BUG-O Bug-O-Matic BUG-5710 User manual

INSTRUCTIONS
AND
PARTS MANUAL
UNIVERSAL
BUG-O-MATIC
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-BUG-O-MATIC-IPM-0415
A DIVISION OF WELD TOOLING CORPORATION
280 TECHNOLOGY DRIVE CANONSBURG, PENNSYLVANIA 15317-9564 USA
PHONE: [phone] http://www.bugo.com FAX: [phone]
Bug-O Systems is guided by honesty, integrity and
ethics in service to our customers and in all we do.

2
MOVING PARTS can
cause serious injury.
PROTECT YOURSELF AND OTHERS FROM SERIOUS INJURY OR DEATH. KEEP
CHILDRENAWAY. BE SURE THATALL INSTALLATION, OPERATION, MAINTENANCE
AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
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. In none exist, use
International Electric Code (IEC) 950.
READ INSTRUCTIONS.
Read the instruction manual before
installing and using the equipment.
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.
PLASMA CUTTING can
produce destructive High
Voltage at High Frequency.
SAFETY
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.
1) If using plasma, see that the machine
as well as the plasma power source is
properly grounded.
2) Do not use older model plasma
machines meant for manual operation.
These can leak high frequency at high
voltages, which can cause dangerous
shock, as well as destroy control
circuits.
3) Read the instruction manual page on
plasma cutting carefully, and follow all
precautions.

3
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.
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.

4
UNIVERSAL BUG-O-MATIC
INSTRUCTIONS AND PARTS MANUAL
TABLE OF CONTENTS
5 ..........Technical Data
6 ..........Pendant Control Functions
7 ..........Universal BUG-O-Matic BUG-5700 Parts List
8 ..........BUG-5710: Drive Box Assembly
9 ..........BUG-5720: Cover Assembly, 120 Vac
1 0 .........BUG-5715: Base Assembly
11 .........BUG-5725: Cross Drive Assembly
12 .........Drive Unit Wiring Diagram
13 .........Electrical Component Chart Drive Unit
14 .........Wiring Harness BUG-5726 Diagram
1 5 .........PCB-5700: Drive Unit Interconnect PC Board
16 .........PCB-5700: Wiring Diagram
17 .........BUG-5775: Control Pendant / Exploded View
18 .........BUG-5775: Control Pendant / Parts List
1 9 .........Control Pendant, BUG-5775 Wiring Diagram
2 0 .........BUG-5751 Pendant Cable Wiring Diagram
21 .........Rail Options
2 5 .........Carriage Options
28 .........Accessories
2 9 .........Service Procedure / Installing The Cross Rail (WPD-1150)
31 .........Warranty
PAGE

5
UNIVERSAL BUG-O-MATIC
TECHNICAL DATA
Power BUG-5700 120 VAC/50-60/1
Requirements: BUG-5702 240 VAC/50-60/1
BUG-5704 42 VAC/50-60/1
Linear Speed: 3-70 ipm (75-1750 mm/min)
Weave Speed: 4-100 ipm (100-2500 mm/min)
Dwell Time: 0-3 seconds, left and right
Weave Width: 0.1 to 2" (2.5-50 mm)
Steering: 2" (50 mm) left and right of center
4" (100 mm) total
Load Capacity: 30 lbs (14 kg)
Net Weight: 22 lbs (10 kg)
The machine can be mounted on MPD-1065 Releasable Carriage, MPD-1055 18" Carriage, FMD-1100
Carriage for Hi-Flex rail, or on BUG-5910 Tube Carriage. By simply changing the carriage, the machine
will run on any BUG-O rail - Aluminum Rigid, Semi-Flex, Bent Rigid, or Hi-Flex . The chart below shows
which types of rail are compatible with each carriage. See pages 21- 27 for details.
CARRIAGES
BUG-5910 Tube Carriage X X X
FMD-1100 Hi-Flex Carriage X
MPD-1055 18" Carriage X
MPD-1065 Releasable Carriage X X
Aluminum Rigid Rail
ARR-1080 & ARR-1085
Bent Rigid Rail
BRR-1180 & BRR-1210
Hi-Flex Rail
FMD-1050
Semi-Flex Rail
AFR-3000
RAILS
The power Supply transformer is contained inside the unit. Pendant control of all functions is pro-
vided, including:
weave speed and amplitude, and centerline steering,
left and right dwell time,
tractor speed and direction,
weld contact on/off.

6
B
D
G
J
C
E
F
H
I
A
BUG-5775 Pendant Control
A. Weave Speed
B. Steering, 2" (50 mm) left or right from center
C. Amplitude, 0-2" (50 mm)
D. Dwell Left, 0-3 sec.
E. Dwell Right, 0-3 sec.
F. Weld Contact Switch
G. Mode Selector Switch
H. Digital Display, Tractor Speed
I. Forward / Off/ Reverse, Tractor Travel
J. Tractor Speed
PENDANT CONTROL FUNCTIONS

7
7
9
2
1
3
5
6
4
2
8
ITEM QTY PART NO. DESCRIPTION
1 1 BUG-2975 Cable Mounting Assembly
2 2 BUG-5462 Right Angle Clamp
3 1 BUG-5710 Drive Box 120 V
1 BUG-5712 Drive Box 240 V
1 BUG-5714 Drive Box 42 V
4 1 BUG-5751 Pendant Cable
5 1 BUG-5775 Pendant Control
6 1 BUG-9180-6 Rod, 6" (152 mm)
7 1 BUG-1853 Machined Rack, 7.5"
8 1 BUG-5455 Gun Mounting Group
9 1 BUG-5965 Handle Assembly
UNIVERSAL BUG-O-MATIC BUG-5700 PARTS LIST

8
7
7
4
7
7
6
6
6
7
7
7
7
7
7
2
6
6
67
7
5
3
1
ITEM QTY PART NO. DESCRIPTION
1 1 BUG-5707 Left Side Panel
2 1 BUG-5708 Right Side Panel
3 1 BUG-5715 Base Assembly
4 1 BUG-5720 Cover Assembly 120 V
5 1 BUG-5725 Cross Drive Assembly
6 6 FAS-0114 Pan Hd Scr 6-32" x 3/8"
7 12 FAS-0124 Pan Hd Scr 8-32" x 3/8"
BUG-5710: DRIVE BOX ASSEMBLY

9
Included
w/item #6
12
17
20
14
8
9
4
1
2
511
13
15
10
15
16
6
3
19
7
13
16
13
Included
w/item #6
18
* For 240V and 42V machines, refer to Electical Component List on pg 13.
ITEM QTY PART NO. DESCRIPTION
1 1 ARM-2279 Toggle Switch
2 1 BUG-1393 Volt trap 120 VAC
3 1 BUG-1770-PW Motor control board
4 1 BUG-2923 Circuit Breaker 0.7 amps
5 1 BUG-2924 Reset Button Seal
6 1 BUG-5218 Transformer 117 VAC
7 1 BUG-5721 Cover panel anodized
N/S 1 BUG-5726 Wire harness
8 1 BUG-9445 Power Cord
9 1 BUG-9446 Cord Grip
10 1 BUG-9487 Cable connector 2-T
11 1 BUG-9884 On-Off switch plate
12 1 CAS-1770 Speed Control
13 8 FAS-0114 Pan Hd Scr 6-32 x 3/8"
14 1 FAS-0124 Pan Hd Scr 8-32 x 3/8"
15 8 FAS-0205 Rnd Hd Scr 4-40 x 1/2"
16 8 FAS-1305 Hex nut 4-40
17 1 FAS-1320 Hex nut 8-32
18 1 FAS-1330 Hex nut 10-24
19 1 PCB-5700 Interconnect board
20 1 WAS-0221 #8 INT Star lock washer
BUG-5720: COVER ASSEMBLY, 120 VAC*

10
10
9
8
2
6
3
5
6
7
4
1
ITEM QTY PART NO. DESCRIPTION
1 1 BUG-5709 Base Plate
2 1 BUG-5716 Clutch Assembly
3 2 BUG-5723 Attachment Bar
4 4 FAS-0557 Soc Hd Cap Scr 1/4-20 x 3/4"
5 4 FAS-0825 Flt Hd Slot Scr 8-32 x 1/2"
6 8 FAS-0923 Flt Hd Soc Scr 8-32 x 5/16"
7 1 GOF-3014 Drive Pinion w/ Key & Set Scr
8 1 MPD-1015 Gear Motor (60:1)
9 1 WPD-1013 Rubber Ring Gasket
10 1 WPD-1045 Brake Assembly
BUG-5715: BASE ASSEMBLY

11
1
3
6
4
42
8
7
9
5
5
14
11
10
12
13
ITEM QTY PART NO. DESCRIPTION
1 1 BUG-5590 Gear motor
2 1 BUG-5591 Pinion
3 3 BUG-5592 Spacer
4 4 BUG-5594 Slt Pan Hd Scr 3mm x 18mm
5 1 BUG-5595 Pot/ Gear Assembly
6 2 BUG-5670 Adj. Leg & Wheel Assembly
7 2 BUG-5675 Fixed Leg & Wheel Assembly
8 1 BUG-5728-A Cross Drive Support
9 1 WPD-1164 Arm Stop
10 1 FAS-0539 Screw, 10-24 x 1"
11 1 WPD-1150 Cross Arm, 15.50"
12 2 WAS-0230 #10 SAE Flat Washer
13 2 FAS-0537 Screw, 10-24 x 3/4"
14 1 WPD-1177 Post
BUG-5725 CROSS DRIVE ASSEMBLY

12
BUG-655X DRIVE UNIT / WIRING DIAGRAM

13
ITEM DESCRIPTION BUG-5990
120 VAC
BUG-5992
240 VAC
BUG-5994
42 VAC
PC Power Cord BUG-9445 GOF-3115 BUG-9442
CB Circuit Breaker BUG-2923 BUG-2952 BUG-2933
TR Transformer BUG-5218 BUG-5231 BUG-5232
SW Toggle Switch ARM-2279
IB Interconnect Board PCB-5700
CN1 Connector, to Pendant BUG-5527
CN2 Connector, to Weld Contact BUG-1034
MT Tractor Motor MPD-1015
BR Brake WPD-1045
MW Weave Motor BUG-5590
MC1 Motor Control, Tractor BUG-1770-UB
MC2 Motor Control, Weave CAS-1770
SVP Servo-Pot BUG-5240
BUG-655X DRIVE UNIT / ELECTRICAL COMPONENT CHART

14
BUG-5726 WIRING HARNESS / WIRING DIAGRAM

15
PCB-5700 DRIVE UNIT INTERCONNECT PC BOARD

16
PCB-5700 / WIRING DIAGRAM

17
BUG-5775 CONTROL PENDANT / WIRING DIAGRAM

18
11,16,17
1,9,11
11,16,17
10
13
4,10
15
12
24
3
5
20
14
20
8
21,22,25
20
1,11,16
2,19,23
6,11,16
18
11
7
6,11,16
BUG-5775 CONTROL PENDANT / EXPLODED VIEW

19
ITEM QTY PART NO. DESCRIPTION
1 2 BUG-1562 Potentiometer, 10k, 3 turn
2 1 BUG-1764 Digital Meter
3 1 BUG-2034 Teon Washer
4 1 BUG-2255 Toggle Switch, DPDT, On-Off-On
5 1 BUG-2436 Knob Screw
6 2 BUG-5054 Potentiometer, 500 K
7 1 BUG-5363 Rotary Switch, 3-P, 4-position
8 1 BUG-5687 Panel Connector, 10-T, F
9 1 BUG-5757 Knob, Large
10 2 BUG-5758 Toggle Switch Seal
11 7 BUG-5759 Pot Shaft Seal
12 1 BUG-5760 Control Board
13 1 BUG-5761 Toggle Switch, SPDT, On-On
14 1 BUG-5772 Rear Panel
15 1 BUG-5773 Front Panel
16 5 BUG-9621 Knob
17 2 BUG-9677 Potentiometer, 10 K
18 1 BUG-9694 Knob (Pointer)
19 4 FAS-0104 Pan Hd Scr, 4-40 x 3/8 L
20 8 FAS-0114 Pan Hd Scr, 6-32 x 3/8 L
21 4 FAS-0205 Rnd Hd Scr, 4-40 x 1/2 L
22 4 FAS-1305 4-40 Hex Nut
23 1 MDS-1011 Display Bezel
24 1 PAN-1033 Rod Clamp
25 4 WAS-0201 Star Washer #4
BUG-5775 CONTROL PENDANT / PARTS LIST

20
A__________________ T Common
B__________________ S
C__________________ R
D__________________ B Osc. Speed
E__________________ P (Osc. Dir)
F__________________ D Brake Release
G__________________ E Tractor Speed
H__________________ L Weld Contact
J___________________ M Weld Contact
K__________________ H Gear Pot.
BUG-5751 PENDANT CABLE / WIRING DIAGRAM