,
Programmable module contactor, both or neither.
Stitch Parameter setup. Configure and save stitch parameters.
Exit. Return to Main Operating screen.
STITCH PROGRAM SETUP
To configure the stitch parameters use button from the Setup menu. The User will be
prompted to set the stitch parameters one at a time. Each setup screen shows the parameter to be
set and its current value. The setup screen for travel speed while welding is shown in figure 4.
Figure 4: Setup screen for travel speed while welding.

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STITCH PROGRAM SETUP (CONT’D.)
The following controls are used when configuring the stitch parameters:
Increase or Decrease value
Enter. Accept value and proceed to next parameter
Undo. Reset current parameter
Save.
The stitch parameters are listed below in the order that they appear during setup.
Travel speed of the tractor when welding.
NOTE: This is the default speed setting when the unit is powered up. Tractor speed
canalsobechangedwhileweldingorfromtheMainOperatingscreen,butthosechanges
willNOTbe saved.
Puddle buildup time.
Weld length.
Back-step distance after the weld.
Crater-fill time.
Skip distance.
Number of welds to perform before stopping.
Home Distance.User defines Home position relative to thestart ofthe firstweld. Usethis
feature to minimize machine interference when changing work pieces.

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STITCH PROGRAM SETUP (CONT’D.)
End of Cycle Action. Select between Stop at Limit or Rapid Return mode. With
Stop at Limit, the machine will stop in place upon completion of the last weld in the
program.In Rapid Return mode, the machine willreturn to Home upon completion of the
last weld.
MODES OF OPERATION
The MDS-1004 offers three operating modes - New, Resume, and Manual. The current mode
isdisplayed inthe lowerright corner of the upper screen portion for any operating screen(see figure
2).
From the Main Operating screen, use button to change the operating mode.
New Stitch Weld Mode
Use New stitch weld mode when setting up a new weld start position or a new weld pattern.
This is the default operating mode for the MDS-1004. After setting-up the stitch program, position
the drive unit so that the welding gun is positioned at the beginning of the first weld. To begin
welding, ENABLE the weld contactor(s) then START the machine in forward.
NOTE: It is not necessary to ENABLE and START at the same time.
Resume Mode
Resume mode can only be used after a stitch weld has been started in New stitch weld mode.
Resume mode allows the User to stop the machine during a weld pattern and resume welding in
the same location or move the machine anywhere within the weld pattern then resume welding at
the machine's current position. This is useful if a previous weld was not complete or has to be re-
welded.
Resume mode is also used when the same weld pattern is to be performed on multiple work
pieces. To do this, the User should set an appropriate Home Distance and select Rapid Return for
the End of Cycle Action. Upon completion of the last weld, the machine will return to the Home
position and the operating mode will default to Resume mode. Position the new work piece and
START the machine in forward to repeat the stitch weld pattern. The machine will advance to the
start of the first weld then begin welding.
Manual Mode
Manual mode gives the User full control over the weld process and allows the User to weld
without configuring a stitch program. This is useful for creating continuous welds. When operating
inManual mode, ENABLINGthe weld contactorwill immediately turnit ON. Motion must be started
and stopped separately. DISABLE the weld contactor to turn it OFF.
CAUTION: Inmanualmode, enablingthecontactor willturnit ON, immediately!

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ENABLING CONTACTOR(S)
From the Main Operating screen, use button to enable or disable the selected weld
contactor(s). An icon will appear in the upper right hand corner of the display, indicating that the
contactor is ON or ENABLED. When the contactor is DISABLED, no status icon appears on the
operating screen (refer to figure 2).
NOTE:UsermustENABLEweld contactorbeforeSTARTINGinNeworResumemode.
Contactor ENABLED. Contactor will cycle ON and OFF according to the stitch weld
program after the machine is started.
CAUTION: Inmanualmode,enabling the contactorwillturn itON!
Contactor ON.
MOTION CONTROL
TheModular drive unit can operatein forwardor reverse. Motioncontrol optionsvary based on
the current state of the machine. An overview of the motion control options is provided below.
START machine in the forward direction.
Start machine in the reverse direction.
Increase or Decrease value. This icon indicates that the setting in the top half of the
screen can be adjusted by turning the corresponding knob.
STOP machine motion.
CAUTION: STOPPINGthemachineinmanualmodewillNOT turnweldcontactorOFF.
UsermustDISABLE contactor.
Return to Home.
After the machine is started and is moving, the unnecessary controls are removed from the
bottom half the display as shown in figure 5. Notice how the Select Mode button is now the Stop
button.

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Figure 5: Machine Running Screen
STITCH PROGRAM EXAMPLE
The following is a step-by-step example for setting up and using the MDS-1004 to perform
stitch welding.
Program the MDS-1004 to weld 6 stitches, 3.5 in. long and spaced 9.0 in. apart. Set puddle
build-up and crater fill times both at 0.3 seconds, and back-step distance to 0.1 inch. Assume
this pattern will be used on several work pieces, so the machine should be set to return 6.0 in.
beyond the start of the first weld to allow change-out of work pieces.
1. Connect MDS-1004 to Modular Drive Unit.
2. Set-up the Modular Drive Unit on the appropriate rail.
3. Connect weld contactor on Modular Drive Unit to welding feed system.
4. Turn Modular Drive Unit ON.
5. Change Operating Mode to MANUAL . Use Mode Select button .
6. Use Motion Controls to position welding gun at start of first weld .
7. Change Operating Mode to NEW STITCH WELD . Use Mode Select button .
8. Go to the Setup menu .
9. Set Units to ENGLISH (IN).
a. Open the Unit Selector menu .
b. Use control knob to select desired units.
c. Press ENTER to accept changes and return to Setup menu.

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10.Select Contactor(s) to be used.
a. Open Contact Selector menu .
b. Use control knob to select desired contactor arrangement.
c. Press ENTER to accept changes and return to Setup menu.
11.Setup Stitch Parameters.
a. Open Stitch Parameter Setup .
b. Press ENTER after each parameter is set.
c. Set Tractor speed . Use control knob to adjust speed to 10 in/min.
d. Set Puddle buildup time . Use control knob to adjust time to 0.3 sec.
e. Set Weld length . Use control knob to adjust length to 3.5 in.
f. Set Back-step distance . Use control knob to adjust distance to 0.1 in.
g. Set Crater fill time . Use control knob to adjust time to 0.3 sec.
h. Set Skip distance . Use control knob to adjust distance to 9 in.
i. Set Number of welds . Use control knob to adjust number of welds to 6.
j. Set Home distance . Use control knob to adjust distance to 6.0 in.
k. Select End of cycle action. Use control knob to select Rapid Return mode .
l. Save Stitch Parameters .
12.EXIT Setup Menu and return to Main Operating screen.
13.Enable weld contactor. Use Contactor Enable button from Main Operating Screen.
Look for the ENABLED icon in upper right corner of display .
14.Start welding. Use Start forward motion button to begin weld program.
15.Adjust machine speed while welding. From the Main Operating screen, use the control knob
to adjust this speed.
NOTE: Thisexample assumesthe useof FCAW, 0.045"diameter wire;75Ar/25CO2
shielding gas; 220 ipm wire feed; 24V.

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WARRANTY
For a period of twelve (12) months from delivery, BUG-O Systems warrants to the original purchaser (does not
include authorized distributors), that a new machine is free from defects in material and workmanship and
agrees to repair or replace, at its option, any defective parts or machine. This warranty does not apply to
machines, which after our inspection, are determined to have been damaged due to neglect, abuse,
overloading, accident or improper usage. All shipping and handling charges will be paid by customer.
BUG-O Systems makes no warranty of merchantability and makes no other warranty, expressed or implied,
beyond the warranty expressly set forth above. Buyer’s remedy for breach of warranty, hereunder, shall be
limited to repair or replacement of non-conforming parts and machines. Under no circumstances shall
consequential damages be recoverable.
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 he cannot give you the necessary service, write or phone us to
tell us exactly what difficulty you have experienced. BE SURE to mention the MODEL and SERIAL
numbers.
Limited Warranty Model ____________________________
Serial No. _________________________
Date Purchased: ___________________

NOTES: