Bug-O Systems MDS Series Technical reference manual

INSTRUCTIONS
and
PARTS MANUAL
MODULAR DRIVE
SYSTEM’S
PROGRAMMABLE
SHAPE MODULE
A DIVISION OF WELD TOOLING CORPORATION
161 HILLPOINTE DRIVE CANONSBURG, PENNSYLVANIA 15317-9564 USA
PHONE: [phone] http://www.bugo.com FAX: [phone]
Please record your equipment identication 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-MDSPSM-IPM-0319
Bug-O Systems is committed to empowering our customers by providing operator
controlled mechanized solutions for their welding, cutting and custom applications.

2
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
POSSIBLE.
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.
4) Verify the customer-supplied power
connections are made in accordance
with all applicable local and national
electrical safety codes. If none exist, use
International Electric Code (IEC) 950.
5) Never remove or bypass the equipment
power cord ground. Verify the equipment
is grounded in accordance 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.
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.
4) Remove from the worksite and store in
a safe location when not in use.
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.
MOVING PARTS can
cause serious injury.
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.

3
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 specied 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.
HIGH FREQUENCY WARNINGS
WARNING: HIGH FREQUENCY CAN EFFECT MACHINE
OPERATION AND 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.

4
TABLE OF CONTENTS
MDS PROGRAMMABLE SHAPE MACHINE
INSTRUCTIONS AND PARTS MANUAL
PAGE
5 ..... Setup/Positioning the Machine on the Track
6 ..... MDS Programmable Shape Machine/Description/Operation
8 ..... Step By Step Instructions for Operation
9-10 ... Pendant Control
10 ..... Programming
11 ..... Programmable Shape Machine/Segment Types
12 ..... Data Entry Required for Programming
14 ..... Auxiliary Modes: Type 6, Quadrant 3
14 ..... Set % Speed, Fraction of Set Speed: Type 6, Quadrant 4
16 ..... Dimensions Required
17 ..... Example: Obround Shape
18 ..... Example: Repeat Function
19 ..... MDS-1165 Panel Controls
20 ..... MDS Shape Machine Major Components / Exploded View / Parts List
21 ..... Connecting a MDS-117x Solenoid Kit to a MPD-100x Master Drive
22 ..... MDS-1165 Control Module Wiring Diagram/Component List
23 ..... Pendant Cable Wiring Diagram
24 ..... Warranty

5
The wheels along one side of the carriage have stainless
steel shim washers (C) underneath. These wheels are adjust-
able. Readjust these wheels (if necessary) by rotating the hex
bolt (D) with a 1/2" wrench.
Grasp the sides of the carriage. The wheels are too loose if
it is possible to move the carriage from side to side or up and
down. Use a nger to keep one of the adjustable wheels from
rotating as the carriage is manually pushed along the track.
The wheels are adjusted too tight if rm nger pressure is not
enough to prevent wheel rotation. Repeat the process for the
other adjustable wheel.
Always check for proper carriage wheel adjust-
ment before using the machine. Turn the wheel
engagement knob (A) on the side of the carriage
until the wheels are fully moved towards the
center of the carriage (engaged). Then rotate the
drive clutch knob (B) fully counter clockwise to
disengage the drive pinion. Slide the carriage
onto the end of a track. The wheels should slide
into the track V-grooves and the carriage will
move smoothly along the track if the wheels are
property aligned.
POSITIONING THE MACHINE ON THE TRACK
Position the rail using magnet plates or vacuum cups. Wipe the track grooves free of
weld splatter and other debris. This will prevent binding and premature rail and wheel wear.
Lubricate the rack using a dry spray, if desired, for extended track life.
Turn the wheel engagement knob (A) on the side of the carriage fully counter clockwise to
disengage the wheels. Then rotate the Master Drive clutch knob (B) fully counter clockwise to
disengage the drive pinion. The carriage can now be placed anywhere on the track. Turn the
wheel engagement knob (A) clockwise to engage the wheels rmly in the V-grooves. Verify
all four wheels are in the grooves. Manually move the carriage along the track to verify the
motion is smooth and the wheel alignment is correct. Rotate the Master Drive clutch knob
(B) fully clockwise while gently rocking the machine forward and backward to fully engage
the drive pinion. The rocking motion is necessary to help insure proper gear mesh.
SETUP
C
D
B
A

6
This is a 2-axis machine that runs on a track and carries a cutting torch on a motorized cross-arm. It can
be used for ame or plasma cutting, or welding, of a variety of shape programmed and stored in memory.
DESCRIPTION
The machine has 20 storage areas in memory for different programmed shapes, numbered 0 to 9. At
any time, one of these shape numbers is the current one, and will stay current even when the power is
shut off and turned back on, until the shape number is changed by the operator.
All programming is done with the hand-held terminal provided; this may be plugged into the connector
on the rear of the machine or unplugged at any time. The terminal is not needed to run the machine
once programmed.
Shapes are built up only from the segments provided: circular arcs and straight lines, square or inclined,
by selecting type and quadrant for each segment. A shape can have up to 50 segments. Some other
operations, like solenoid On/Off, time delay, or repeat another shape a number of times, also count as
one segment each if used.
In normal operation, rst position the machine at the starting point. Next turn on the preheat gases, and
wait until the required preheat is reached. Push the Run button; the machine will turn on the cutting
oxygen and start cutting the current shape. At the end of the shape the machine will turn off the cutting
oxygen and stop. Manually turn off the preheat gases.
PLASMA CUTTING & WELDING OPERATION
The Programmable Shape Machine can be used successfully for plasma cutting; however it is important
to take certain precautions to avoid interference and protect the control circuits. (These comments also
apply to TIG welding or any process that uses high frequency to strike an arc). An external relay box is
available separately or in the welding kit to provide the contact signal to the plasma source.
OPERATION:
When rst plugged in, the position the machine is in becomes the reference Start position.
Now there are three (3) options (the pendant terminal is not needed for the rst two):
1. MOVE
To change the Start position, push the STOP button, move the machine manually
to the required position using the toggle switches, and push the RESET button.
2. RUN
Push the START/RUN button to cut a shape.
3. PROGRAM ( entry or change)
The Programming operation is selected by pressing keys A,B,C,D, E.
A: All segments; data entry for new shape consists of:
Total number of segments
Data for each: Type (arc, x/y line or slope)
Quadrant 1-4
Size (radius, or x/y dimension)
MDS PROGRAMMABLE SHAPE MACHINE

7
The data should be tabulated on paper from a diagram before entering.
B: Program Segment
Press B on the terminal to re-program a single segment. This is useful if there is an
error in data for just one segment, so the whole shape does not have to be reentered.
C: CHANGE Shape Number
Press C on the terminal to change the current shape number, and enter the desired
number at the prompt. The program switches to the new number in memory, and
to whatever shape is stored there.
D: DISPLAY Shape Data
Press D to display the data for the current shape. The terminal display shows
Total Number of segments, and data for each segment one by one each time you
press Enter.
E: END of Segment Slowdown.
Press E to set deceleration value for the shape, when the machine approaches
the end of each segment. This is useful when the shape has sharp corners, to
prevent overshoot. 99 is maximum slowdown, 0 is no slowdown.
IMPORTANT:
1. Once the STOP button is pressed, computer control is halted until the RUN or the
RESET button is pressed. Therefore the programming cannot be done with the
handheld terminal in this state; the RESET button should be pressed rst.
2. After pushing A and programming a new shape, End of segment Slowdown will still
have the old value unless reprogrammed. To set new value, push E.
See Shape programming for details.
For example, a 2 inch diameter circle could be
4 Segments:
1. 2, 1, 100 Counterclockwise arc, quadrant 1, 1.00 inch radius
2. 2, 2, 100 Counterclockwise arc, quadrant 2, 1.00 inch radius
3. 2, 3, 100 Counterclockwise arc, quadrant 3, 1.00 inch radius
4. 2, 4, 100 Counterclockwise are, quadrant 4, 1.00 inch radius

8
1. Set up the main track that the machine is to run on, parallel to the work-piece. Slide the
machine onto the track, front end rst.
2. Plug the machine into the power line of correct voltage, and push the RESET button.
3. Push the red STOP button and use the toggle switches to move the machine and cross
rail to the starting position. Press the Reset button to make this the starting point.
4. Set the speed knob for correct speed. Speed can be checked by moving the machine
manually using the toggle switches.
5. If the required shape has not been programmed, refer to Shape Programming, and enter
the program. If the shape has been programmed, turn on the preheat gases, set the torch
height and ignite the torch.
6. When the work piece is heated enough, press the black RUN button. The solenoid will
turn on the cutting oxygen, the machine will start moving along the programmed shape,
and at the end of the shape it will stop and turn off the solenoid. Manually turn of the
preheat gases. The machine is now ready for the next cut.
STEP BY STEP INSTRUCTIONS FOR OPERATION

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PENDANT CONTROL:
This is the Pendant Control with keypad and display, which plugs into the Pendant Control Connection on the
control panel.
ALPHA KEYS: Press Keys A, B, C, D, or E for the function desired, as described in the programming section
of this manual.
DIGIT KEYS: Use the digit keys to enter pipe diameters or dimensions.
ENTER: Push the enter button to store the numeric value entered.
BACKSPACE: The backspace key removes the last digit keyed in before pushing the enter button, if a
correction is required.

10
PROGRAMMING
NOTE: All programming is done using the PENDANT CONTROL.
For programming use the following “Alpha Keys”.
Push A: To select the type of cut and enter dimensions.
B: To enter the time delay (for plasma cutting).
C: To change Cut Number in memory (numbers 0 – 9).
D: To display the type and dimensions of the cut.
E: To enter end of cut slowdown.
PENDANT CHARACTER MAP: Direct and Shifted Characters.
Shift Key
U: set Units, inch or metric
R: set Ratio
T: Test drives & encoders, function
V: Version Number
SHIFTED CHARACTER SET E.g. to
type U for units,
press Shift Key, then “9”
Shift Key
PENDANT CONTROLS

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PROGRAMMABLE SHAPE MACHINE
WELD/OXY
ON
WELD/OXY
OFF
WAIT FOR
START
BUTTON
TIME DELAY
REPEAT
ANOTHER
SHAPE
AUXILIARY
MODES
PERCENT
SPEED
SEGMENT TYPES: QUADRANT:
#1 #2 #3 #4
1. Clockwise 900arc
2. Counterclockwise
900arc
3. X or Y Axis Line
4. Oblique Line
5. Functions
6. Functions
7. Clockwise Partial Arc
8. Counterclockwise
Partial Arc

12
To program a complete new shape ( press ‘A’ ):
Count the number of segments or operations and enter the total.
For each segment, enter:
TYPE: select from 1 through 8
Quadrant: 1,2,3 or 4; refer to chart
Size: One or more dimensions per segment as described below; 100 per inch
or 10 per mm ( depending on machine version ); or for time, 100 per sec.
of delay. Eg. 150 = 1.5", or for metric 375 = 37.5 mm
Detailed description of TYPES :
Type 1.
Clockwise, 900arc segments.
Quadrant determined by which quarter of a full circle makes the arc. (See chart) .
Dimensions required: Radius only.
Type 2.
Counterclockwise, 900arc segments.
Quadrant determined by which quarter of a full circle makes the arc. (See chart).
Dimensions required: Radius only.
Type 3.
Line along X or Y axis.
Quadrant determined by direction of movement. (See chart)
( East: 1, North: 2, West: 3, South: 4 ).
Dimensions required : Length only.
Type 4.
Angled straight line.
Quadrant determined by direction of movement. (See chart)
(NE: 1, NW: 2, SW: 3, SE: 4 ).
Dimensions required : (1) X - dimension ; movement along X axis
(2) Y - dimension ; movement along Y axis
Type 5.
Functions or other operations.
Quadrant by selecting function. ( See chart )
1. Weld/oxygen ON : turn ON weld contact relay or cutting oxygen solenoid.
Dimensions required : None.
2. Weld/oxygen OFF.
Dimensions required : None.
3. Pause : Machine stops and waits until Start/Run button is pushed again.
Dimensions required : None.
4. Delay : Machine stops and holds position for a programmed time period, up to 99.99
seconds.
Dimensions required : time in .01 second units. (eg. 2.5 seconds = 250)
DATA ENTRY REQUIRED FOR PROGRAMMING

13
DATA ENTRY REQUIRED FOR PROGRAMMING CONTINUED
Type 6.
Special functions.
Quadrant by selecting function.
1. Repeat: Another complete shape will be repeated the specied number of times.
Shape No. of the repeated shape MUST BE LOWER then the Shape
No. of the current shape being programmed. Therefore it CANNOT BE
USED IN SHAPE No. 0.
Data required: (1) Shape Number to be repeated
(2) Number of times.
2. Ellipse: This is provided for making a complete true ellipse, always starting from the
left ( West extremity) and moving clockwise.
Dimensions required: (1) diameter along X-axis.
(2) diameter along Y-axis.
3. Auxiliary Modes: Provides commands to turn ON or OFF the contactor outputs
independently, and also switch speeds from set speed to Rapid Traverse and back.
Mode numbers are from 1 to 8.
4. Set Percent Speed: Used to change speed of the machine in the middle of a shape to
a lower speed.
Type 7.
Clockwise arc, must be less than 1800.
Quadrant determined by direction of end point of arc relative to the start point. (See
chart).
Dimensions required:
(1) X-dimension; offset along X-axis from start to end point.
(2) Y-dimension; offset along Y-axis from start to end point.
(3) Radius of arc.
Type 8.
Counterclockwise arc, must be less than 1800.
Quadrant determined by direction of end point of arc relative to the start point.
(See chart).
Dimensions required:
(1) X-dimension; offset along X-axis from start to end point.
(2) Y-dimension; offset along Y-axis from start to end point.
(3) Radius of arc.
Detailed description of TYPES continued :

14
Mode
Number Output 1. Output 2. Speed
0. Off Off Set
1. Off On Set
2. Off Off Hi
3. Off On Hi
4. On Off Set
5. On On Set
6. On Off Hi
7. On On Hi
These extra controls have been added to independently turn the two internal Relay outputs ON and
OFF, and to switch the machine into Rapid Traverse mode or Set Speed.
The machine is shipped with OUTPUT (1) wired to the contactor relay. By default, this Output turns
ON when the Start button is pressed to run a shape, and turns OFF at the end. The relay contacts are
located on the MDS Drive.
OUTPUT (2) is not wired. The machine can be changed to use Output 2 instead of Output 1 but both
outputs cannot be used at the same time. To change from one output to the other:
1. Open the module.
2. Move the connector from the current output jack to the to the desired jack.
3. See Control Module Wiring Group drawing (MDS-1155-WD)
4. Close module.
By default Output (2) is OFF when a shape is started, until specically turned ON by the Solenoid/
Weld ON command Type 5, Quad 1.
While running, the Type 5 ON and OFF commands can be used to turn both Outputs On and Off
together, and both turn Off at the end.
When programming Type 6 Quad 3, a Mode Number is required to be entered. The 8 auxiliary modes,
numbered 0 through 7, allow the setting of a mode with any combination of Outputs On or Off, and
choice of Set Speed by the speed knob, or maximum speed regardless of setting. The combinations
are listed in the table below:
Selecting Type 6-4 allows the speed to change to a fraction of the set speed. Display will read “Speed
%”, and data entry is accepted from 1 to 99. Entering 0 or just return will make the speed 100%,
which is the same as set speed.
When the program reaches a Type 6-3 segment while running, the speed will change to the percent
entered, and continue at this setting until there is a later Type 6-3 segment which changes it to
another % setting or back to 100%.
Note: If Type 6-3 has been set for HI ( rapid traverse ), then this setting will cut down the HI speed to
the same % .
Settings below 10% are not recommended.
AUXILIARY MODES: TYPE 6, QUADRANT 3
SET % SPEED, FRACTION OF SET SPEED: Type 6, Quadrant 4

15
1. Draw the required shape on paper to some convenient scale.
2. Refer to the Segment Chart and divide the shape into straight line and arc segments.
3. Decide on the operation sequence and mark any other operations such as turning torch on
or off, or delay.
4. Number all the segments in sequence, including other operations if any, and make a table with
required data. Example for a clockwise circle starting from the top: (dimensions described for
metric version)
Segment Number Type Quadrant Dimensions
1. 1 1 300 (30 mm)
2. 1 4 300 (30 mm)
3. 1 3 300 (30 mm)
4. 1 2 300 (30 mm)
5. With the machine powered up and pendant plugged in, select which shape number this will be -
say we want No. 3.
Push C : display reads “Shape No._”
Push 3 for No. 3, press Enter key (backward arrow)
The program is now in Shape no. 3
6. Push A : display reads “Total segments ?”
Push 4 for 4 segments and Enter.
Display reads “1. Type?” waiting for Segment 1 data.
7. Push 1 for type, clockwise arc. (Refer to the table prepared).
Display reads “Quadrant?”
Push 1 for quadrant 1.
Display reads “mm x 10”
Push 3, 0, 0, Enter, for 300, which is 30.0 mm.
Segment 1 has now been entered, display reads “2. Type ?”, asking for data for segment 2.
8. Repeat above steps to enter data for all segments, in sequence.
Display will read “Ready” after all segments are entered.
The shape program is now stored in memory as shape no. 3, and the machine is ready
to cut the shape.
SHAPE PROGRAMMING

16
DIMENSIONS REQUIRED
R R
L
XY
R
X
Y
Y
X
1 2 3
4 6-2
78
R
X
Y

17
EXAMPLE: OBROUND SHAPE
START A
B C
D
F E
4.0
10.0
6.0 Cutting path:
A-B-C-D-E-F-A
Total number of segments = 6
AB: Type 1 species Clockwise Arc
Quadrant Number is 2
Size 300 species Radius = 3.00 inches (Metric: 300=30.0 mm).
Segment Number Type Quadrant Size Comment
AB 1 1 2 300 CW Arc, 3.00" radius
BC 2 3 1 400 X-axis line, 3.00"
CD 3 1 1 300 CW Arc
DE 4 1 4 300 CW Arc
EF 5 3 3 400 X-axis line
FA 6 1 3 300 CW Arc

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EXAMPLE: REPEAT FUNCTION
START A
13.0
F
E
8.0
D
C
B
Total number of segments = 6
D
Total number of segments = 4
START A E
B
C
Shape No. 1
Shape No. 2
Shape No. 1
Segment Number Type Quadrant Size Comment
AB 1 3 1 100
BC 2 3 2 200
CD 3 3 1 100
DE 4 3 4 200
Shape No. 2
Segment Number Type Quadrant Size Comment
AB 1 3 4 800
Shape 1 2 6 1 1 Repeat #1
6 6 times
CD 3 3 1 100
DE 4 3 2 600
EF 5 2 1 200
FA 6 3 3 1100

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MDS-1165 PANEL CONTROLS
Reset
(SW1)
Start/Run
(SW2)
Manual Jog
Y Axis
(SW5)
Manual Jog
X Axis
(SW4)
Pendant Control
Stop/Pause
(SW3)
Speed
Control
(P)
QUADRANT
32
1
4
Y Y
X
X
MADE IN USA
SHAPE MODULE
EN1

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MDS SHAPE MACHINE MAJOR COMPONENTS
ITEM QTY PART NO. DESCRIPTION
1 1 MPD-1000 Master Drive Unit 120 VAC
1 1 MPD-1002 Master Drive Unit 240 VAC
1 1 MPD-1004 Master Drive Unit 42 VAC
2 1 MDS-1165 Shape Control Module
3 1 WPD-1100-40 Linear Weaver
4 1 BUG-6050 Hand Held Terminal
5 1 MPD-1065 Releasable Carriage 12"
6 1 MPD-1035 Handle w/Cable Anchor
7 1 WPD-1178 Post w/Fasteners
8 1 BUG-5462 Right Angle Clamp
9 1 BUG-1853 Machine Rack 7-1/2"
10 1 BUG-5455 Gun Mounting Group
11 1 BUG-5188 Torch Holder Assembly
PARTS LIST
6
2
3
1
5
4
11
8
9
10
Note: 40" cross arm is part number: WPD-1150-40
Note: Solenoid Kit (not shown) is required for Oxyfuel cutting.
7