Bug-O Systems UNI-BUG II Technical reference manual

A DIVISION OF WELD TOOLING CORPORATION
PHONE:[phone] http://www.bugo.com FAX:[phone]
280 TECHNOLOGY DRIVE CANONSBURG, PENNSYLVANIA, USA 15317-9564
Please record your equipment identification information below for future
reference. This information can be found on your machine nameplate.
ModelNumber:
Serial Number:
Date of Purchase:
Whenever you request replacement parts or information on this equipment,
always supply the information you have recorded above.
LIT-UBII-IPM-0308
UNI-BUG II
THE UNIVERSAL BUG-O
INSTRUCTIONS
AND
PARTS MANUAL

SAFETY
PROTECT YOURSELF AND OTHERS FROM SERIOUS INJURY OR
DEATH.KEEPCHILDRENAWAY.BESURETHATALLINSTALLATION,
OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
1.Do not plug in the power cord without
first verifying the equipment is OFF
and the cord input voltage is the same
as required by the machine or serious
damage may result.
2.Do not leave the equipment unattended.
Remove from the worksite and store in a
safe location when not in use.
Read the instruction manual before
installing and using the equipment.
1.The equipment is not waterproof.
Using the unit in a wet environment
may result in serious injury. Do not
touch the equipment when wet or
standing in a wet location.
2.Never open the equipment without first
unplugging the power cord or serious
injury may result.
3.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.
4.Never remove or bypass the equipment
powercord ground. Verity the equip-
ment is grounded in accordance with all
applicable local and national electrical
safety codes. If none exist, use lnterna-
tional Electrical Code (IEC) 950.
ELECTRIC SHOCK can
kill.
READ INSTRUCTIONS
EQUIPMENT DAMAGE
POSSIBLE.
1. Never try to stop the pinion from
movingexcept by removing power or
by using the STOP control.
2.Do not remove any protective panels,
covers or guards and operate equipment.
FALLING EQUIPMENT
can cause serious personal
injury and equipment
damage.
Faulty or careless user installation is
possible. As a result, never stand or
walkunderneath equipment.
MOVING PARTS can
cause serious injury.
CAUTION
DO NOT LEAVE EQUIPMENT UNATTENDED
WHEN NOT IN USE!
Remove from work site and store in a safe location.

UNI-BUG II
INSTRUCTIONANDPARTSMANUAL
PAGE
TABLE OF CONTENTS
THIS PRODUCT IS COVERED BY ONE OR
MORE PATENTS WORLD WIDE.
4,5 ..... INTRODUCTION / FEATURES / SET-UP
6 ........ TECHNICAL DATA / DIMENSIONS
7 ........UNI-BUG II KITS
8 ........PARTS LIST / UNI-1000 UNI-BUG II
9 ........EXPLODED VIEW / UNI-1000 UNI-BUG II
10 ...... EXPLODED VIEW / PARTS LIST BUG-1875 UNI-BUG CUTTING GROUP
11 ...... EXPLODED VIEW / PARTS LIST BUG-1856 UNI-BUG WELDING GROUP
12 ...... WIRING DIAGRAM / ELECTRICAL COMPONENT CHART
13 ......EXPLODED VIEW / PARTS LIST BUG-1795 COMPACT CORNER
FOLLOWER
15 ...... EXPLODED VIEW / PARTS LIST UNI-1350 UNI-BUG DUAL WELDING
14 ...... UNI-BUG II FOR DUAL WELDING / RACKMOUNTING / UNI-1019
GROUP
16 ...... UNI-BUG BULB FLAT WELDER
17 ......UNI-BUG II WITH STITCH MODULE
18 ...... TROUBLESHOOTINGGUIDE
20 ...... WARRANTY
STEEL DRIVE ROLL
3

4
The UNI-BUG II is a small, lightweight, versatile machine originally de-
signedfor theshipbuilding industryto weldor cutcoamings, flanges, stiffen-
ers and similar joints. Previously this work could not be automated because
therewas notenough room to mount a machine track system orthe available
machines were too large to follow some of the workpiece curves or get into
tight work areas.
The UNI-BUG II is small enough to carry a cutting torch or welding gun
into tight work areas or around very tight curves without the use of a track.
The built-in carrying handle allows for easy mounting and removal at any
point along the workpiece. The UNI-BUG II can weld or cut both straight line
and on an inner radius as small as 6"(152 mm). It will travel at speeds of
4-75 ipm (102-1905 mm/min) with a 50 lb. (22.7 kg) horizontal pulling
capacity.
The UNI-BUG II is designed to run on the edge of a bar or stiffener up to
2" (50.8 mm) thick as shown below. Front and rear rollers support the
machine and tilt it forward for better control and traction. This also sets the
working direction. The machine must be turned around to weld the other
side of the workpiece.
INTRODUCTION
Direction of Travel
UNI-BUG II straddling an I-beam
(Torch holding devices not shown for clarity)
Idler screw knob
Rear support
roller
Front support roller
Carrying handle
21
NOTES:

5
TheUNI-BUG II canoperate without atrack asshown below. Agear motor
turns two drive wheels on one side of the workpiece. On the other side of the
workpiece is a bracket which has four idler wheels mounted on it. An idler
screw knob is used to move the idler wheel bracket into the workpiece and
clamp it between the four idler wheels and the two drive wheels.
BUG-1855 Welding Group is required to clamp and position a welding
gun. BUG-1875 Cutting Group is available for cutting applications.
INTRODUCTION(CONT’D.)
1.Loosen the idlerscrew knob toopen the gapbetween the idler wheels and
the drive wheels. When the gap is large enough, drop the machine over
the workpiece edge.
2. The machine should be firmly resting on the front and back roller
supports and tilt forward in the direction of desired travel.
3. Engage the idler screw knob until all of the idler and drive wheels are
contacting the workpiece. Tighten another 1/2-3/4 turn to firmly clamp the
workpiece.
4. Adjust the UNI-BUG II racking attachment so the welding gun or cutting
torch is properly positioned. The are should always be placed below the
center of the machine so that the gun or torch can hold the same relative
position as the machine moves from a straight to a curved work section.
5. Set the machine speed using the speed control.
6. Set the travel switch to “ON”.
7. Turn on the weld contactor switch to begin welding.
FEATURES
Supportroller Idler screw knob
(to engage idler
wheels)
Frontmotor drivewheel
to move UNI-BUG II
Frontidler wheel Bracket that holds
idler wheels
SET-UP
20
WARRANTY
FOR A PERIOD OF TWELVE (12) MONTHS FROM DELIVERY, BUG-O SYSTEMS
WARRANTSTOTHEORIGINAL PURCHASER(DOESNOTINCLUDE AUTHORIZED
DISTRIBUTORS),THAT ANEW MACHINEIS FREEFROM DEFECTSIN MATERIAL
AND WORKMANSHIP AND AGREES TO REPAIR OR REPLACE, AT ITS OPTION,
ANYDEFECTIVE PARTS OR MACHINE.THIS WARRANTY DOES NOT APPLYTO
MACHINES,WHICHAFTEROURINSPECTION, ARE DETERMINEDTOHAVEBEEN
DAMAGEDDUETONEGLECT,ABUSE,OVERLOADING,ACCIDENTORIMPROPER
USAGE.ALLSHIPPINGAND HANDLINGCHARGESWILL BEPAIDBY CUSTOMER.
BUG-OSYSTEMS 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
OFNON-CONFORMING PARTS AND MACHINES.UNDER NO CIRCUMSTANCES
SHALLCONSEQUENTIAL 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.
LIMITEDWARRANTY MODEL _____________________
SERIALNO.__________________
DATEPURCHASED: ___________

6
TECHNICALDATA
Power Requirement: UNI-1000 120 VAC/50-60/1
UNI-1002 240 VAC/50-60/1
UNI-1004 42 VAC/50-60/1
Dimensions: 8.00" L x 7.62" W x 10. 50" H
(203 x 194 x 267 mm)
Speed Range: 4 ipm to 75 ipm
(102 to 1905 mm/min)
Maximum Stiffener
Size: 2" (50.8 mm)
Net Weight: 14 lbs. (6.35 kg)
Shipping Weight: 16 lbs. (7.26 kg)
DIMENSIONS
7.62''
(194 mm)
6.25''
(159 mm)
10.50''
(267 mm)
6.00''
(152 mm)
2.00''
(51 mm)
2.00''
(51 mm) 8.00''
(203 mm)
5.75''
(146 mm)
19
TROUBLESHOOTINGGUIDE(CONT’D.)
PROBLEM CAUSE REMEDY
Unit runs, but no Faulty control - Unplug the machinefrom power.
speedcontrol. card. Verify there are no bad connections
to the control card or on the board.
Replace the card.
Failed speed - Replace if visually appears damaged.
potentiometer. Verify no loose or broken connec-
tions to the part.
Unit runs, but erratic Poor input voltage - Verify the machine power source is or
poorspeed control. regulation. stable and at the correct voltage.
Measure at the outlet.
Faulty control - Unplug themachine frompower.
card. Verify there are no bad connections
to the control card or board. Replace
theboard.
Damaged wheel - Turn the machine upside down and
or wheel assy. off. Replace any wheels that are
damaged. Replace any idler wheels
that do not freely turn.
Pitted workpiece. - Verify the workpiece is not pitted or
damaged in a way that will give an
uneven drive surface to the machine
wheels. Verify the workpiece thick-
ness does not vary significantly where
themachine wheels travel.

7
UNI-1100 UNI-BUG II Welding Kit 120 VAC
UNI-1102 UNI-BUG II Welding Kit 240 VAC
UNI-1104 UNI-BUG II Welding Kit 42 VAC
Net Weight: 19 lbs. (8.62 kg)
Shipping
Weight: 21 lbs. (9.53 kg)
Includes:
(1) BUG-1855 UNI-BUG Welding Group
(1) UNI-100_ UNI-BUG II
UNI-1200 UNI-BUG II Cutting Kit 120 VAC
UNI-1202 UNI-BUG II Cutting Kit 240 VAC
UNI-1204 UNI-BUG II Cutting Kit 42 VAC
Net Weight: 20 lbs. (9.07 kg)
Shipping
Weight: 22 lbs. (10.0 kg)
Includes:
(1) BUG-1875 UNI-BUG Cutting Group
(1) UNI-100_ UNI-BUG II
UNI-BUGIIKITS
18
PROBLEM CAUSE REMEDY
Does not run. Indicator No input power. - Turn on the circuit breaker.
light off. - Plug in the line cord.
- Insure there is power at the outlet.
Broken Wire. - Unplugthemachinefrompower.
- Examine internally and rewire at
fault.
Bad circuit. - Replace if breaker has input power
and no output when in the “ON”
position.
Bad travel switch. - Replace if switch has input power
and no output when ‘ON”.
Does not run. Indicator Wiring short. - Unplug the machine from power.
light off and circuit Examine internally and rewire at
breaker is tripped. fault.
Burned out part. - Unplug the machine from power.
Examine internally and replace any
part that looks burned up.
Other. - Can only be determined by factory
or qualified repair person.
Does not run. Indicator Bad connection. - Unplug the machine from power.
light on. Examine internally and fix any
brokenconnections.
- Tighten terminal screws on speed
control board.
Open transformer. -Replace the transformer if there is
input power on the primary and no
outputon the secondary.
(12VAC/CT is expected)
Burned out part. - Unplug the machine from power.
Examine internally and replace any
part that looks burned up.
Wiring short. - Unplug themachinefrompower.
Examine internally and rewire fault.
Failedmotor. - Replace the motor if it has
input voltage and does not turn.
Failed control - Unplug the machine frompower.
card. Check the card for damaged traces
or parts. Repair or replace if required.
- Verify the card has 12 VAC/CT
input power. Replace the card if the
output to the motor leads is OV
with the speed knob at maximum.
Other. - Can only be determined by factory or a
qualified repair person.
TROUBLESHOOTINGGUIDE
MORE

8
ITEM QTY PART NO. DESCRIPTION
* 1 1 BUG-1393 VoltTrap120VAC
* 2 1 BUG-1415 Pilot Light 120 VAC
3 1 BUG-1550 Gear Motor (15O: 1)
4 1 BUG-1725 Precision Speed Control
5 1 BUG-1785 Handle
6 1 BUG-1854 Screw Block with Insert
7 2 BUG-1858 Soc Hd Shr Scr 5/16 x 1 1/4 x 1/4-20
8 2 BUG-1859 BearingSpacer
9 1 BUG-1863 IdlerChannel
10 1 BUG-1865 Bearing Block Assembly
11 1 BUG-1867 Bearing Block Guard
12 1 BUG-1869 Toggle Switch SPST On-Off
13 2 BUG-1888 Drive Roll
14 3 BUG-1889 Spacer .875 Dia x 1.375 Lg
15 2 BUG-1893 Retaining Ring 1/2" External
16 2 BUG-1895 Roller Bearing Assembly
17 2 BUG-1897 Sleeve
18 2 BUG-1898 Axle
19 4 BUG-1899 Washer 1 1/16 OD x 1/2 ID x 1/32 Thk
20 2 BUG-1988 Belleville Washer .323 ID x .709 OD
21 4 BUG-2012 Bearing
* 22 1 BUG-2923 Circuit Breaker 0.7 A
23 1 BUG-2924 Reset Button Seal
24 4 BUG-5121 Stand Off
25 1 BUG-9103 Cord Grip
26 1 BUG-9444 ToolKit
* 27 1 BUG-9445 Power Cord 120 V
28 1 BUG-9486 Panel Connector, 2-T, M
29 1 BUG-9487 Cable Connector, 2-T, F
30 1 BUG-9621 Knob
* 31 1 BUG-9675 Transformer 120V
32 1 BUG-9677 Potentiometer
33 1 BUG-9884 On-Off Switch Plate
34 4 CON-1029 Washer 5/16 x .015 Thk
35 12 FAS-0114 Pan Hd Scr 6-32 x 3/8
36 7 FAS-0124 Pan Hd Scr 8-32 x 3/8
37 4 FAS-0204 Rnd Hd Sor 4-40 x 3/8
38 4 FAS-0357 Hex Hd Cap Scr 1/4-20 x 3/4
39 3 FAS-0359 Hex Hd Cap Scr 1/4-20 x 1”
40 2 FAS-0452 Set Scr 1/4-20 x 1/4
41 4 FAS-0525 Soc Hd Cap Scr 8-32 x 1/2
42 1 FAS-0957 Fit Hd Soc Scr 1/4-20 x 3/4
43 4 FAS-1305 Hex Nut 4-40
44 3 FAS-1320 Hex Nut 8-32
45 1 FAS-1445 Si Pan Hd Th Rolling 10-32 x 1/2
46 4 FAS-2824 Fit Hd Sit Scr 8-32 x 1 3/4
47 1 MUG-1192 RotarySwitchw/Knob, 4P, 3-Pos
48 1 UNI-1016 Cover
49 1 UNI-1017 Left Side Panel
50 1 UNI-1018 Right Side Panel
51 1 UNI-1021 Base Plate
52 2 UNI-1022 Slave Shaft
53 2 UNI-1023 Bearing 5/8 OD x 1/2 ID x 1/4 Thk
54 2 UNI-1024 Slave Pinion
55 1 UNI-1025 Pinion w/set screw
56 4 UNI-1028 Thrust Washer
57 2 UNI-1029 Shaft Spacer
58 1 UNI-1030 Tensioning Screw Assembly (includes items 62,63,64)
59 1 RPS-0117 Roll Pin 3/32 x 3/4
60 1 UNI-1031 1/2-13 Threaded Stud
61 1 UNI-1032 Knob
62 3 WAS-0221 #8 Internal Star Lockwasher
63 1 WAS-0230 #10Washer
64 7 WAS-0240 1/4 SAE Washer
* See Electrical Component Chart for 240 VAC and 42 VAC Part Numbers
PARTS LIST / UNI-1000 UNI-BUG II
17
UNI-BUGIIWITHSTITCHMODULE
UNI-BUG II w/Stitch Module
UNI-1550 120VAC/50-60/1
UNI-1552 240VAC/5O-60/1
UNI-1554 42VAC/50-60/1
“Remote” Position
The UNI-1550 is a modification of the UNI-BUG II, that has been adapted
to connect to a Stitch Module on a remote pendant.
A rotary selector switch enables the Stitch Module, and transfers control
of the speed, travel times and weld contactor to the pendant. For safety
reasons, the Weld Contact Toggle Switch on the UNI-BUG must be set in
the “0” or OFF when using the UNI-BUG in the Remote mode, or the weld
contactor will not operate.
With the Stitch Module removed, the unit will function as a standard
UNI-BUG II. The “Remote” position of the Rotary Switch will be disabled.
Rotary Travel
Switch
Weld Contact
Toggle Switch

9
1
EXPLODED VIEW / UNI-1000 UNI-BUG II
28 29
12
2
32
30 37
43 5
35
36 62
44 33
36
62
48
35
49 36
35
47
3
44 62
36
35
50
25
27
31
44
36 23
22 4
24
58
56
55
54 57
56
38
67
41
9
46
18
16
34
41
51
42
53
26
45 63 20 21 8
52
57
40
17
15
21
7
660 61
58
59
39
14
19
13
19
10
11
64
16
UNI-BUGBULBFLATWELDER
Dimensionsof machine
without torch mounts.
(Torchmountsshown on
earlierpages).
TheUNI-1305, Bulb
FlatWelder Adaptor
Kit can be used with
thestandard UNI-BUG
for bulb flat welding.
*Spacer Block For 280 to 430 mm
UNI-BUGBulb Flat Welder will weld large bulb anglesfrom 140-430 mm
7.62
(194 mm)
6.25
(159 mm)
10.50
(267 mm) 6.00
(152 mm)
2.00
(51 mm)
4.6
(117 mm)
5.75
(146 mm)
8.00
(203 mm)

10
ITEM QTY PART NO. DESCRIPTION
1 1 BUG-1853 Machined Rack 7-1/2"
2 1 BUG-5188 Torch Holder Assembly
3 1 BUG-5451 3.5" Rackholder
4 1 BUG-5462 Right Angle Clamp
5 1 BUG-9729 Spacer
6 1 CIR-1010-2 Hose Assembly
7 2 FAS-0957 Flt Hd Soc Scr 1/4-20 x 3/4
8 2 FAS-2353 Hex Hd Cap Scr 1/4-20 x 1-1/2
9 1 GOF-3025 Quick-Acting Manifold
EXPLODED VIEW / PARTS LIST / BUG-1875
UNI-BUG CUTTING GROUP
8
2
7
4
1
3
6
9
5
15
EXPLODED VIEW / PARTS LIST /
UNI-1350 UNI-BUG DUAL WELDING GROUP
Converts a standard UNI-1000 into a dual welder.
ITEM QTY PART NO. DESCRIPTION
1 4 BUG-1853 Machined Rack 7-1/2"
2 1 BUG-1881 Cable Anchor w/Swivel Clamp
3 1 BUG-1891 Double Racker Mounting Angle
(includes 2 of item # 4)
4 4 FAS-0557 Soc Hd Cap Scr 1/4-20 x 3/4
5 2 BUG-2708 Clamp
6 2 BUG-5451 3.5" Rackholder
7 2 BUG-5462 Right Angle Clamp
8 2 CON-1020 Swivel Clamp Assembly
9 2 FAS-0957 Fit Hd Soc Scr 1/4-20 x 3/4 lg.
10 2 UNI-1036 Rackrider w/Post
2
7
10
58
14
4
35
10
8
6
1
7
1
9
6
1