bug-o welding and cutting

A DIVISION OF WELD TOOLING CORPORATION

280 TECHNOLOGY DRIVE CANONSBURG, PENNSYLVANIA 15317-9564 USA PHONE: 1- 412-331-1776 http://www.bugo.com FAX: 1- 412-331- 0383

AUTOMATIC HEIGHT CONTROL

Affordable Automation for Welding, Cutting and

Semi-Automatic Processes

The CAS-0100 AUTOMATIC HEIGHT CONTROL is a compact, easy to use accessory for Bug-O Systems equipment which is designed to maintain a constant welding torch-to-work distance. This control can be used with Sub Arc, Innershield and MIG welding. It includes a solid-state control box and a motorized slide which will bolt onto any standard Bug-O Systems carriage and can be used for a wide variety of welding applications where a constant arc length is critical. This system requires a constant voltage (CV) power supply for operation.

PATENTS WORLDWIDE

Litho in U.S.A. LIT-AHC-BRO-1008A DIVISION OF WELD TOOLING CORPORATIONA QUALITY PRODUCT FROM BUG-O SYSTEMS • 280 TECHNOLOGY DRIVE • CANONSBURG, PA 15317-9564 USA

© Weld Tooling Corp. ROM 1:16

AUTOMATIC HEIGHT CONTROLWith the CAS-0100 the actual weld current is sensed continuously by means of a current shunt, 50mV full scale. The signal is filtered, amplified and compared to a set point value. Any error is fed to a second order control loop which sends a velocity signal to the height adjustment drive.

The control holds the error to zero for a flat piece of work, or for a weld with a uniform rise along its length. The drive for the motor is a four-quadrant servo control which enables smooth accurate height corrections. Therefore, the control can easily follow contours.

In addition to BUG-O carriages, the CAS-0100 can be used on fixtures or manipulators to provide constant wire stick-out length.

It provides automatic control of welding torch-to-work distance with the following:

• Multi-turn potentiometer, for adjusting current set point, which is directly read from a turn-counting dial.

• Automatic shut-off of height-adjusting drive when current is off or falls below a pre-set lower limit.

• Built-in time delay after arc is struck before drive activation.

• Manual up-and-down height adjustment buttons which override automatic controls, and function when drive is either active or inactive.

• Speed potentiometer sets adjustment speed in manual mode and also limits top speed in automatic mode.

• Self-contained control, independent of the rest of the equipment, such as drives, power sources, wire feeders, etc.

NOTE: CAS-0100 requires a 50mV Current Shunt (500 amp min.) BUG-O Part No. S17078-5) (Not supplied with CAS-0100)

Power Requirements: CAS-0100 120 VAC/50-60HZ/1PH CAS-0102 240 VAC/50-60HZ/1PH CAS-0104 42 VAC/50-60HZ/1PH

Vertical Travel: 4" (100 mm)

Load Capacity: 20 lb (9.1 kg) within 4" (100 mm) of the slide’s mounting plate. The slide uses a slip clutch to protect the motor from overloads.

Net Weight: Slide: 9 lb. (4.1 kg) Control Box: 6 lb (2.7 kg)

Dimensions: Slide: 5.00"W x 15.25"H x 2.38"D (127 mm x 387 mm x 60 mm)

Control Box: 8.00"W x 4.50"H x 3.63"D (203 mm x 114 mm x 92 mm)

Technical Data:

Bug-O SystemsAffordable Track Cutting and

Welding Systems.

www.bugo.com

BEAM BUG IIIReduces Material Handling, Cut Beams,

Channels And Angles In Place.

BEAM BUG III

ARR-9114ARR-9214ARR-9236

ARR-9120

ARR-9045ARR-9046

ARR-9114 BEAM RAILfor square cutting beams ONLY.Capacity: Cuts 2"-18" (50-450 mm) flanges and 14" (350 mm websLength: 46 1/2" (1180 mm)Net Weight: 18 lbs (8 Kg)Shipping Weight: 28 lbs (13 kg)

ARR-9214 SWIVEL MOUNTED BEAM RAILfor straight, bevel, coping and miter cuts on the web – may also be used for miter cuts on the flanges by rotating the beam.Capacity: Cuts 2"-18" (50-450 mm) flanges and 36" (900 mm) websMiter Cuts On: 14" (350 webs)Length: 72" (1830 mm)Net Weight: 28 lbs (13 kg)Shipping Weight: 41 lbs (18 kg)

ARR-9236 SWIVEL MOUNTED BEAM RAILsame as above but, with greater capacity.Capacity: Cuts 2"-18" (50-450 mm) flanges and 66" (1675 mm) websMiter Cuts On: 36" (900 mm) websLength: 102" (2590 mm)Net Weight: 36 lbs (16 kg)Shipping Weight: 51 lbs (23 kg)

ARR-9120 SWIVEL MOUNTED BEAM RAILsame as above but, with greater capacity.Capacity: Cuts 2"-18" (50-450 mm) flanges and 120" (3050 mm) websMiter Cuts On: 72" webs (1830 mm)Length 150" (3810 mmm)Net Weight: 62 lbs (28 kg)Shipping Weight: 94 lbs (43 kg)

ARR-9045 ADJUSTABLE BEAM RAILincludes two squaring bars and adjustablelocks for miter cuts on webs and flanges-36" (915 mm) of travel.Miter Cuts Flanges: 00-450 to 14" (350 mm) wideMiter Cuts Webs: 00-130 to 36" (915 mm) wide 00-450 to 24" (610 mm) wideLength: 65" (1651 mm)Net Weight: 50 lbs (23 kg)Shipping Weight: 75 lbs (34 kg)

ARR-9046 ADJUSTABLE BEAM RAILincludes two squaring bars and adjustablelocks for miter cuts on webs and flanges -36"(915 mm) of travel.Miter Cuts Flanges: 00-450 to 14" (350 mm) wideMiter Cuts Webs: 00-340 to 60" (1524 mm) wide 00-450 to 50"Length: 102" (2590 mm)Net Weight: 65 lbs (30 kg)Shipping Weight: 90 lbs (41 kg)

A QUALITY PRODUCT FROM BUG-O SYSTEMS • 280 TECHNOLOGY DRIVE • CANONSBURG, PA 15317-9564 USALitho in U.S.A. LIT-BBIII-BRO-0808A DIVISION OF WELD TOOLING CORPORATION © Weld Tooling Corp. ROM 1:16

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BEAM BUG III

1. Portable, lightweight, only 34 lbs. (15 kg)2. Positive Rack and Pinion Drives3. Infinitely Variable Speed Control of horizontal and vertical movement 2-50 ipm (50-1270 mm/min)4. Manifold Control of gases5. Push-button Clutch for horizontal travel6. Independent Control of movement in three planes; x, y and z7. Swivel Torchholder Assembly

8. Circuit Breaker9. Limit Switches for flange rail10. Beam Rail11. Angle and Magnet Assembly12. Beam Clamp

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The BEAM BUG III is a lightweight, easy to carry machine designed to cut beams, channels and angles from one rail setting. It produces smooth, square, accurate cuts and virtually eliminates grinding and touch-up. Now, you can take the machine to the work and greatly reduce material handling costs.

The BEAM BUG III is positioned on the workpeice by placing the beam rail on top of the beam. This rail is held in position by powerful permanent magnets and beam clamps. The beam rails enable miter cuts on webs, and when the work can be positioned, on the flanges too.

The BEAM BUG III carriage has a push-button clutch and locks onto the beam rail. It is easily removed for handling and/or storage. A single speed control sets both vertical and horizontal travel speed. Movement in either direction is selected by a toggle switch. Positive rack and pinion drives with infinitely variable speed control insure precise cutting speeds. Limit switches prevent vertical (flange rail) over-run. Gases are controlled by a quick-acting manifold which eliminates repetitive torch adjustment. Double-bearing wheels provide rigidity and accuracy. The torchholder and torch, swivel to the correct position and positioning pins set bevel angles. The BEAM BUG III is supplied with a 10" (254 mm) two-hose machine torch and three cutting tips. (Specify fuel gas and voltage when ordering.)

3

BEAM BUG III

Technical Data:

Travel Speeds: 2-50 ipm (50 - 1270 mm/min)

Flange: 22" (560 mm)

Dimensions: 10"L x 10.50"W x 12.38"H (254 mm x 267 mm x 314 mm)

Net Weight: W/O TORCH & TIPS 34 lbs (15.4 kg) W/TORCH & TIPS 38 LBS (17.2 kg)

ShippingWeight: W/O TORCH & TIPS 41 lbs (18.6 kg) W/TORCH & TIPS 45 LBS (20.4 kg)

30.50"(775 mm)

10.00"(254 mm)

30.50"(775 mm)

4.00"(102 mm)

10.50"(267 mm)

NOTE: The BEAM BUG III must be used with one of the beam rails described on the next page.

HOW IT WORKS:

ONLY ONE RAILSETTING REQUIRED

BUG-1490-ACETBEAM BUG III 120 VAC ACETYLENEBUG-1490-PROPBEAM BUG III 120 VAC PROPANE

BUG-1492-ACETBEAM BUG II 240 VAC ACETYLENEBUG-1492-PROPBEAM BUG II 240 VAC PROPANE

8

2

Bug-O SystemsAffordable Track Cutting and

Welding Systems.

www.bugo.com

BEAM BUG IIIReduces Material Handling, Cut Beams,

Channels And Angles In Place.

BEAM BUG III

ARR-9114ARR-9214ARR-9236

ARR-9120

ARR-9045ARR-9046

ARR-9114 BEAM RAILfor square cutting beams ONLY.Capacity: Cuts 2"-18" (50-450 mm) flanges and 14" (350 mm websLength: 46 1/2" (1180 mm)Net Weight: 18 lbs (8 Kg)Shipping Weight: 28 lbs (13 kg)

ARR-9214 SWIVEL MOUNTED BEAM RAILfor straight, bevel, coping and miter cuts on the web – may also be used for miter cuts on the flanges by rotating the beam.Capacity: Cuts 2"-18" (50-450 mm) flanges and 36" (900 mm) websMiter Cuts On: 14" (350 webs)Length: 72" (1830 mm)Net Weight: 28 lbs (13 kg)Shipping Weight: 41 lbs (18 kg)

ARR-9236 SWIVEL MOUNTED BEAM RAILsame as above but, with greater capacity.Capacity: Cuts 2"-18" (50-450 mm) flanges and 66" (1675 mm) websMiter Cuts On: 36" (900 mm) websLength: 102" (2590 mm)Net Weight: 36 lbs (16 kg)Shipping Weight: 51 lbs (23 kg)

ARR-9120 SWIVEL MOUNTED BEAM RAILsame as above but, with greater capacity.Capacity: Cuts 2"-18" (50-450 mm) flanges and 120" (3050 mm) websMiter Cuts On: 72" webs (1830 mm)Length 150" (3810 mmm)Net Weight: 62 lbs (28 kg)Shipping Weight: 94 lbs (43 kg)

ARR-9045 ADJUSTABLE BEAM RAILincludes two squaring bars and adjustablelocks for miter cuts on webs and flanges-36" (915 mm) of travel.Miter Cuts Flanges: 00-450 to 14" (350 mm) wideMiter Cuts Webs: 00-130 to 36" (915 mm) wide 00-450 to 24" (610 mm) wideLength: 65" (1651 mm)Net Weight: 50 lbs (23 kg)Shipping Weight: 75 lbs (34 kg)

ARR-9046 ADJUSTABLE BEAM RAILincludes two squaring bars and adjustablelocks for miter cuts on webs and flanges -36"(915 mm) of travel.Miter Cuts Flanges: 00-450 to 14" (350 mm) wideMiter Cuts Webs: 00-340 to 60" (1524 mm) wide 00-450 to 50"Length: 102" (2590 mm)Net Weight: 65 lbs (30 kg)Shipping Weight: 90 lbs (41 kg)

A QUALITY PRODUCT FROM BUG-O SYSTEMS • 280 TECHNOLOGY DRIVE • CANONSBURG, PA 15317-9564 USALitho in U.S.A. LIT-BBIII-BRO-0808A DIVISION OF WELD TOOLING CORPORATION © Weld Tooling Corp. ROM 1:16


280 TECHNOLOGY DRIVE CANONSBURG, PENNSYLVANIA USA 15317-9564 PHONE: 1- 800-245-3186 http://www.bugo.com TELEFAX: 1- 412-331- 0383

Produce clean machined bevels on plate or pipe.

Reduce the cost of weld preparation with the Bug-OPortable Plate Beveling Machine Model PBM-2000.

Welding and Cutting Solutions Since 1948.

The Bug-O Portable Plate Beveling Machine, PBM-2000, is a machining tool that allows anyone toproduce perfect bevels everytime. The machine is easily adjusted to cut any bevel angle between 150 to 600

and has a maximum bevel width/face of 3/4" (20 mm). The PBM-2000 uses a powerful 1-1/2 horsepowermotor with a dual milling head that has 12 indexable cermetallic inserts which increase metal removal. Withits specially designed handle, low noise, low vibration and a weight of 42 pounds the PBM-2000 is extremelyergonomic. Optional pipe beveling attachment available for 6-1/4" (159 mm) diameter or larger.

A (In.) 16.5 (420 mm)

B (In.) 13 (330 mm)

R (In.) 12 (305 mm)

S (In.) 3/4 (20 mm)

D min 6-5/16 (160 mm)

O (0) 150-600

O (0) 150-600

Options:

Facing O=00 YES

Pipe Beveling YES

PORTABLE PLATE BEVELING MACHINE

Features & Benefits

• Chamfering capacity up to 3/4" (20 mm).• Adjustable bevels from 150 to 600.• Uses 4 sided indexable cermetallic cutting

blade for optimal economy.• Each cutting insert averages 400' to 600'

(122-183 m) per side.

Specifications

Power Supply: 120 voltsNominal Amperage: 14 ampsMaximum Amperage: 18 ampsStart Up Current: 11 ampsHorsepower: 1-1/2 horsepowerCutting Speed: 1800 SFPMAngle Range: 150 to 600

Bevel Width: 3/4" (20 mm) maxWeight: 42 lbs. (19.05 kg)

min

PBM-2000 (15-60)standard

A

R

B

S

SDmin

• Dual milling head for increased efficiency.• No damage from heat hardening or

oxidation as with oxy-fuel.• Automatic overload protection.• Easy to set-up and use.• Optional pipe & tube attachment for 6-1/4"

(159 mm) diameter or larger.

Plate

Pipe

PBM-2100Pipe Adaptor(optional)

A QUALITY PRODUCT FROM BUG-O SYSTEMS • 280 TECHNOLOGY DRIVE • CANONSBURG, PA USA 15317-9564Litho in U.S.A. LIT-PBM-BRO-0408A DIVISION OF WELD TOOLING CORPORATION © Weld Tooling Corp. ROM 1:16

PBM-2051 Cutting Insert (12 required)

Welding & Cutting AutomationSince 1948.

Increase Welding Production.Improve Weld Quality.

The BUG-GY…Automatic Fillet Welder.

For more information on the BUG-GY call 800-245-3186 or 412-331-1776.

BUG-GY Fillet Welder AFW-3000

Features:

1. Lightweight. 2. Easy to carry. 3. Permanent magnet for powerful traction. 4. Built-in programmable stitching by distance. 5. Dual mode selector switch for stitch or continuous welding. 6. 4 to 60 ipm (10 - 152 cm/m) welding speed range can be preset. 7. Rapid traverse between welds at 120 ipm (300 cm/m). 8. Built-in dual weld contactor connection.

9. Adjustable end on weld back-up. 10. Dynamic braking for crisp starts and stops. 11. Digital LCD speed indicator. 12. Closed loop speed & position control. 13. Limit switches provide automatic weld stop. 14. Spatter guard on work-side wheels. 15. Versatile gun support will most MIG guns. 16. Precision micro-adjustable “Y” & “Z” slides for gun positioning. 17. Available in three operating voltages: 42, 110 & 220 VAC.

Specifications:

PowerRequirements: AFW-3000 120 VAC/50-60/1 AFW-3002 240 VAC/50-60/1 AFW-3004 42VAC/50-60/1

Travel Modes: 1.Continuous 2. Stitch: weld craterfill skip

Travel Speeds: Welding 4-60 ipm (10-152 cm/m) Skip 120 ipm (300 cm/m)

Net Weight: 27 lbs. (12.5 kg)

Shipping Weight: 34 lbs. (15.5 kg)

Dimensions:

15"(381 mm)

15"(381 mm)

22"(559 mm)

A QUALITY PRODUCT FROM BUG-O SYSTEMS • 280 TECHNOLOGY DRIVE • CANONSBURG, PA 15317-9564 USALitho in U.S.A. LIT-AFW-BRO-0708A DIVISION OF WELD TOOLING CORPORATION © Weld Tooling Corp. ROM 1:16

2

Controls:

A. Digital travel speed display. B. Weld length programming button. C. Skip length programming button. D.Reversecraterfillprogramming button. E. Programming button. F. Travel start button - left. G. Travel stop button. H. Travel start button - right. I. Travel speed knob. J. Mode select switch, continuous or stitch. K. Arc enable On/Off switch #1. L. Arc enable On/Off switch #2. M. Power switch. N. Weld contactor.

BUG-GY Fillet Welder AFW-3000The BUG-GY Fillet Welder is designed for making continuous or intermittent stitchweldsonfillet, laporbutt joints. It isa lightweightportable carriage that uses powerful magnets and guide wheels to clamp and track on the work piece. The BUG-GY is self-guiding and requires little operator input once it is set up. It can be programmed for stitch weldingbydistanceand featuresautomaticweldback for crater fill.Between stitch welds the BUG-GY accelerates to a top speed of 120 ipm (300 mm/min). Dynamic breaking and closed loop feed back allow the BUG-GY to make crisp starts and stops and to travel at precise speeds. Limit switches provide automatic shutoff at the end of the joint.

The BUG-GY can follow any outside edge.

The BUG-GY can weld lap joints with a minimum height of 3/8” (9.53 mm).

ED

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BUG-GY Fillet Welder AFW-3000Optional Equipment:

AFW-2275 Dual Gun Mounting Group.This optional support group provides dual welding on stiffeners up to 18” (460 mm) high.

Optional Sub Arc Gun.15’ long, 550 amp, 60% duty cycle sub arc gun works in conjunction with the BUG-GY to perform automatic submerged arc welds. Available with either Lincoln or Miller connectors. Designed for running 1/16” - 5/64” or3/32” wire.

Lincoln® Style Connector.AFW-2285-5/64 AFW-2285-3/32Replacement Contact Tips:AFW-2291 1/16” wire sizeAFW-2292 5/64” wire sizeAFW-2293 3/32” wire size

Miller® Style Connector.AFW-2290-5/64 AFW-2290-3/32

Welding & Cutting AutomationSince 1948.

Increase Welding Production.Improve Weld Quality.

The BUG-GY…Automatic Fillet Welder.

For more information on the BUG-GY call 800-245-3186 or 412-331-1776.

BUG-GY Fillet Welder AFW-3000

Features:

1. Lightweight. 2. Easy to carry. 3. Permanent magnet for powerful traction. 4. Built-in programmable stitching by distance. 5. Dual mode selector switch for stitch or continuous welding. 6. 4 to 60 ipm (10 - 152 cm/m) welding speed range can be preset. 7. Rapid traverse between welds at 120 ipm (300 cm/m). 8. Built-in dual weld contactor connection.

9. Adjustable end on weld back-up. 10. Dynamic braking for crisp starts and stops. 11. Digital LCD speed indicator. 12. Closed loop speed & position control. 13. Limit switches provide automatic weld stop. 14. Spatter guard on work-side wheels. 15. Versatile gun support with most MIG guns. 16. Precision micro-adjustable “Y” & “Z” slides for gun positioning. 17. Available in three operating voltages: 42, 110 & 220 VAC.

Specifications:

PowerRequirements: AFW-3000 120 VAC/50-60/1 AFW-3002 240 VAC/50-60/1 AFW-3004 42VAC/50-60/1

Travel Modes: 1.Continuous 2. Stitch: weld craterfill skip

Travel Speeds: Welding 4-60 ipm (10-152 cm/m) Skip 120 ipm (300 cm/m)



Dimensions:

15"(381 mm)

15"(381 mm)

22"(559 mm)

A QUALITY PRODUCT FROM BUG-O SYSTEMS • 280 TECHNOLOGY DRIVE • CANONSBURG, PA 15317-9564 USALitho in U.S.A. LIT-AFW-BRO-0708A DIVISION OF WELD TOOLING CORPORATION © Weld Tooling Corp. ROM 1:16

Increase welding production,improve weld quality andeliminate operator fatigue.

A battery powered, magnetic travel carriage forwelding in the vertical or horizontal position.

BUG-GY-VERTIncrease welding production,improve weld quality andeliminate operator fatigue.


BUG-GY-VERT

Bug-O SystemsAutomated Cutting and

Welding Systems.www.bugo.com

2

BUG-GY-VERTThe BUG-GY-VERT is a portable battery powered 4-wheeldrive welding carriage with or without torch oscillation. Strongpermanent magnets hold the machine on the workpieceallowing it to travel on vertical or oblique work surfaces. Guidewheels on the BUG-GY-VERT automatically track the torch inthe fillet joint.

The BUG-GY-VERT is compact, lightweight and easy toposition. It will accommodate most hand held welding guns.By providing consistent travel speed the BUG-GY-VERT canincrease the productivity and the quality of welding applica-tions in many areas of steel fabrication or shipbuilding.

BUG-GY-VERT ControlsWith Oscillator.

Speed Control

Direction

Power Switch

Torch Contactor

14.4 RechargeableBattery

Magnet Actuator

Oscillation Speed

Oscillation Width

Dwell Right

Torch Holder

OscillatorPower Switch

Stop

Safety ChainAnchor

OscillatorStart

Dwell Left

Torch Trigger Switch

BUG-GY-VERT Without Oscillation BUG-GY-VERT With OscillationVFW-3150 110 volt - includes 1 battery and 1 charger.VFW-3152 220 volt - includes 1 battery and 1 charger.

VFW-3000 110 volt - includes 1 battery and 1 charger.VFW-3002 220 volt - includes 1 battery and 1 charger.

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BUG-GY-VERT

Power Supply: 14.4V (2Ah-rechargeable battery)Position of Weld: Vertical & HorizontalDimensions: See page 4Carriage to Work Clearance: .25" (6.5 mm)Minimum Plate Thickness: 3/16" (5 mm)Wheel Movement: 4 wheel driveWeight without Oscillator: 22 lbs. (11 kg.)

Weight with Oscillator: 28 lbs. (14 kg.)Travel Speed: 2.5-50 ipm

(60-1250 mm/min)Oscillation Width (amplitude): 0-.75" (0-19 mm)Oscillation Frequency: 20-60 cycles/min.Dwell-Independent Each Side: 0-1.5 seconds

Technical Data:

Accessories:

H01134-001-01-0214.4 volt rechargeable battery.

Vertical carrying capacity varies with material thickness. On 3/8" (9.5 mm) plate, carrying capacity is 20 lbs (9.1 kg).NOTE: Surface must be clean and unpainted. Cables should be supported independently.

Caution: Always use safety cable when working in the vertical position. Fall arrestor safetycables available. Contact the factory for additional details.

VFW-3210Auxiliary MagnetsFor increased magnetic holding power and traction.

BMV-1510 110 volt AdaptorBMV-1512 220 volt AdaptorPower Adaptors - converts machine from batterypower to 110 volt or 220 volt line power.

H01113-001-01-03 110 volt battery charger.H01113-001-01-02 220 volt battery charger.

Increase welding production,improve weld quality andeliminate operator fatigue.


BUG-GY-VERTIncrease welding production,improve weld quality andeliminate operator fatigue.


BUG-GY-VERT

Bug-O SystemsAutomated Cutting and

Welding Systems.www.bugo.com

BUG-GY-VERT

Each unit will be delivered with one (1) battery and charger.

Bug-O SystemsVisit us online at: www.bugo.com


Dimensions:

The BUG-GY-VERT features "Torch Quick Connect" which allows the operator to easily remove or installthe torch from the BUG-GY-VERT for quick nozzle cleaning, wire cutting and hand welding.

.50" (13 mm)

1.250" (32 mm)

3"/6.5"76/165 mm

8.125"206 mm

13.188"/16.688"335/424 mm

12.625"321 mm

8.188"208 mm

16.250"413 mm

Litho in U.S.A.

LIT-BUG-GY-VERT-BRO-0208

A DIVISION OF WELD TOOLING CORPORATIONA QUALITY PRODUCT FROM BUG-O SYSTEMS • 280 TECHNOLOGY DRIVE • CANONSBURG, PA USA 15317-9564


Bug-O Gantry / Side BeamAutomatic Welding Systems

BUG-O SYSTEMSAutomated Welding & Cutting Since 1948www.bugo.com

A QUALITY PRODUCT FROM BUG-O SYSTEMS • 3001 WEST CARSON STREET • PITTSBURGH, PA USA 15204-1899Litho in U.S.A. LIT-BRO-BG-0405A DIVISION OF WELD TOOLING CORPORATION © Weld Tooling Corp. ROM 1:16

Bug-O Gantry and Side Beam Units are custom designed assemblies that are used in a variety of applicationssuch as automated seam welding, beam and stiffener fabrication as well as cutting applications such asstripping and edge preparation. A wide range of gantry and side beam carriage designs are available and canbe used to suite a specific application. Systems are available in programmable or manually operated versions.Consult your Bug-O distributor for more information.

Bug-O Gantry / Side BeamAutomatic Welding Systems

Gantry Style Welding System

Side Beam Welding System

Mechanical torch tracking devicesmaintain proper torch position.

Affordable Automationfor Welding, Cutting and


Bulb Flat Welder

The UNI-BUG II Bulb Flat Welder enables you to run the UNI-BUG II on a wide variety of bulb flats.This machine is easy to use. It has a built-in quick release for easy on/off access to bulb flats inbulkheads and areas where you can't start the machine at the end of the bulb flat.

UNI-BUG

140-430 mm

The UNI-BUG Bulb Flat Welder will weld bulb angleswith heights from 140 to 430 mm.

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UNI-BUG Bulb Flat Welder

Technical Data:Power Requirements:

UNI-1300 UNI-BUG Bulb Flat Welder 120 VAC

UNI-1302 UNI-BUG Bulb Flat Welder 240 vac

UNI-1304 UNI-BUG Bulb Flat Welder 42 VAC

Speed Range: 4-75 ipm (102-1900 mm/min)


Shipping Weight:31 lbs. (14 kg)

For 140 to 280 mm.

3

UNI-BUG Bulb Flat Welder

Spacer Block For 280 to 430 mm.*Dimensions shownwithout torch mounts(Torch mounts shown on next page).

Special assembly note:When converting a UNI-BUG IIto a BULB WELDER, be sure thatboth top rollers are mounted on thebottom of the base plate.(see drawing at right)

8.00(203 mm)

5.75(146 mm)

7.62(194 mm)

6.25(159 mm)

10.50(267 mm)

6.00(152 mm)

2.00(51 mm)

2.00(51 mm)

4.6(117 mm)

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Tool Positioning Assembly OnBulb Flat Welder

ITEM QTY Part No. Description1 4 BUG-1853 Machined Rack 7 1/2"2 1 BUG-1881 Cable Anchor w/Swivel Clamp3 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 lg5 2 BUG-2708 Clamp6 2 BUG-5451 3.5" Rackholder7 2 BUG-5462 Right Angle Clamp8 2 CON-1020 Swivel Clamp Assembly9 2 FAS-0957 Flt Hd Soc Scr 1/4-20 x 3/4 lg10 2 UNI-1036 Rackrider w/Post

UNI-1350 Dual Welding Group

BORE WELDING SYSTEMSBORE WELDING SYSTEMS

Welding & CuttingInnovations Since 1948.Welding & CuttingInnovations Since 1948.

PORTABLE BORE REPAIR SYSTEMS PRODUCE

CONTINUOUS 3600 SPIRAL WELDS.

REDUCE WELDING AND MACHINING TIME.

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BORE WELDER - FEATURES

• Smooth, high quality welding oninternal bores from 1.25"-15" (32-381 mm).

BWS-2000: 1.25''-15'' (32-381mm)BWS-2000-045: 1.8''-15'' (46-381mm)

Optional accessories for internaldiameters from 16"-24" (406-610mm), external diameters and facewelding are also available.

• Easy operation. Simply measurediameter, find setting on the chartand set rotation knob.

• Adds axial feed and rotary motionto existing MIG welder.

Kit Includes:• Remote Weld Switch.

• Conduit Assembly & Supportw/Aux. Support Rod.

• Tack Nut.

• Tool Kit.

• Large Diameter TorchAssembly.

FEATURES:

• Telescoping extension tubeallows multiple in-line welding withone easy set up.

• Reaches 24'' (609mm) into a borewith a 7'' (177mm) stroke.

• Extension tube is reversible toallow welding of two separateparallel bores.

• Interfaces with boring bars.

• Kit accommodates various sizeof welding wire:

BWS-2000: .030 mmBWS-2000-045: .045 mm

.035 mm diameter wire availableby request.

• “T” Base w/Tack Plate.

• Extra Nozzles, Tips, andDiffusers to support 1.25" or1.8'' to 15" (32-381 or 46-381mm) diameters.(5 stub diffusers, 10 .8 mm stubtips, 5 stub nozzles, 10 .8 mmtips, 5 nozzles, 5 mini nozzles,5 mini diffusers).

3

BORE WELDER - TECHNICAL DATA

BWS-2000-045Bore Welding System for .045'' Wire

Current Rating: 200 amp, 60%duty cycle

Net Weight: 25 lbs. (11 kg.)

Shipping Weight: 70 lbs. (34 kg.)

Wire Diameters: .030 to .045

Diameter Range: 1.8'' to 15'' (46-381 mm)(up to 24'' [610mm] withoptional accessories)

BWS-2000 Bore Welding SystemBore Welding System for .030''-.035'' Wire

Current Rating: 150 amp, 60%duty cycle

Net Weight: 25 lbs. (11 kg.)

Shipping Weight: 70 lbs. (34 kg.)

Wire Diameters: .030 and .035

Diameter Range: 1.25'' to 15'' (32- 381mm)(up to 24'' [610mm] withoptional accessories)

One Quick Setup - will attach to your Boring Bar Kit.

TECHNICAL DATA:

Call factory for specials, boring bar systems and components or power supply wire feeder options.1-800-245-3186 or 412-331-1776

BORE WELDER - ACCESSORIES

A QUALITY PRODUCT FROM BUG-O SYSTEMS • 3001 WEST CARSON STREET • PITTSBURGH, PA USA 15204-1899Litho in U.S.A. LIT-BWS-2000-BRO-0907A DIVISION OF WELD TOOLING CORPORATION © Weld Tooling Corp. ROM 1:16

Optional Accessories to weld from 15'' to 24'' (381-610 mm):

Item Description QuantityBWS-1042 Extension Tube 2BWS-A119 8'' (203mm) Radial Support Extender 1

BWS-A127 Face TorchOptional face torch attaches to yourBore Welder and will automaticallyweld faces from 0-24'' (0-610mm).

Boring Bar Adaptor KitsBoring Bar Adaptor Kits provideeasy, one-step setup.(Part number varies dependingon Boring Bar Kit.)

BWS-A114 O.D. TorchAttachment for performingexternal outside diameter welds.O.D. Torch 0-12'' (0-305mm)

Additional Options Available:BWS-A129 Auto Skip OptionBWS-A108 Centering Cone Set

Additional Accessories Available:

Welding TipsStub Tips:BWS-1058 .030 (.8mm)BWS-1059 .035 (.9mm)BWS-1060 .045 (1.2mm)

Standard Tips:BWS-1061 .030 (.8mm)BWS-1062 .035 (.9mm)BWS-1063 .045 (1.2mm)

Welding Nozzles andDiffusersMini Nozzle:BWS-1092 1.25''-2'' (32-50mm)

Stub Nozzle:BWS-1066 Use for smalldiameters

Standard Nozzle:BWS-1067 Use for largediameters

Mini Diffuser:BWS-1093 1.25''-2'' (32-50mm)

Diffuser:BWS-1057 Use with all torches

9.63''(245 mm)

6.34''(160 mm)

32'' (812 mm) min.48.56'' (1234 mm) max.

5.88''(150 mm)

OPERATORSMANUAL


3001 WEST CARSON STREET PITTSBURGH, PENNSYLVANIA USA 15204-1899 PHONE: 1- 800-245-3186 http://www.bugo.com TELEFAX: 1- 412-331- 0383

BWS-2000PORTABLE BOREWELDING SYSTEM

Please record your equipment identification information below for future reference. This information can be foundon your machine nameplate.

Model Number

Serial Number

Date of Purchase

Whenever you request replacement parts or information on this equipment, always supply the information youhave recorded above.

LIT-BWS-IPM-O404

TABLE OF CONTENTS

TITLE OF SECTION PAGE

1. SAFETY INFORMATION --------------------------------------------------------- 11.1. Machine Safety --------------------------------------------------------- 11.2. Operator Safety --------------------------------------------------------- 11.3. General Safety Requirements-------------------------------------- 11.4. Additional Safety Information-------------------------------------- 2

2. MAJOR COMPONENTS AND THEIR FUNCTIONS ---------------------- 22.1. Conduit Assembly ----------------------------------------------------- 22.2. Torch ----------------------------------------------------------------------- 22.3. Torch Mover-------------------------------------------------------------- 22.4. Other Support Components ---------------------------------------- 32.5. Tools Provided ---------------------------------------------------------- 3

3. SPECIFICATIONS ----------------------------------------------------------------- 3

4. ALIGNMENT ------------------------------------------------------------------------ 44.1. Parallelism --------------------------------------------------------------- 44.2. Concentricity ------------------------------------------------------------ 54.3. Axial Positioning ------------------------------------------------------- 6

5. WELDING TORCH - USE, COMPONENTS, AND RANGE ------------- 65.1. Liner Stick-Out ---------------------------------------------------------- 65.2 Liner Stick-Out Adjustment ----------------------------------------- 65.3. Mini Components ------------------------------------------------------ 65.4. Stub Components------------------------------------------------------ 65.5. Standard Components ----------------------------------------------- 75.6. Large Diameter Components -------------------------------------- 75.7. Outside Diameter Components ----------------------------------- 75.8. Attachment --------------------------------------------------------------- 75.9. Radial Adjustment ----------------------------------------------------- 75.10. Axial Adjustment ------------------------------------------------------- 8

6. CONDUIT ASSEMBLY INSTALLATION ------------------------------------- 8

7. FINAL PREPARATION FOR WELDING ------------------------------------- 8

8. WELDING ---------------------------------------------------------------------------- 9

9. SPECIAL SITUATIONS ---------------------------------------------------------- 99.1. Welding in High Temperature Environments ----------------- 99.2. Single Plane Welding ------------------------------------------------- 9

10. MAINTENANCE -------------------------------------------------------------------- 910.1. Spindle -------------------------------------------------------------------- 9

10.2. Extension Tube --------------------------------------------------------- 910.3. Remaining Components --------------------------------------------- 10

11. CARE---------------------------------------------------------------------------------- 10

ILLUSTRATIONS:Torch Mover and Support Components ----------------------------------- Fig 1Use of Standard Torch ---------------------------------------------------------- Fig 2Use of Large Diameter and OD Torch -------------------------------------- Fig 3Set-Up Information --------------------------------------------------------------- Fig 4In-Line Bore Setups -------------------------------------------------------------- Fig 5Cones - Using For Alignment ------------------------------------------------- Fig 6Wire Stability ----------------------------------------------------------------------- Fig 7Use of the “T” Base -------------------------------------------------------------- Fig 8“T” Base Support Configurations ------------------------------------------- Fig 9

APPENDIX:Useful Information:

1. Welding Time - Single Revolution --------------------------------- A2. Buildup Times ------------------------------------------------------------ A3. Deposition Rates -------------------------------------------------------- A

1. SAFETY INFORMATION. Many accidents are caused by operation and maintenance, which disregardbasic safety rules. Carefully read and adhere to the safety measures and precautions described in thisinstruction manual.

1.1. Machine Safety.1.1.1. The BWS-2000, while designed to be durable, is not designed to be dropped. Should you

do so, carefully inspect for damage. If any is found, repair or replace before continuingoperation.

1.1.2. Never leave the machine running unattended. Overtravel can result in machine damageand workpiece damage.

1.1.3. Keep the machine clean. Failure to do so can result in premature wear.1.1.4. Never remodel the machine.1.1.5. Never use the machine outdoors when the weather is wet. This could cause failure of the

machine and could cause a fatal accident by electric shock.1.1.6. The input electrical power rating for operating the BWS-2000 is 115 volts and 50 or 60 Hz.

Input power voltage which varies more than 10% from the above rating will damage theunit. Note:This refers to the electrical power to run the rotation function, not thewelding power or electrical power required to run the welding power supply.

1.1.7. The BWS-2000 should only be powered from properly grounded three prong outlets. Allelectrical connections should only be made in accordance with the appropriate andapplicable national and local electrical codes by a qualified electrician. Note: When usingthe BWS-2000 in a location where the power requirements listed in 1.1.6. above arenot available, a 150 (minimum) volt-ampere isolation transformer should be used toprovide said requirements.

1.2. Operator Safety.1.2.1. Read this instruction manual before setting-up or operating the BWS-2000.1.2.2. Always use a protective eye shield which conforms to ANSI Z87.1 standards when

observing the machine in use. Observing the arc directly or its reflection, without the useof such a shield can result in permanent eye damage.

1.2.3. Always use approved safety glasses with side shields when setting up or running theBWS-2000.

1.2.4. Anyone being exposed to the arc or its reflection should wear protective clothing over asmuch exposed skin as possible. Other areas should use a “sun block” cream with anappropriate “SPF” value.

1.2.5. Anyone close to the welding operation should wear heavy flame resistant clothing forprotection from sparks and flame.

1.2.6. The operator should not use loose clothing which might get wrapped around the rotatingmembers of the BWS-2000.

1.2.7. Before connecting the power plug make sure that the enable switch is in the OFF position.1.2.8. Removal of the machine cover without disconnecting the power may result in dangerous

electrical shock.1.2.9. Gases and fumes may be produced by the welding process which are dangerous to

breathe and should be avoided. Only use the BWS-2000 where there is adequateventilation.

1.2.10. Do not contact electrically live parts. Dangerous electrical shock may result.1.2.11. Do not operate the machine in damp areas or on metal floors without adequately insulating

yourself from the ground, the machine or machine components, or the workpiece.1.2.12. Make sure the BWS-2000 is adequately secured before using - especially when using in

an elevated location. Falling and striking the operator or others could cause serious injury.1.2.13. Always wear a “hard hat” when using the BWS-2000 in an elevated location or when near

others working in an elevated location.

1.3. General Safety Requirements.1.3.1. Keep the welding area neat and free from combustible materials - especially near

locations where welding spatter might land.1.3.2. A fire extinguisher should be readily available when welding.1.3.3. Inspect all electrical cables and conduits for signs of wear and replace or repair as

1.

required before use of the equipment.1.4. Additional Safety Information. (1) Recommended reading for users in the USA: “Safety in

Welding and Cutting”, American National Standard ANSI Z49.1, which can be purchased from theAmerican Welding Society, Inc., 550 NW Lejeune Road, Miami, FL 33126, USA. TelephoneNumber is 1-800-443-9353. (2) Users outside the USA refer to the relevant safety regulationspromulgated by the appropriate competent authority for your location.

2. MAJOR COMPONENTS AND THEIR FUNCTIONS.

2.1. Conduit Assembly. Provides a connection between the power supply and torch, and allows thetransmission of welding current, shielding gas, and welding wire. See Figure #1.2.1.1. Connector. Connects the Conduit to the wirefeeder. Type: EuroConnector, also known

as the Binzel KZ-2.2.1.2. Conduit. Flexible connection between the wirefeeder and the BWS-2000.2.1.3. Extension Tube. Allows the Torch to be extended to reach the bore to be welded.2.1.4. Liners. Liners extend from the wirefeeder to the welding Tip.2.1.5. Torch Swivel. Allows the Torch to be pivoted to reach the diameter to be welded.2.1.6. Swivel Lock. Locks the Torch in the desired angular position.2.1.7. Welding Switch. Allows the welding process to be turned ON and OFF.2.1.8. Welding Switch Cord. Allows the welding switch to be remotely operated.

2.2. Torch. Specially designed welding torch for the building up of bores. See Figure #2.2.2.1. Torch Body. Attaches to the Torch Swivel, and provides an attachment location for the

Diffuser and support of the liner. The body also conveys electric current, and shieldinggas for welding.

2.2.2. Standard Torch Extender. Can be inserted between the Torch Swivel and the Torch Bodyto allow greater diametric reach of the Torch.

2.2.3. Diffuser. Attaches to the Torch Body, and provides for attachment of the Tip and Nozzle,and support and positioning of the end of the liner. It also conveys electric current, andshielding gas.

2.2.4. Tip. Attaches to the Diffuser, and conveys wire for the welding process. It also transferselectric current to the wire.

2.2.5. Nozzle. Attaches to the Diffuser and directs shielding gas to the welding location.2.2.6. Torch Locking Nut. Locks the Torch in the desired angular position.

2.3. Torch Mover. Provides the necessary motion and speed adjustment to allow the build up ofbores of various sizes. See Figure #1.2.3.1. Housing. The backbone of the Torch Mover. Encloses necessary electrical and

mechanical components.2.3.2. Spindle. Supports the Extension Tube and provides the necessary motion for welding.2.3.3. Tube Clamp. Provides a rigid attachment to and telescoping of the Extension Tube, as

well as an upper stop for the Spindle.2.3.4. Spindle Collar. Provides a lower stop for the Spindle and Spindle support and position

when doing a single plane weld.2.3.5. Clutch Lever. Allows the Clutch to be disengaged for rapid positioning of the Spindle.

The Clutch Lever can also be locked for single plane welding.2.3.6. Rotation Direction Switch. Determines the direction of rotation of the Spindle. This

switch also has a center OFF position.2.3.7. Rotation Speed Knob. Determines the speed of rotation of the Spindle.2.3.8. Cooling Gas Fitting. Allows the introduction of cooling gas to allow the use of the BWS-

2000 in severe heat conditions.2.3.9. Support Bracket. Provides support to the Torch Mover at 8 positions around the

centerline.2.3.10. Power Cord. Provides electrical power to the BWS-2000 to drive the rotation motor.

Required input is 115v, 50/60 Hz.2.3.11. Receptacle. Provides a fused connection for the Power Cord.

2.

2.4. Other Support Components. Provide a connection between the Support Bracket andattachment to a rigid surface. See Figure #1.2.4.1. Support Rod. Provides support and axial adjustment for the BWS-2000.2.4.2. Swivel Base. Supports and allows the Support Rod to be adjusted to be parallel to the

bore axis. Anchor the Swivel Base by tack welding or clamping. Use the Swivel Basewhen aligning the BWS-2000 with Centering Cones.

2.4.3. Tack Nut. Supports the Support Rod. Does not allow adjustment of the Support Rodonce tack welded in place. Typically used when the attachment surface is known to beperpendicular to the axis of the bore, and when other means of support are not availableor are not practical.

2.4.4. “T” Base. Supports the Support Rod and provides a simple means for manual parallelismand concentricity adjustment.

2.4.5. Base Extender. Is bolted to the “T” Base and extends the point of attachment of theSupport Rod 3 inches toward the center of the bore, thereby allowing the welding of largerbores.

2.4.6. Radial Support. Attaches at one end to the Support Bracket and at the other end to theSupport Rod. It projects the BWS-2000 4 inches from the Support Rod and allows thewelding of larger diameter bores. It also allows the BWS-2000 to be moved closer andfarther from the point of attachment as required, thereby providing centering capabilities.An 8 inch Radial Support is also available.

2.4.7. Tack Plate. Supports, and provides an attachment location and alignment for the “T”Base. To be welded to a rigid support at an appropriate location to allow the BWS-2000 tobe centered over the bore to be built up.

2.4.8. Rod Collar. Provides support for the BWS-2000 when the Support Bracket or RadialSupport clamps are loosened. This is especially useful when setting up to weld a verticalaxis bore.

2.5. Tools Provided.2.5.1. Hex Wrench, 3/4”. Use on the “T” Base Leveling Bolts and Clamping Nut.2.5.2. Hex Wrench, 9/16”. Use on the Support Ball clamp, and Machine and Radial Support

clamp hex head cap screws.2.5.3. Allen Wrench, 1/2”. Use on the Base Extender bolts.2.5.4. Allen Wrench, 1/4”. Use on Support Plate socket head cap screws.2.5.5. Allen Wrench, 3/16”. Use on Tube Clamp, Spindle Collar and Support Rod Clamp socket

head cap screws, and Center Cones socket set screws.2.5.6. Allen Wrench, 5/64”. Use on Liner end socket set screws.2.5.7. Support Rod Tightener. Use to tighten Support Rod.

3. SPECIFICATIONS.3.1. Weight (Positioner and Torch). 11.4 kg (25 lb.)3.2. Diameter Range.

3.2.1. Standard ID Torch. 32 to 204 mm (1.25 to 8 in.)3.2.2. Standard ID Torch w/Extender. 32 to 280 mm (1.25 to 11 in.)3.2.3. Large ID Torch w/Extenders. 200 to 610 mm (8 to 24 in.)3.2.4. Standard OD Torch. 0 to 305 mm (0 to 12 in.)

3.3. Torch Reach (ID) – w/Extender. 1070 mm (42 in.)3.4. Torch Reach (OD; Minimum) – 204 mm (8 in.)3.5. Maximum Uninterrupted Axial Weld Length. 170 mm (6.7 in.)3.6. Maximum Continuous Welding Current - Standard. 140A3.7. Welding Process. MIG (GMAW)3.8. Welding Wire Diameter Range. .8 to 1.2 mm (.030 to .045 in.). Note: The recommended wire

diameter for welding steel is .8 mm (.030 in.).3.9. Operating Conditions. Complies with Standards EN60204-1/EN60974-1.3.10. Housing Cooling with Compressed Air. Recommended when working for sustained periods in

environments with temperatures greater than 200 degrees Fahrenheit. Attach air line to BWS-2000 using 1/8 NPT.

3.

4. ALIGNMENT OF THE BWS-2000 TO THE BORE BEING WELDED. Alignment is comprised of threemajor factors: (1) Parallelism - Positioning the axis of the BWS-2000 parallel with the axis of the borebeing welded, (2) Concentricity - Positioning the axis of the BWS-2000 directly in-line with the axis ofthe bore, and (3) Axial Positioning - Positioning the torch in a beginning axial location where it can weldas much of the bore as possible without stopping. See Figures #4, 5, 8 & 9.

4.1. Parallelism. The BWS-2000 is designed to allow parallelism alignment in several ways: (1)Unassisted, (2) Use of the Centering Cones, (3) Alignment directly from a boring bar, and (4)Attachment to an aligned boring bar adapter.

4.1.1. Unassisted.4.1.1.1. Weld the Tack Plate on a rigid support so that the Anchor Bolt is the appropriate

distance from the center of the bore to be welded, and the surface of the TackPlate is within 5° of being perpendicular to the axis of the bore. Notes: (1) SeeFigures #9 & 10 in order to determine the Anchor Bolt to bore-center distance,as well as appropriate support components for the size of bore to be welded. (2)The Support Bracket can be attached to the BWS-2000 in any one of 8 angularpositions around the Spindle centerline in order to facilitate the ease ofattachment and use of the BWS-2000. This feature is particularly important whenspace is limited.

4.1.1.2. Attach the “T” Base to the Tack Plate by setting the Base over the Anchor Bolt sothat the Anchor Bolt protrudes through the Base slot, installing a ½ inch FlatWasher, 4 Spring Washers, and locking it into place with a ½-13NC ClampingNut. See Figure #8.

4.1.1.3. Screw the Support Rod into the “T” Base.4.1.1.4. Adjust the Leveling Screws until the Support Rod is parallel to the bore axis. This

can most easily be accomplished by adjusting the 2 Screws at the top of the “T”,first to get one plane of adjustment aligned with the bore, and then the singleScrew at the bottom of the “T” to get the perpendicular plane of adjustmentaligned with the bore. See Figure #8.

4.1.1.5. Adequate parallelism in each of these planes of adjustment can be judged byinserting a straight edge into the bore, aligning it parallel to the bore axis, andsighting or measuring the distance between the Support Rod and straight edgefor each plane.

4.1.1.6. A level can also be used to achieve parallelism if the axis of the bore is known tobe either horizontal or vertical.

4.1.2. Centering Cones. The use of centering cones is a good choice when there are two ormore in-line bores to be welded. The use of centering cones as described below achievesnot only parallelism, but also concentricity. See Figure #6.4.1.2.1. Slide a 31.75 mm (1.25 in.) diameter tube or rod of sufficient length to reach into

at least two of the bores to be welded.4.1.2.2. Slide two Centering Cones onto the tube - one onto each end. Lock one of the

cones onto the tube and then slide the other cone into the bore until it forces thetube and opposite-end cone to the center of the bore. Once so centered, lock thesecond cone into position.

4.1.2.3. Slide the BWS-2000 - minus the Conduit Assembly - over the centering tube.(The tube will now extend through the Spindle.)

4.1.2.4. Weld or clamp the Swivel Base or Tack Nut while attached to the BWS-2000 to anappropriate rigid support.

4.1.2.5. After tightening all support clamping screws, the Centering Cones and tube canbe removed and the Conduit Assembly inserted in the Spindle for welding.

Note: An alternative but similar method involves the use of bushings instead ofcones. In this instance, bushings with OD’s nearly as large as the bores and ID’s1.25 inches in diameter, are inserted into the bores. A 1.25 inch diameter tube orrod is then inserted through the ID’s of the bushings. The tube/rod is nowcentered in the bore. Proceed as in 4.1.2 above.

4.

4.1.3. Alignment from Boring Bar. If the boring bar is to be set-up before welding the bore, thismethod is preferred over alternatives due to its speed and accuracy.4.1.3.1. If a 31.75 mm (1.25 in.) diameter boring bar is used, slip the BWS-2000, with the

Torch Assembly removed, on the boring bar at the axial location desired. If a largerdiameter boring bar is used, remove the boring bar, install bushings in the boring barbearing ID’s, insert a 31.75 mm (1.25 in.) diameter tube in the bushings, and slip theBWS-2000 on the tube.

4.1.3.2. Weld or clamp the Swivel Base or Tack Nut while attached to the BWS-2000, to anappropriate rigid support.

4.1.3.3. Remove the boring bar and insert the Conduit Assembly in the Spindle for welding.Note: It may be necessary to remove the boring bar, bearing insert or the entirebearing in order to allow the torch to have adequate radial reach.

4.1.4. Boring Bar Adapter. Several manufacturers of popular boring bars offer adapters whichallow attachment of the Support Rod and assure its alignment. Once so aligned, the SupportBracket can be directly attached to the rod and the BWS-2000’s axis will be reasonablyparallel to the bore to be welded.

4.2. Concentricity. Use of centering cones, as described above, provides concentricity of the BWS-2000as well as parallelism. However, unassisted set up or use of a boring bar adapter generally requiressome additional adjustment in order to achieve concentricity. This adjustment is done afterparallelism adjustments have been completed.4.2.1. Unassisted. Achieving concentricity when doing an unassisted set up will typically require the

adjustment of two axes. See Figure #8.4.2.1.1. By using the attached Support Bracket, set the BWS-2000 on the Support Rod at an

appropriate axial location. Note:If the axis of the bore to be welded is vertical ornearly vertical, the use of a 1 ¼ inch diameter locking Rod Collar located under theradial support is recommended. Use of this collar when locked into the appropriateposition on the Support Rod, allows the free rotation of the Radial Support without thenuisance of it sliding down the Support Rod.

4.2.1.2. If not already in place, insert the Conduit Assembly in the Spindle and clamp. Also,install the Torch.

4.2.1.3. Attach the Power Cord to the BWS-2000 and energize with 115v, 50 or 60 Hzelectrical power. The Spindle should now be capable of rotating when the RotationDirection Switch is in either of its active positions.

4.2.1.4. Extend the Torch into the bore to be welded either by disengaging the Clutch andmanually moving the Spindle, or by unclamping the Tube Clamp and extending theExtension Tube.

4.2.1.5. Once into the bore, rotate the Torch until the Nozzle is pointing toward, and thendirectly away from the Support Rod. Note the distance from the end of the Nozzle tothe bore wall for both of these positions. If these distances are not equal, loosen theAnchor Nut and slide the “T” Base until the distances are equal. Retighten theAnchor Nut. This completes the centering process for one axis.

4.2.1.6. Rotate the Torch 90 degrees from the positions just used in order to achieve the firstaxis of centering, ie., perpendicular to a line running between the bore center and theSupport Rod.

4.2.1.7. Note the distance of the Nozzle from the bore wall and again rotate the Torch 180degrees and compare the Nozzle/wall distance.

4.2.1.8. Adjust the Nozzle/wall distances by unclamping the Support Bracket from the SupportRod, and swiveling the BWS-2000 around the Support Rod until the Nozzle/walldistance is equal at both positions. Reclamp the Support Bracket to the SupportRod.

4.2.1.9. The Torch should now be centered in the bore and the centerlines of the bore and theBWS-2000 parallel. Rotate the Torch 360° at the top and bottom of the bore toconfirm. Note: Nozzle to wall distance consistency of from 1 to 1.2 mm (.04 to .05in.) is generally adequate.

4.2.2. Boring Bar Adapter Assisted. Use of a boring bar adapter generally provides the first axis ofcentering and does not require the use of the Radial Support. Follow the instructions abovefrom 4.2.1.6. thru 4.2.1.9. in order to achieve second axis centering.

5.

4.3. Axial Positioning. Several factors can affect the axial position of the various components, andtherefore the axial range of the welding process. They include the: (1) Location of attachment ofthe Tack Plate or Swivel Base, (2) Position of attachment on the Support Rod, (3) Axial positionof the Spindle, and (4) Axial position of the Extension Tube. See Figure #4.4.3.1. Location of Tack Plate or Swivel Base. For most welding situations there is only one

logical mounting surface - adjacent to one of the bores to be welded, and at about thesame plane as on end. When several in-line bores are to be welded, it might be desirableto attach the Tack Plate or Swivel Base between the bores, thereby allowing an easy reachto bores on either side. This is possible because the Extension Tube can be inserted inthe Spindle with the torch coming out of either end of the BWS-2000. The only changethat has to be made to accommodate reversing the position of the torch is swapping thelocations of the Spindle Collar and the Tube Clamp. See Figure #5.

4.3.2. Position of the BWS-2000 on the Support Rod. The Support Rod is 560 mm (22 in.) long.The Radial Support or Support Bracket can be positioned along the rod wherevernecessary.

4.3.3. Axial Position of the Spindle. The axial position of the Spindle determines the length ofstroke available for welding before repositioning is necessary. It should be consideredalong with other axial position contributors, and the length of the bore when determiningthe best combination. The axial position of the Spindle is changed by disengaging theClutch and manually sliding the Spindle to the desired location.

4.3.4. Axial Position of the Extension Tube. The position of the Extension Tube and Spindleallows bores located approximately 1000 mm (40 in.) away from the Tack Plate mountingsurface to be welded. This extension capability allows the quick movement of the torchfrom bore to bore. The position of the Extension Tube is changed by loosening the TubeClamp and manually extending or retracting the Extension Tube to the desired location.Note: In order to maintain stability of the Torch, the Extension Tube should not protrudebeyond the end of the Tube Clamp more than 530 mm (22 in.).

5. WELDING TORCHES. The BWS-2000 has the capability of welding inside diameters from 32 to 940mm (1.25 to 37 in.) and outside diameters up to 305mm (12 in.). Welding this range of diameters isachieved by using either the Standard, Large Diameter or OD Torch, using the appropriate nozzle, tip,diffuser and extender, and by pivoting the torch to the proper radial location. See Figures #2, 3 & 4.Note: (1) In order to keep weight and electrical resistance to a minimum, many of the Torchcomponents are manufactured out of aluminum. Take care not to overtighten these components asdamage to the threads may result. (2) The ID Torches are coated to prevent accidental arcing tothe torch bodies. Take care not to wear off the coating.

5.1. Liner Stick-Out. Proper Liner stick-out from the end of the Torch before installing a Diffuser is afollows: (1) Standard Diffuser – 29 mm (1.15 in.); (2) Mini Diffuser – 6 mm (.25 in.). See Figure#2.

5.2. Liner Stick-Out Adjustment. The Liner stick-out can be adjusted by loosening the TorchAttachment Locknut and screwing the Torch either in or out as necessary to provide proper stick-out. Following adjustment, the Torch Attachment Locknut should be retightened. See Figure #2.

5.3. Mini Components. Use the Standard Torch with these components in order to weld borediameters from 32 to 50 mm (1.25 to 2 in.). See Figure #2.5.3.1. Diffuser, Mini (PN. 1093). Screws into the Standard Torch Body and contains the end of

the liner. It also supports the tip and nozzle, and transfers electrical power to the tip.5.3.2. Tip, Stub (PN. 1058). Screws into the diffuser and provides transfer of electrical power

from the diffuser to the welding wire.5.3.3. Nozzle, Mini (PN. 1092). Screws onto the diffuser and directs the shielding gas.

5.4. Stub Components. These components, when used with the Standard Torch, allow the welding ofdiameters as small as 45 mm (1.8 in.). They are capable of being used to weld diameters aslarge as 145 mm (5.7 in.). See Figure #2.5.4.1. Diffuser (PN. 1057). Screws into the torch body and contains the end of the liner. It also

6.

supports the tip and nozzle. Note: Attach only Diffuser numbers 1057 or 1093 to theStandard Torch. Use of other diffusers may cause damage to the liner and torchthreads.

5.4.2. Tip, Stub (PN. 1058). Screws into the diffuser and provides transfer of electrical powerfrom the diffuser to the welding wire.

5.4.3. Nozzle, Stub (PN. 1066). Screws onto the diffuser and directs the shielding gas. Thisnozzle is electrically isolated.

5.5. Standard Components. When used with the Standard Torch, these components allow thewelding of diameters from 70 mm to 204 mm (2.75 to 8 in.). See Figure #2.5.5.1. Diffuser (PN. 1057). Same use as above.5.5.2. Tip, Standard (PN. 1061). Same use as above.5.5.3. Nozzle, Standard (PN. 1067). Same use as above. Note: Only use Nozzles number

1066 and 1067 when attaching directly to the Standard Torch. Other Nozzles may losetheir electrical isolation when used with this torch.

5.5.4. Standard Torch Extender. Use of the Standard Torch Extender extends the length of theStandard Torch by 100 mm (4 in.). Its use increases the diameter capability of the abovecomponents by approximately 75 mm (3 in.). It is attached at the swivel end of theStandard Torch, and requires use of a liner segment about 4 inches longer than is usedwithout it. See Figure #2.

5.6. Large Diameter Components. The use of the Large Diameter Torch allows the welding of boresfrom 200 to 380 mm (8 to 15 in.). Use the same Diffuser, Tip, and Nozzle as are listed underStandard Components. If Torch Extenders are also used, the maximum diameter capability isextended to a maximum of 610 mm (24 in.). See Figure #3.5.6.1. Liner With Attached Tubular Liner Aligner. The Liner protruding from the Torch is

extended by slipping the Liner Aligner over the Torch Liner.5.6.2. Torch Extenders. Thread the lengthened liner through the Torch Extender(s) and screw

the Extender(s) on the Large Diameter Torch. The Liner should now protrudeapproximately 29 mm (1.15 in.) beyond the end of the Extender - cut as necessary.Installation of the Diffuser should now place the Liner in its proper orientation relative tothe Tip. Any of the Tips, Diffusers, or Nozzles listed above can be used with the LargeDiameter Torch. Note: When using the Large Diameter Torch,, Tweco Diffuser number35-50, and Nozzle number 21-62 are acceptable.

5.7. Outside Diameter Components. The use of the OD Torch, allows the build-up of outsidediameters from 0 to 305 mm (0 to 12 in.) for a minimum length of 204 mm (8 in.). Special torchbodies can be provided to accommodate diameter and length requirements outside of the rangeslisted above. All Tips, Diffusers, and Nozzles that are used with the ID Torches, can be used withthe OD Torch. See Figure #3.

5.8. Attachment of the Welding Torch. See Figure #2 & 3.5.8.1. Remove the Nozzle and Diffuser from the torch. This allows the Liner to be manually

deflected into the threaded diffuser-attachment-hole when it reaches that point duringtorch attachment.

5.8.2. Insert the end of the Liner coming out of the Conduit Assembly into the end of the Torch,and screw the Torch on the Torch Adapter.

5.8.3. Once adequate engagement is achieved, the liner is protruding through the diffuser-attachment-hole approximately 29 mm (1.15 in.) for the standard Diffuser and 6 mm (.25in.) for the Mini Diffuser, and the diffuser-attachment-hole is pointing in the direction ofTorch adjustment, screw the Torch Lock Nut until it tightens against the Torch, therebylocking the Torch into position.

5.9. Radial Adjustment of the Welding Torch. See Figure #2, 3 & 4.5.9.1. If tightly locked, loosen the Radial Adjustment Lock Nut.5.9.2. Pivot the Torch until the closest point of the Nozzle is about 2 to 4 mm (.08 to .16 in.) from

the inside of the bore (or outside of pin).5.9.3. Lock the Torch in position by hand tightening the Radial Adjustment Lock Nut.

7.

5.10. Axial Adjustment of the Welding Torch. (See 4.3. above.)

6. CONDUIT ASSEMBLY INSTALLATION. The Conduit Assembly extends all the way from the WirefeedConnector to the Torch Adapter. See Figure #7.6.1. Insert the Conduit Assembly into the Spindle, the Extension Tube end first. Note: (1) If the Torch

is attached, remove the Nozzle and Diffuser first. (2) Make sure that the Extension Tube is clean,by wiping it with a clean soft cloth to remove any loose dirt or buildup before installation. Failureto keep the Extension Tube clean could result in binding with the Spindle bore.

6.2. Clamp the Extension Tube in position using the Tube Clamp. It can be clamped with the torch-attachment-end from 0 to 560 mm (0 to 22 in.) from the end of the Tube Clamp.

6.3. Attach the flexible end of the Conduit Assembly to the wirefeeder.6.4. If possible, position the wirefeeder so that the Flexible Conduit is oriented in a “Stable Wire

Feeding Setup” similar to those shown in Figure #7. Weld beads produced by a stable wirefeeding setup will be straighter. Also, there will be much less likelihood of incomplete weldcoverage of the bore.

7. FINAL PREPARATION FOR WELDING.

7.1. Adjust the radial position of the Torch as specified above.7.2. Adjust the axial position of the Torch - using techniques specified above - to the desired starting

position so that the welding can proceed from the end of the bore farthest from the BWS-2000toward the BWS-2000. Generally an initial wire contact position of about 2 to 3 mm (.08 to .12 in.)from the start end of the bore is about right. Note: It is advisable - especially in vertical weldingapplications - to attach the conduit to the Radial Support, Support Rod or other stationary objectso that the conduit forms a large radius when exiting the Extension Tube or Spindle. This causesless friction for the welding wire traveling through the Conduit and less friction between theConduit and Extension Tube or Spindle. See Figure #4.

7.3. Set the Rotation Speed Knob to the proper setting based on the diameter to be welded. Anapproximate setting can be read from the chart on the side of the BWS-2000. This chart is basedon welding speeds of 500 mm (20 in.) per minute. Note: Rotation speeds will vary due todifferences in supply voltage and electrical components. To check the actual welding speeddivide circumference of the bore by the time in minutes required to traverse one full revolution.See Appendix A, paragraph #1.

7.4. Check to make sure that the Welding Switch at the end of the welding cord is in the Off position.Note: If the Welding Switch is not in the Off position dangerous welding flash may resultwhen the power supply is energized.

7.5. Energize the welding power supply.7.6. With the ground (-) and/or positive (+) welding leads disconnected, jog the welding wire through

the Conduit Assembly and Torch by depressing the “Jog Button” on your wirefeeder, or if yourwirefeeder does not have a “Jog Button”, move the Weld Switch to the “On” position. Once thewelding wire is through the Conduit Assembly and Torch, move the Weld Switch to the “Off”position. Cut the wire to an appropriate stick-out length. Notes: (1) If the welding leads arenot disconnected, a dangerous welding flash may result when the welding wire exits thetorch. (2) The Diffuser may have to be removed in order for the wire to get around the Liner bendjust before the Diffuser attachment point. Once the wire is through the Liner, the Diffuser (andTip) can be reinstalled.

7.7. Connect the welding current ground (-) lead to the part being welded. Note: Make sure that theground is connected to clean solid metal. A poor ground will adversely affect weld quality.

7.8. Make sure the power supply is set for Constant Voltage operation.7.9. Make sure that the bore to be welded is clean, ie., free from rust, dirt, oil, grease, etc. A dirty bore

will cause poor weld quality, and excessive spatter.7.10. Connect shielding gas. For mild steel welding, use an argon/CO2 mixture with an argon content

of from 75 to 92 percent. Set the flow rate to about 1 m3/hour (35 cfh or 16 litres/minute).7.11. Purge air from the system by depressing the purge button - typically located on the wirefeeder -

for approximately 10 seconds. This should be the last step before welding to assure that no airhas infiltrated the gas feed system.

8.

8. WELDING.

8.1. Make sure that all of the safety precautions mentioned in the Safety Information section of thismanual are being complied with before beginning welding.

8.2. Move the Rotation Direction Switch in the axial direction that the torch is supposed to travel. Thiswill start the rotary and axial motion.

8.3. At the same time that the Rotation Direction Switch is activated, the Weld Switch can beactivated. Note: At this time, the Clutch can be locked in the “disengaged” position for one Torchrevolution to allow a single plane of weld to be deposited before axial motion begins. Thisgenerally gives more complete buildup at the start of the weld.

8.4. Normal weld settings for mild steel are: Voltage - 16 to 17.5; Amperage - 100 to 135, althoughsuccessful welding can be done outside of these settings.

8.5. Adjust the rotation speed, voltage and wire speed settings as necessary to achieve the desiredresults. Be especially careful that the arc is “playing” at the intersection of the previous bead andthe base metal. If the arc is “playing” on the previous bead or in the molten weld puddle, poorfusion to the base metal may result.

8.6. When approaching an area where weld should not be deposited - such as a keyway - move theWeld Switch toggle to the “Off” position to stop welding. Rotation will continue. Once the far sideof the area is reached, move the Weld Switch to the “On” position to continue welding.

8.7. The BWS-2000 is designed to be “manned” when in use in order to make adjustments whennecessary, and to be available when the build up of the bore is completed or the end of the strokeis reached. Note: The BWS-2000 does not automatically shut off when the end of its stroke hasbeen reached. The Clutch will disengage briefly each revolution as the Spindle attempts to moveaxially. While no damage is likely for considerable time, such disengagement does causeexcessive wear, and if occurring during welding will leave a substantial deposit of weld at onelocation.

8.8. Once the build up is completed, shut off the Welding and the Rotation Switches.8.9. To continue welding the same bore or another in-line bore, reposition as indicated above, purge

the system, and begin as described earlier in this section.

9. SPECIAL SITUATIONS.

9.1. Welding in High Temperature Environments. It is suggested that when welding for extendedperiods in environments with temperatures of 93° Celsius (200° Fahrenheit) or greater, that theBWS-2000 housing be cooled by supplying compressed air to the housing interior through theCooling Fitting. The air supplied should be dry, and regulated down to a pressure of about 35Kilonewton per square meter (5 psi). The Cooling Fitting can be attached to by removing theCooling Fitting Plug, and screwing in a 1/8 NPT male fitting. When the air cooling is not in use,the Cooling Fitting Plug should be reinstalled to keep foreign matter out of the BWS-2000housing.

9.2. Single Plane Welding. The BWS-2000 clutch can be locked in the disengaged position bymoving the clutch lever to the detent location. If disengaged, the spindle will not move axiallywhen rotated, thereby allowing face or fillet welding. It also allows a single plane of weld to bedeposited on a cylindrical surface before axial motion begins. Moving the clutch lever out of thedetent position while welding is taking place will allow axial motion to take place during the nextrevolution. Note: When single plane welding, it is generally desirable to move the Spindle Collarto make contact with the Top Bushing, thereby maintaining the desired Spindle position.

10. MAINTENANCE. Very little maintenance is required except regular cleaning.

10.1. Spindle. The Spindle should be wiped down with a clean soft cloth after each use or morefrequently if in an excessively dirty environment. It can be moved from stop to stop so that mostof its length - including the threads - can be cleaned. No lubrication is necessary.

10.2. Extension Tube. There is minimal clearance between the Spindle ID and the Extension TubeOD. If the Extension Tube is not kept clean by regular wiping with a clean soft cloth, binding

9.

between the two can occur. Should movement of the Extension Tube become inhibited, remove itentirely from the Spindle and clean thoroughly. Also clean the ID of the Spindle at the same time.It is suggested that this procedure be done on a daily basis during periods of normal use.

10.3. Remaining Components. All remaining components should be wiped clean on a daily basis.These include the housing, mounting components, torches, cords, and conduits.

11. CARE. The BWS-2000 is designed to be used in an industrial environment, but like any tool requiresreasonable care in order to function as intended.

11.1. The BWS-2000 is designed to be corrosion resistant in order to function properly in humidenvironments. It is not however, designed to be used in the rain or to be immersed in water.Should the unit accidentally get wet, thoroughly dry before using. Using the BWS-2000 wetcould damage the unit as well as create a hazardous situation.

11.2. The BWS-2000 should not be dropped or struck with any object. Should this happen, thoroughlyexamine it - especially the Spindle threads and surface - for damage. Repair or replace anydamaged components before use.

11.3. Inspect all electrical cords for damage. Repair or replace them before use.11.4. Be careful not to expose the BWS-2000 to excessive heat or damage will occur.

10.

Torch Mover And Support ComponentsFigure #1

11.

CONDUIT(2.1.2.)

EXTENSIONTUBE (2.1.3.)

SPINDLE (2.3.2.)

SPINDLECOLLAR(2.3.4.)

TORCHMOVER(2.3.)

TUBECLAMP(2.3.3.)

TORCHSWIVEL

(2.1.5.)

SWIVELLOCK

(2.1.6.)

TORCH(2.2)

SUPPORT ROD(2.4.1.)

RODCOLLAR(2.4.8.)

SUPPORTBRACKET(2.3.9.)

ROTATIONDIRECTION

SWITCH(2.3.6.)

CLUTCHLEVER(2.3.5.)

CLUTCHLEVER

DETENT

ROTATIONSPEED KNOB

(2.3.7.)

HOUSING(2.3.1.)

COOLING GASFITTING (2.3.8.)

RECEPTACLE(2.3.11)

WELDINGSWITCH

(2.1.7.)

“T” BASE(2.4.4.)

SUPPORT RODTIGHTENER(2.5.7.)

Use

Of S

tand

ard

Torc

h

Diff

user

BW

S-10

93

Adj

ust l

iner

stic

kout

to 6

.3m

m (.

25")

Dia

met

er R

ange

-32

to 5

0 m

m(1

.25

to 2

inch

es)

Dia

met

er R

ange

-45

to 1

45 m

m(1

.8 to

5.7

inch

es)

Dia

met

er R

ange

-79

to 2

03 m

m(2

.75

to 8

inch

es)

Dia

met

er R

ange

-70

to 2

70 m

m(2

.75

to 1

1 in

ches

)

Noz

zle

BW

S-10

66

Tip

BW

S-10

58

Diff

user

BW

S-10

57

Noz

zle

BW

S-10

67

Tip

BW

S-10

61

Diff

user

BW

S-10

57

Swiv

el L

ock

(2.1

.6)

Torc

h Lo

ck(2

.2.6

)

Adj

ust t

orch

axia

lly to

ach

ieve

prop

er li

ner

stic

kout

.

Adj

ust a

s ne

eded

.

Line

r B

WS-

1039

(2.1

.4) (

TYP)

Set s

ticko

ut to

29

mm

(1.1

5") a

nd a

lign

torc

hso

line

r is

poin

ting

in th

edi

rect

ion

of p

ivot

.

Noz

zle

(2.2

.5)

Tip

(2.2

.4)

Diff

user

(2.2

.3)

Stan

dard

Com

pone

nts

With

Tor

ch E

xten

der.

Stan

dard

Com

pone

nts.

Stub

Com

pone

nts.

Min

i Com

pone

nts.

Figu

re #

2

12.

Torc

hB

ody

BW

S-11

04(2

.2.1

) (T

YP)

Torc

hEx

tend

erB

WS-

1105

(2.2

.2)

Tip

BW

S-10

58

Noz

zle

BW

S-10

92

Use

Of L

arge

Dia

met

er a

nd O

D T

orch

Figu

re #

3

Dia

met

er R

ange

-12

.7 to

305

mm

(.5 to

12

inch

es)

Torc

h B

ody

BW

S-A

114

Torc

h Ex

tens

ion

Tube

BW

S-10

42

Line

r Alig

ner

BW

S-10

43

Noz

zle

BW

S-10

67

Diff

user

BW

S-10

57 (T

YP)

Tip

BW

S-10

61

29 m

m(1

.15"

)

Torc

h B

ody

BW

S-A

115

Line

r B

WS-

1039

(alig

n to

rch

soth

at li

ner i

spo

intin

g in

the

dire

ctio

n of

piv

ot)Adj

ust t

orch

axi

ally

toac

hiev

e pr

oper

line

r st

icko

ut

Adj

ust a

s ne

eded

Torc

h at

tach

men

t loc

knut

Rad

ial a

djus

tmen

t loc

knut

Torc

h A

ttach

men

t and

Rad

ial A

djus

tmen

tSt

anda

rd C

ompo

nent

sEx

tend

ed R

ange

Com

pone

nts

Out

side

Dia

met

erTo

rch

Dia

met

er R

ange

-1

exte

nsio

n: 3

80 to

610

mm

(15

to 2

4")

Dia

met

er R

ange

-20

0 m

m to

380

mm

(8 to

15"

)

13.

Gen

eral

Set

up In

form

atio

n

Figu

re #

4

Opt

iona

lco

ndui

tsu

ppor

ttu

be

Alte

rnat

ive

met

hod

ofco

ndui

t sup

port

Rub

ber

stra

p-su

ppor

ts c

ondu

it to

achi

eve

grad

ual

swee

p of

con

duit

atto

p of

BW

S-20

00

Con

duit

(to w

irefe

eder

)

Swiv

el b

ase

(wel

d or

cla

mp

in p

lace

)

WO

RK

PIEC

E TO

BE

WEL

DED

Opt

iona

lco

ndui

tsu

ppor

ttu

be

Rad

ial

supp

ort

Supp

ort

Cla

mp

Supp

ort R

od(a

lign

para

llet

ot b

ore

cent

erlin

e)

Torc

h pi

vot

mec

hani

sm

Exte

nsio

n tu

be

Exte

nsio

ntu

becl

amp

Min

imun

dist

ance

toal

low

bui

ldup

of b

ore

340

mm

(13.

5")

BW

S-20

00

14.

In-L

ine

Bor

e Se

t-Ups

Figu

re #

5

Side

Atta

chm

ent

Cen

tral

Atta

chm

ent

(Nor

mal

Tor

ch O

rient

atio

n)

Cen

tral

Atta

chm

ent

(Inve

rted

Tor

ch O

rient

atio

n)

15.

Usi

ng C

ones

For

Alig

nmen

t

Figu

re #

6

Lock

scr

ew(T

YP)

Cen

terin

g ro

d31

,75

mm

dia

.(1

.25"

)

Cen

terin

g co

ne(T

YP)

T TYP

(3)

Tack

pla

te

TT

NO

TE: W

eld

or c

lam

p Ta

ck P

late

in p

lace

and

tigh

ten

all s

crew

s or

nut

s la

bele

d “T

” be

fore

rem

ovin

g C

ente

ring

Rod

.

16.

Wire

Sta

bilit

y

Figu

re #

7

Wire

cas

t and

con

duit

curv

atur

e ar

e in

the

sam

e di

rect

ions

Wire

cas

t and

con

duit

curv

atur

e ar

e in

the

sam

e di

rect

ions

Wire

cas

t and

con

duit

curv

atur

e ar

e in

opp

osite

dire

ctio

ns

Wire

cas

t and

con

duit

curv

atur

e ar

e in

opp

osite

dire

ctio

ns

Wire

cas

t and

con

duit

curv

atur

e ar

e in

opp

osite

dire

ctio

nsUns

tabl

e W

ire F

eedi

ng S

etup

s

Stab

le W

ire F

eedi

ng S

etup

s

NO

TE: W

eldi

ng w

ire in

not

str

aigh

t. Th

e di

rect

ion

itcu

rves

is c

alle

d th

e w

ire c

ast.

“A”

repr

esen

ts w

ireca

st.

17.

Use

of t

he B

SW “

T” B

ase

Figu

re #

8

Mou

nt D

etai

l

(4) S

prin

gw

ashe

rs

Tack

Pla

te

Anc

hor n

ut(1

/2-1

3 N

C) “T

” B

ase

Wor

kpie

ce

Tack

pla

teta

ck w

eld

orcl

amp

tow

orkp

iece

ACB D

180

mm

(7") Su

ppor

t rod

“T”

Bas

eR

odm

ount

Posi

tions

Para

llelis

m A

djus

tmen

t(O

bjec

tive

- alig

n su

ppor

t rod

par

alle

l to

bore

cen

terli

ng)

1. T

o ad

just

in d

irect

ions

A -

B m

ove

scre

ws

1 &

2.

2. T

o ad

just

in d

irect

ions

C -

D m

ove

scre

w 3

.3.

Loo

sen

and

retig

hten

anc

hor n

ut a

s ne

cess

ary

to p

erfo

rmab

ove

adju

stm

ents

.

Con

cent

ricity

Adj

ustm

ent

(Obj

ectiv

e - c

ente

r BW

S-2

000

with

wor

kpie

ce b

ore)

1. L

oose

n an

chor

nut

.2.

Slid

e “T

” bas

e to

cen

ter t

orch

in th

e E

- F

dire

ctio

n.3.

Tig

hten

anc

hor n

ut.

4. L

oose

n su

ppor

t rod

cla

mpi

ng n

ut.

5. R

otat

e B

WS

-200

0 ar

ound

sup

port

rod

to c

ente

r tor

ch in

the

G -

H d

irect

ion.

6. R

etig

hten

sup

port

rod

and

clam

ping

nut

.

19.

“T”

Bas

e Su

ppor

t Con

figur

atio

ns

Figu

re #

9

Supp

ort r

od

“T”

base

152

mm

(6")

Anchor Bolt Location

356

mm

(14"

)

Supp

ort r

od lo

catio

n #2

Bas

eex

tend

er

“T”

base

Supp

ort

rod

Rad

ial

Supp

ort


Bas

e Ex

tend

er &

Rad

ial S

uppo

rt A

dded

Supp

ort r

od

Bas

e Ex

tend

er A

dded

“T”

base


Bas

eex

tend

er254

mm

(10"

)

“T”

base

Supp

ort r

od


180

mm

(7")

Max

bor

e O

114

mm

(4.5

") Max

bor

e O

520

mm

(20.

5")

Max

bor

e O

165

mm

(6.5

")

Max

bor

e O

318

mm

(12.

5")

20.

USEFUL INFORMATIONAPPENDIX A

1. NORMAL TIME OF ONE REVOLUTION OF THE TORCH WHILE WELDING.(Useful when setting up the BWS-2000)

Metric - Calculate by multiplying the diameter (mm) by .38.Example: Diameter or bore = 180 mm.

Normal revolution time = 180 x .38 = 68 seconds

English - Calculate by multiplying the diameter (in.) by 10.Example - Diameter of bore = 3.5 inches.

Normal revolution time = 3.5 x 10 = 35 seconds.

2. NORMAL TIME TO BUILD UP A BORE(Useful when estimating job times.)

Metric - Calculate by multiplying the diameter (mm) by the length (mm) by .002.Example: Diameter of bore = 65 mm; Length of bore = 110 mm.

Normal build up time = 65 x 110 x .002 = 14.3 minutes.

English - Calculate by multiplying the diameter (in.) by the length (in.) by 1.25.Example: Diameter of bore = 4.2 inches; Length of bore = 3.6 inches.

Normal build up time = 4.2 x 3.6 x 1.25 = 18.9 minutes

3. WIRE DEPOSITION RATE.(Useful when calculating anticipated wire usage.)

Metric - Calculate by multiplying the following:For .8 mm wire - Multiply the wirefeed speed in mm/min. by .00022.For .9 mm wire - Multiply the wirefeed speed in mm/min. by .00030.

Example: Wirefeed rate = 7400 mm/min.; Wire diameter = .8 mm.Deposition rate = 7400 x .00022 = 1.63 kg/hr.

English - Calculate by multiplying the following;For .030 in. wire - Multiply the wirefeed speed in in./min by .0123.For .035 in. wire - Multiply the wirefeed speed in in./min. by .0167For .045 in. wire - Multiply the wirefeed speed in in./min. by .0277

Example: Wirefeed rate = 320 in./min.; Wire diameter = .030 in.Deposition rate = 320 x .0123 = 3.94 lb./hr.

21.

BWS-2000 PORTABLE BORE WELDING SYSTEMCOMPONENT LISTWeldingTipsStub Tips:BWS-1058 .8mm (.030)BWS-1059 .9mm (.035)BWS-1060 1.2mm (.045)

Standard Tips:BWS-1061 .8mm (.030)BWS-1062 .9mm (.035)BWS-1063 1.2mm (.045)

Welding Nozzles and DiffusersMini Nozzle:BWS-1092 32-50mm (1.25-2")

Stub Nozzle:BWS-1066 Use for small diameters

Standard Nozzle:BWS-1067 Use for large diameters

Mini Diffuser:BWS-1093 32-50mm (1.25-2")

Diffuser:BWS-1057 Use with all torches

Welding Torches and AccessoriesStandard Torch:BWS-A113 32-204mm (1.25-8")

Large Diameter Torch:BWS-A115 200-380mm (8-15")

Standard Torch Extender:BWS-A116 Increase dia 76mm (3")

Torch Extension Tube:BWS-1042 Diameter Ranges: 1 Tube - 380-580mm (15-23") 2 Tubes - 530-760mm (21-30")

OD Torch:BWS-A114 0-305mm (0-12")

Hand held MIG gun and conduit:BWS-1102 3.6m (12') conduit w/euro

Face Torch:BWS-A127 0-610mm (0-24")

Support ComponentsTack Nut:BWS-1100 Non-adjustable support

“T” Base:BWS-A110 Leveling & centering adjustments

Tack Plate:BWS-1099 Weld/clamp to part & support “T”

Swivel Base:BWS-A106 Use with centering cones & tube

Base Extender:BWS-1097 Attach to “T” for large bore reach

Radial Support Extender 102mm (4")BWS-A118 Extra reach for large bores

Radial Support Extender 203mm (8")BWS-A119 Extra reach for large bores

Centering ComponentsCentering Cone Set:BWS-A108 45-160mm (1.8-6.4")

Centering Tube:BWS-1044 1.8m (72")

MiscellaneousLiner:BWS-1039 1.5m (60") for torches

Liner, Conduit ReplacementBWS-1038 4.5m (15')

Thru-Bar bore measuring tool kit: (46-305mm)(1.8-12")BWS-A131 For use with boring bar

Liner Aligner:BWS-1073 Use with torch extension tubes

Welding wire, large diameter cast 70S6BWS-1103 30 lb. spool .8mm (.030")BWS-1202 30 lb. spool .9mm (.035")

Auto-Skip Option:BWS-A129 enables partial borewelds

Call factory for specials, boring bar systems and components or power supply wire feeder options.



CARRIAGES

The BUG-O Systems Carriages are made of high-strength, lightweight aluminum alloy. Thecarriage wheels ride in opposed recessed grooves or ways, in the Aluminum Rigid Rails, lockingthe carriage to the rail in all positions. The pinion from the drive unit goes through the carriage andengages the rack on the rail, providing a positive drive. One set of wheels on each carriage isadjustable to allow for smooth accurate travel. The wheels contain permanently lubricated sealedbearings. All steel components are plated to resist corrosion.

PATENTS WORLDWIDE

MPD-1065RELEASABLECARRIAGE12" (305 mm)

BUG-5250 CARRIAGE12" (305 mm)

BUG-5260 CARRIAGE18" (457 mm)

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2

CARRIAGES

Close-up showing a front view of a carriagemounted on Aluminum Rail.

BUG-5250 CARRIAGE 12" (305 mm)Net Weight: 5 lbs. (2.26 kg)Shipping Weight: 7 lbs. (3.17 kg)

• Mounts a DC IV DriveUnit

• 100 lb (45 kg) carryingcapacity.

BUG-5260 CARRIAGE 18" (457 mm)Net Weight: 8 lbs. (3.62 kg)Shipping Weight: 10 lbs. (4.53 kg)

• Mounts a DC IV DriveUnit.

• 100 lb (45 kg) carryingcapacity with a DC IVmounted on thecarriage.

• 150 lb (67.5 kg)carrying capacitywhen used as atrailer.

• Longer deck to mountaccessories, wirefeeder, etc.

BUG-2790 CARRIAGE 24" (609 mm)Net Weight: 11 lbs. (5 kg)Shipping Weight: 15 lbs. (6.80 kg)

• Mounts a DC IV Drive Unit.

• 100 lb (45 kg) carrying capacitywith a DC IV mounted on thecarriage.

• 200 lb (90 kg) carrying capacitywhen used as a trailer.

• Longer deck to mountaccessories, wire feeder, etc.

2.00"(50 mm)

8.00"(203 mm)

24.00"(609 mm)

2.00"(50 mm)

18.00"(457 mm)

8.00"(203 mm)

2.00"(50 mm)

12.00"(305 mm)

8.00"(203 mm)

3

CARRIAGES

8.00"(203 mm)

2.00"(50 mm)

36.00"(914 mm)

BUG-2785 CARRIAGE36" (914 mm)Net Weight: 16.5 lbs. (7.50 kg)Shipping Weight: 23.0 lbs. (10.44 kg)


• 100 lb (45 kg) carrying capacitywith a DC IV mounted on thecarriage.

• 200 lb (90 kg) carrying capacitywhen used as a trailer.

• Longer deck to mount accessories,wire feeder, etc.

2.00"(50 mm)

8.00"(203 mm)

12.00"(305 mm)

MPD-1065 Releasable CarriageNet Weight: 7.75 lbs. (2.52 kg)Shipping Weight: 9lbs. (4.09 kg)


• 100 lb (45 kg) carrying capacity.

• Releasable (can be installedanywhere along the track.

BUG-5910 Split CarriageNet Weight: 7 lbs. (3.17 kg)Shipping Weight: 8 lbs. (3.62 kg)

• Mounts a DC IV Drive Unit ora Modular Drive Unit.

• 100 lb (45 kg) carrying capacity.

• Releasable (can be installedanywhere along the track.

• Runs on straight or BRR Ring Rail.

8.12"(206 mm)

2.56"(65 mm)

12.00"(305 mm)

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CARRIAGES

8.00"(203 mm)

2.00"(50 mm)

12.00"(305 mm)

BUG-2205 Carriage Trailer w/HitchNet Weight: 6 lbs. (2.72 kg)Shipping Weight: 8 lbs. (3.62 kg)

• 100 lb (45 kg) carrying capacity • Used to carry accessories, wirefeeder, etc.

8.00"(203 mm)

6.18"(157 mm)

2.00"(50 mm)

12.00"(305 mm)

MUG-1140 Spotting CarNet Weight: 6 lbs. (2.72 kg)Shipping Weight: 8 lbs. (3.62 kg)

• Knob is used manually to move thecarriage along the track.

• Bottom knob locks carriage to a fixedrail position

MUG-1148 Torch SpotterNet Weight: 3 lbs. (1.36 kg)Shipping Weight: 4 lbs. (1.81 kg)

• Knob is used manually to move thecarriage along the track.

• Bottom knob locks carriage to a fixedrail position

4.00"(102 mm)

6.25"(159 mm)

9.00"(229 mm)



CIR-O

CIR-O machines are lightweight, heavy-duty, multiple-use circular drives. Each of the three sizes of machineshas a positive rack and pinion drive and infinitely variablespeed control which provides smooth, accurate travel inall positions. The carriage provides a mounting surfacefor a variety of different process tools. A single center-punch mark is all that is needed to locate the machineon the workpiece. It is then ready to flame-cut, bevel orweld. Permanent magnets or vacuum cups can bepurchased separately to hold it in place.


3001 WEST CARSON STREET PITTSBURGH, PENNSYLVANIA USA 15204-1899

PHONE: 1- 800-245-3186 http://www.bugo.com TELEFAX: 1- 412-331- 0383

1. BUG-5100-F drive unit provides the power with a solid-state variable speed control.

2. CIR-3040, CIR-4040 and CIR-5040 carriage insuresaccurate work paths by meshing firmly with the gear.A quick-acting manifold with a short connection hose,and a centering pin are mounted on the carriage.

3. CON-3000, CON-4000, CON-5000 ring and gearassembly with its perfectly round cut gear makes everycut true.

4. OPTIONAL CIR-9002 offset leg and magnet assembly- four of these units are used to eliminate the blind spotunder the ring. Each unit clamps onto a standard leg. Anadjustable tip adaptor must be used to offset the cuttingtip under the ring.

5. Standard 2" (50 mm) leg [four supplied with the machine].

6. OPTIONAL CIR-9021 5" (127 mm) leg [use with tem-plate kit and CIR-9020 magnet foot].

7. OPTIONAL CIR-9020 magnet foot [use with CIR-90215" (127 mm) leg] locks machine to work - four required.

8. Center location with stainless steel center pin.

9. Rotating post mount - this combination of modulesprovide accurate positioning of a torch for any singletorch operation.

1

2

4 5

7

6

3

9

8

CIR-O HEAVY DUTY CIRCLE CUTTER

Dimensions:

TEMPLATE KIT - consists of a sheet aluminummaster template, alignment bars, spacer legs,tensioning assembly and torchholder. Pattern iscut in tempered hardboard and bolted to ring.

ANNULAR CARRIAGE - for special weldingand cutting applications - when material to be cutor welded passes through the ring track.

CIR 3

CIR 4

CIR 5

24" (610 mm)

32" (813 mm)

40" (1016 mm)

25

.50

" (6

48

mm

)

33

.87

" (8

60

mm

)

42

.25

" (1

07

0 m

m)

"X"

"X" = 8.18" (208 mm)with 2" legs

"X" = 11.18" (284 mm)with 5" legs

NOTE: Torches, tips and magnets or vacuum cups must be ordered separately.

PART POWER PART SHIPPING NETNUMBER REQUIREMENT NUMBER WEIGHT WEIGHT

CIR-3303 120 VAC/50-60-1 CIR-3303 66 lbs. (30.0 kg) 48 lbs. (21.8 kg)CIR-3323 240 VAC/50-60-1 CIR-3323CIR-3313 42 VAC/50-60-1 CIR-3313

CIR-4404 120 VAC/50-60-1 CIR-4404 90 lbs. (40.8kg) 65 lbs. (29.5 kg)CIR-4424 240 VAC/50-60-1 CIR-4424CIR-4414 42 VAC/50-60-1 CIR-4414

CIR-5505 120 VAC/50-60-1 CIR-5505 128 lbs. (58.0 kg) 90 lbs. (40.9 kg)CIR-5525 240 VAC/50-60-1 CIR-5525CIR-5515 42 VAC/50-60-1 CIR-5515

INSIDE DIAMETER OUTSIDE DIAMETER

CIR-3303 CIR-3323 CIR-3313 3"-14" (75-356 mm) 26"-56" (660-1422 mm)

CIR-4404 CIR-4424 CIR-4414 3"-22" (75-559 mm) 34"-64" (864-1626 mm)

CIR-5505 CIR-5525 CIR-5515 3"-30" (75-760 mm) 42"-72" (1060-1830 mm)

Optional Accessories:

3 .4-8 75 10-210

6 .8-16 150 20-420

10 1.4-28 250 35-700

14 2-39 350 50-1000

26 3.5-70 650 90-1805

30 4-80 750 105-2100

34 4.5-92 850 120-2400

38 5.2-105 950 130-2640

42 5.7-115 1050 50-3000

46 6.3-125 1140 60-3200

50 6.8-135 1250 175-3500

56 7.6-155 1420 200-4000

3 .3-5 75 7-140

6 .6-11 150 14-280

10 .9-18 250 23-460

14 1.3-26 350 32-650

18 1.7-33 450 42-840

22 2-40 550 50-1000

34 3.2-63 850 80-1600

38 3.5-70 950 87-1760

42 3.9-78 1050 97-1950

46 4.3-85 1150 105-2130

50 4.6-93 1250 115-2300

54 5-100 1350 125-2500

58 5.4-110 1450 135-2700

64 6-120 1625 150-3000

3 .2-4 75 5-100

6 .4-8 150 10-210

10 .7-13 250 17-350

14 1-19 350 24-500

18 1.3-25 450 32-640

22 1.5-30 550 38-760

26 1.8-37 650 45-900

30 2-41 750 52-1050

42 2.9-57 1050 73-1458

46 3.2-63 1150 80-1600

50 3.4-68 1250 87-1750

54 3.7-75 1350 94-1900

58 4-80 1450 100-2000

62 4.3-85 1550 105-2150

66 4.5-90 1650 115-2300

72 4.9-100 1825 125-2500

DIAMETERDIAMETER

INCH IPM MM MM/MIN

Capacities and Speed Ranges

INS

IDE

RIN

G

OU

TS

IDE

RIN

G

INS

IDE

RIN

GO

UT

SID

E

RIN

G

INS

IDE

RIN

GO

UT

SID

E

RIN

G

CIR

-III

CIR

-IV

CIR

-V

DIAMETER

VACUUM MOUNTS - CON-1006 for use onnon-ferrous material such as stainless, alumi-num etc. Use with ARV-2020 Vacuum Pump Kit.

A QUALITY PRODUCT FROM BUG-O SYSTEMS • 3001 WEST CARSON STREET • PITTSBURGH, PA USA 15204-1899

Litho in U.S.A. LIT-CIRO-BRO-0307A DIVISION OF WELD TOOLING CORPORATION© Weld Tooling Corp. ROM 1:16

CIR-9030 CIR-IIICIR-9040 CIR-IVCIR-9050 CIR-V

CIR-3304 CIR-IIICIR-4405 CIR-IVCIR-5506 CIR-V

CON-1006



CON-OPrecision Contour Saddle CutterCON-O Precision Contour Burning and Beveling MachinesProduce Elliptical Cuts and Bevels in Pipes and Cylinders.

Welding & Cutting Innovations Since 1948.

The CON-O automatically follows symmetrical surfaces to produce smooth, accurate cuts andbevels. It is portable and easily taken to the work. The CON-O locates from a center-punch markand is set to a radius mark. Powerful permanent magnets stabilize the machine (two outriggersupport kits are supplied with the CON-3 and CON-4, four outrigger support kits are supplied withthe CON-5).

PATENTS WORLDWIDE

CON-O PRECISION CONTOUR SADDLE CUTTER

Dimensions:Technical Data:PART POWER NET SHIPPINGNUMBER: REQUIREMENT: WEIGHT: WEIGHT:

CON-3303 120 VAC/50-60-1 CON-3303, 3313, 3323CON-3313 42 VAC/50-60-1 65 lbs. (29.5 kg) 83 lbs. (37.6 kg)CON-3323 240 VAC/50-60-1

CON-4404 120 VAC/50-60-1 CON-4404, 4414, 4424CON-4414 42 VAC/50-60-1 80 lbs. (36.3 98 lbs. (44.5 kg)CON-4424 240 VAC/50-60-1

CON-5505 120 VAC/50-60-1 CON-5505, 5515, 5525CON-5515 42 VAC/50-60-1 105 lbs. (47.7 kg) 130 lbs. (59.0 kg)CON-5525 240 VAC/50-60-1

CON-3303 3 .4-8 75 10-2106 .8-16 150 20-420

10 1.4-28 250 35-70014 2-39 350 50-1000

CON-4404 10 .9-18 250 23-46014 1.3-26 350 32-65018 1.7-33 450 42-84022 2-40 550 50-1000

CON-5505 18 1.3-25 450 32-64022 1.5-30 550 38-76026 1.8-37 650 45-90030 2-41 750 52-1050

DIAMETER DIAMETERINCH IPM MM MM/MIN

Capacities and Speed Ranges

IMPORTANT NOTICESaddle cut diameters should not exceed 2/3 the diameter of the pipe.The smallest size pipe that is practical is 12" (305 mm). (Example:8" (203 mm) hole maximum on a 12" (305 mm) pipe). Maximumdiameters practical will be reduced when bevel cuts are made. Theabove chart shows diameter for straight cuts.

1

2

45 6

3

1. BUG-5100-F drive unit provides the power with asolid-state variable speed control.

2. CON-3040, CON-4040, and CON-5040, carriageinsures accurate work paths by meshing firmlywith the gear. A quick-acting manifold with ashort connection hose, centering pin andcounter-balanced floating plate, for torch mounting, are mounted on the carriage.

3. This combination of modules provides accuratepositioning of the torch for saddle cuts andbevels. The guide wheel, diametrically oppositethe torch tip, maintains accurate nozzle-to-workdistance on symmetrically contoured vessels.

4. CON-3000, CON-4000, CON-5000 ring and gearassembly, with its perfectly round cut ring gear,makes every cut true.

5. Legs and alignment bars position machine on anysymmetrical steel surface.

6. CON-1010 outrigger support kit.

7. Center locator with stainless steel center pin.

NOTE: A cutting torch is not furnished with themachine unless specified separately.

CON-3CON-4CON-5

24" (610 mm)32" (813 mm)40" (1016 mm)

25-1

/2"

(648

mm

)33

-7/8

" (8

60 m

m)

42-1

/4"

(107

3 m

m)

CON-3CON-4CON-5

37" (940 mm)45" (1143 mm)53" (1346 mm)

19"(483 mm)

1-3/4"(45 mm)

A QUALITY PRODUCT FROM BUG-O SYSTEMS • 3001 WEST CARSON STREET • PITTSBURGH, PA USA 15204-1899Litho in U.S.A. LIT-CONO-BRO-0905A DIVISION OF WELD TOOLING CORPORATION © Weld Tooling Corp. ROM 1:16

ON PIPE AND PRESSURE VESSELS

AUTOMATIC CIRCLEBURNING AND WELDING

AUTOMATIC CIRCLEBURNING AND WELDINGON PIPE AND PRESSURE VESSELS

No Hose or Cable Wrapup Regardless of Direction of Rotation.Oxy-Fuel Cutting Units. Plasma Cutting Units. Welding Units.

CYPRESS WELDING EQUIPMENT INC.A DIVISION OF WELD TOOLING CORPORATION

280 Technology Drive • Canonsburg, PA USA 15317-9564Telephone: 1-412-331-1776 • 1-800-245-3186 • Fax: 1-412-331-0383

www.cypressweld.com

2

Cypress Makes The …

Wire reel adaptor for 30 lb. (13.6 kg) spools onCW-5s. 60 lb. (27 kg) wire reels included onCw-7s and 11s.

Torch angle adjuster (optional on CW-5)standard on all other machines.

Racking groups for horizontal and verticaladjustment of the welding gun. Motorizedracking is available.

Welding gun and cable assembly.

Rise and fall cam, raises and lowers the torchto follow the contour of the pipe or vessel.

For sub-arc applications, a 25 lb. (11 kg) fluxhopper is included on the CW-5AX, CW-7sand CW-11s.

Strong permanent magnet motor and gear traininsure smooth movement of the welding torch.

Electric oscillatorsare available.

3

Weld Go Round.

Rotation Speed Control.Direction and On-Off Switch.

Volt meter and amp meter, allow the welder tocontrol the weld parameters at the machine.(optional on the CW-5, included on all othermodels).

Welding controls: manual/automatic weld/rotation switch, cold wire inch, purge switch,wire up-down switch, wire feed speed,burnback control and preflow-postflow times.

Collector rings and brushes for rotation andcontrols.

Collector rings and brushes, for welding current.

Wire feed motor.(See chart for wire sizes page 5.)

3 jaw expandable chuck, 3 sizes available. Positions themachine on the nozzle.

No hose or cable wrap-upregardless of the direction of rotation!

4

Circle Welders

The CW-5AX (CWO-1560) Circle Welder is designed forsingle pass or multi pass welding of couplings and nozzleson pipe and vessels. The unit is available for Sub Arc, MIG orFlux Cored process.

The CW-5AX offers all the same features as the CW-5but in addition incorporates a meter kit, torch angle adjusterand flux hopper.

CW-5 (CWE-1500) Circle Welder with Remote Control.The CWE-1500 is designed for single or multipass welding ofcouplings or nozzles on pipe and vessels utilizing MIG or FluxCore process, with gas shield. The machine is equipped withits own wire feeder, rotation drive motor, rise and fall camassembly and welding gun. Horizontal and vertical racking toposition the torch and a 30 lb (14 kg) spool holder.

The remote control box has a digital readout for rotation speed.It also has controls for: wire feed speed, cold inch/purge, pre-flow and post-flow, burn back and wire feeder forward andreverse. Overlap is also adjustable. This control has both manualand automatic settings. In the manual setting, you can checkall your controls and travel speed to make sure the machineis functioning properly. In the automatic setting, with one pushof a button, the unit will start the weld process, weld completelyaround the workpiece, overlap the end of the weld, turn theweld off and return to the start position. It is ready for the nextweld. The CW-5 is supplied with the following cables: 50'' (15.2m) of gas hose, 50'' (15.2 m) hot lead, 50'' (15.2 m) controlcable and all cables from the remote box to the circle welder.

The CW-5 (CWO-1500) Circle Welder has the same featuresas the CW-5 with Remote (CWE-1500). All controls for thismodel are located on the machine.

CW-5

CW-7 Circle Welder (CWO-1700) is equipped for MIG,Flux Core and Sub Arc welding on vessels and domedheads. The CW-7 has a working range of 6"-24" (152-610mm) O.D. nozzles with no cable wrap up for multi-passwelding. This unit is capable of using welding wire sizesfrom .035"-3/32" (.8-2.4 mm).

The machine is equipped as shown and will carry 60 lbs.(27 kg) spools of wire. The unit is complete with wirefeeder, gun and cable assembly, flux hopper, wire reeland meter kit. Mounts on 3-jaw chuck. (See chart belowfor welding capacities).

CW-7

CW-5 withRemote

CW-5AX

5

Circle Welders

Circle Welder Capacities

CW-11 CircleWelder (CWO-1100) is equippedfor MIG, Flux Coreand Sub Arcwelding on largevessels, domedheads and flatsurfaces. TheCW-11 has aworking range of10"-50" (254-1270 mm) O.D.nozzles with nocable wrap up form u l t i - p a s swelding. Remotecontrol of ampsand volts. The unitis capable ofusing welding wirediameters from.035''-1/8'' (.8-3.2mm).

CW-18 Circle Welder (CWO-1800) isdesigned for welding of nozzles into vesselsor domed heads utilizing SUB-ARC. The CW-18 mounts on a 3-Jaw Chuck welding diameter6" to 50" (152-1270 mm) O.D. It is capable ofusing welding wire diameters 3/32-7/32'' (2.4-5.6 mm).

CW-18

Model Process Welding Welding Rotation Rise and Rating Standard EquipmentCapabilities Diameter Wire Size Speeds Fall Cam amps

CW-5CWO-1500

MIG/MAG, 1-12" .035-1/16" 3-130 ipm 0-5" 300 amps Burn back control, horizontalCW-5 FCAW (25-300 (.8-1.6 (75-3300 (0-125 100% duty and vertical adjustmentW/Remote mm) mm) mm/min) mm) cycle gun and cableCWE-1500

CW-5AX MIG/MAG, 1-12" .035-3/32" 3-130 ipm 0-5" 500 amps Same as CW-5 plus: meterCWO-1560 FCAW, SAW (25-300 (.8-2.4 (75-3300 (0-125 100% duty kit, torch angle adjuster,

mm) mm) mm/min) mm) cycle flux hopper, nozzle and cone.

CW-7 MIG/MAG, 6-24" .035-3/32" 4-137 ipm 0-7" 500 amps Burn back control, horizontalCWO-1700 FCAW, SAW (150-600 (.8-2.4 (100-3500 (0-175 100% duty and vertical adjustment gun

mm) mm) mm/min) mm) cycle and cable.

CW-11 MIG/MAG,. 10-50" Solid Wire .06-72 ipm 0-7" 500 amp CO2

Burn back control, horizontalCWO-1100 FCAW, SAW (254-1270 .035-1/8" (0.8-3.2 mm) (0-175 mm) 400 amp and vertical adjustment gun

mm) (.8-3.2 mm) mixed gases and cable.60% dutycycle

Flux CoredWire.068-.120"(1.7-3.0 mm)

CW-18 SAW 10-50" Solid Wire .06-72 ipm 0-7" 60% duty Burn back control, horizontalCWO-1800 (254-1270 3/32-7/32" (0.8-3.2 mm) (0-175 mm) cycle and vertical adjustment gun

mm) (2.4-5.6 mm) and cable.

NOTE: Welding diameter capacities cannot exceed two thirds diameter of the workpiece.

CW-11

66

Circle Welders

CWO-3670 Step Adaptor for Threaded OutletsA stepped centering device used to center the machine onthreaded I.D. weld-o-lets. The range of the Step Adaptor is1/2" to 4" (13-102 mm) diameter.

CWO-3675 Step Adaptor for Grooved Outlets1 1/4" - 1 1/2" - 2" - 2 1/2" - 3", 4"

CWO-5790 Cone AdaptorA tapered centering devise used to center themachine on nozzles. The range of the ConeAdaptor is 1-1/4" to 4" (32-102 mm) diameter.

Accessories

CWO-3660 Lathe Chuck2"-10" (50-254mm) lathe chuck for small fittingsand nozzles.

3-Jaw Expandable ChuckMounts and automatically centers the Circle Welder on nozzleswith or without flanges. For use with all circle welders.

Chucks

PART NO. FOR NOZZLE I.D.’s WEIGHTCWO-3660 2"-10" (50-254 mm) 69 lbs. (31.3 kgs)CWO-3661 8"-16" (204-405 mm) 36 lbs. (16 kgs)CWO-3662 10"-24" (255-610 mm) 51 lbs. (23 kgs)CWO-3663 24"-42" (610-1065 mm) 64 lbs. (29 kgs)

CWO-3023-1 Torch Angle AdjusterAllows the operator to adjust the angle of thegun precisely, without unclamping the holdingdevise.

CWO-1645 Torch WeaverProvides a pendulum-type motion to the gunfor weave welding. The speed and stroke ofoscillation are adjustable.

7

Circle Welders

CWO-4530 CarriageMay be used only with CW-5 CIRCLE WELDERS. The car-riage, which is mounted on a standard monorail, is used tomove the welder along a length of pipe.

Carriages

CWO-4540 CarriageThis carriage, which is mounted on a standard monorail, isused with the CB-1P AIR PLASMA MACHINE. A winch holdsthe machine and prevents the machine from falling into thehole when the slug drops. This carriage may also be usedwith CW-5 CIRCLE WELDERS.

CWO-4550 Motorized CarriageMay be used with either the CW-5 CIRCLE WELDER or theCB-1P AIR PLASMA MACHINE. Provides motorized verticaltravel of the machine.

CWO-2020 Submerged Arc Flux Recovery SystemContinuously removes and recycles all unused flux. Avail-able on any CW-5AX, CW-7, CW-11 and CW-18.

Flux Recovery System installed on a CW-11.

8

Circle Burners

CB-3 Circle Burner (CBO-3000)Uses oxyfuel for square or beveled hole cuts (see chart forcapacities). Unit includes 2-hose oxy-fuel machine torch,adjustable tip adaptor, variable speed rotation, vertical andhorizontal torch adjustment and rise and fall cam. The CB-3must be mounted on a column and boom, manipulator or fixture.

Model Burning Mounting Process Rise and Fall Net UseDiameter Cam Weight

CB-2 1.5"-42" beveled holes manually oxyfuel 0-7" 225 lbs. vessels, large diameter pipe(40-1066 mm) operated (0-175 mm) (102 kg)4"-48" square cut magnet(100-1220 mm)

CB-3 1.5"-42" beveled holes carriage or oxyfuel 0-7" 170 lbs. domed heads, vessels, large(40-1066 mm) manipulator (0-175 mm) (77 kg) diameter pipe, flat plate4"-48" square cut(100-1220 mm)

CB1P .5"-12" beveled holes manually plasma 5" 170 lbs. vessels, large diameter pipe(11-300 mm) operated (127 mm) (77 kg)

magnet

Circle Burner Capacities

NOTE: Burning diameter cannot exceed two thirds diameter of the workpiece.

CB-2 Circle Burner (CBO-2000)Uses oxyfuel for square or beveled hole cuts (see chart for capacities).The CB-2 is mounted on a special frame with a releasable permanentmagnet base. Machine includes variable speed rotation, 2-hose oxy-fuel machine torch, adjustable tip adaptor, vertical and horizontaltorch adjustment and rise and fall cam.

CB-1P Plasma Circle Burner, for cutting beveledholes in lightwall pipe or vessels with wall thicknessesup to 3/8" (7 mm). This machine is supplied with aThermal Dynamics air plasma power source, torch and50' (15 m) leads. The unit operates on 220/50-60/1power (3 phase also available). The CB-1P must bemounted on a carriage or fixture.

CB-1P (CBO-1020) Plasma Circle Burner

CB-3CB-2

CB-1P

9

Saddle and Elbow Cutters

The MM1 is a computer controlled machine that automates the cutting of profiles, holes and shapes on pipe with diametersfrom 4"-16" (100-400 mm). It rotates the pipe on it’s roller bed with a three jaw chuck while simultaneously moving a cuttingtorch back and forth along the pipe’s axis. Pre-programmed shapes such as saddle, hillside, lateral and miter cuts can bemade by simply selecting the type of cut from the menu, then entering the diameters of the pipe being processed and pressingthe run button to cut your pipe.

*Oxy-fuel versions are available.*Optional: Machine cutting capacity can be increased to 24" (610 mm) diameter at factory.

MM1 Programmable Pipe Cutter (SEO-3500)

10


NOTE: SEO series machines do notinclude torch or plasma machine.

The SE-2PTD and SE-4PTD provide dual programmingcapabilities. A “Pipe” program for making Saddle Cuts,Offset Cuts, Laterals and Miters. A second (selectable)program is used for cutting customized shapes in pipe.Both are suitable for plasma and oxy-fuel cutting andeliminates the need to make templates or layoutcomplex cuts.

SE-2PTDSEO-4250-OX Oxy-Fuel VersionSEO-4250-PL Plasma Version

SE-4PTDSEO-4400-OX Oxy-Fuel VersionSEO-4400-PL Plasma Version

Programmable SE-2PTD andSE-4PTD Pass Through Machines

The SE-4PD is a programmable machine. It will cutsaddles, laterals, miters, offsets (hillsides) and elbowsusing a micro-processor and handheld terminal. Oxyfuelor Plasma may be used. Cutting diameter 1"-12" (25-300 mm). (Maximum length of pipe to be cut, 18" [450mm]).

The maximum rotation speed is 3.7 rpm, which is 47ipm (1160 mm/min) on 4" (102 mm) O.D.’s.

SE-4PD Programmable Saddle andElbow Cutter.

SEO-4520-OX Oxy-Fuel VersionSEO-4520-PL Plasma Version

Model Process Pass Pipe Diameter Speed Range of Pipe LengthsThrough Range Rotation that can be Cut

SE-2PTD Plasma or 1" - 4" 1" - 14" .3 3"-18"Oxyfuel (25 - 102 mm) (25 - 356 mm) 3.7 rpm (76 - 457 mm)

SE-4PD Plasma or N/A 1" - 12" .3 3"-18"Oxyfuel (25 - 305 mm) 3.7 rpm (76 - 457 mm)

SE-4PTD Plasma or 4" - 12 3/4" 4" - 20" .2 3"-20"Oxyfuel (102 - 324 mm) (102 - 508 mm) 3 rpm (76 - 508 mm)

MM1 Plasma or N/A Standard Machine 4"-16" .2 3"-38 ft.Oxyfuel (102 - 406 mm) 3 rpm (76 mm - 11.6 m)

Optional 4"-24" (102 - 610 mm)

Saddle and Elbow Cutter Capacities:

SEO-4400-3 AXISSE-4PTD with third axis option as shown on left.

An additional third axis-torch rotation is available. Theprogrammed torch rotation only works with cuts:1, 2, 4 and 5(see page 11).

11


Hand Held Terminal:

OFFSETSADDLE

NOZZLE CUTS(Hillside)

Capabilities

TYPE 3

TYPE 1

TYPE 2

LATERAL NOZZLECUTS

MITER CUT

TYPE 4SADDLE NOZZLE

CUTS

HOLE CUTTINGAT VARIOUSANGLES

TYPE 5

SHAPE PROGRAMCUSTOM IRREGULARSHAPES

1. Press the reset button on the machine. Thehand held terminal will display “READY”.

2. Press “A” on the terminal. The terminal willask you what type of cut you want. (See Types1-5).

3. Press the number desired and then press“ENTER”.

4. The terminal will ask for the diameter of thesmall pipe. Press the appropriate dimen-sions and press “ENTER”.

5. The terminal will ask for the diameter of thelarge pipe. Press the appropriate dimensionsand press “ENTER”.

6. Enter the offset dimension.

7. Enter the “ANGLE” in degrees.

8. Press “START” on the machine to begin thecut. It couldn’t be easier!

When using Plasma, press “B” and enter thetime delay required (which is stored untilchanged again).

Example: Programming Sequence for Type 3 Cut.

6

Sprinkler Fabrication Equipment

Position your pipe and move the CB-1P along the pipe to cutsmooth, accurate holes. Position the CW-5 with a step adapteron the fitting and make the contour weld.

The approximate time for a cut is 6-10 seconds, dependingupon diameter and thickness. The approximate time for a weldis 15-20 seconds. For detailed information please ask for ourspecial sprinkler brochure.

Sequence of Operation

CYPRESS WELDING EQUIPMENT, INC.A DIVISION OF WELD TOOLING CORPORATION

280 Technology Drive • Canonsburg, PA USA 15317-9564Telephone: 1-412-331-1776 • 1-800-245-3186 • Fax: 1-412-331-0383

LIT-CGB-BRO-0308


http://www.cypressweld.com

TYPICAL SET UP FOR SPRINKLER FABRICATION

3/4" x 6" x 26" Bar(19 x 152 x 660 mm)

Tack Weld 1/8" x 1"(3x25 mm) longon 16" (406 mm)centers top & bottom

8" (203 mm)

1-1/2" (38 mm)Pipe

5.31"(135 mm)1" (25 mm)30" (762 mm)

36" (914 mm)

40" (1 m)

22"(559mm)

WeldingPowerSource

5" (127 mm)Pipe

1-1/2" (38 mm) Pipe

Welder

3/8" (9.5 mm) x 3"(76 mm) Flat Bar

4" x 8" x 1/4"(102 x 203 x 6 mm) WallRectangular Tubing

8" (203 mm) Pipe

10 Harness snaps withswivel eyes to supportcables and hoses.

Length of Pipe + 6' (1.83 m)

Eye Bolt1/4" (6 mm)Cable

Burner

3" (76 mm)Pipe

Pipe ViseCast IronFlanges

PlasmaPower Source

5'(1.5 m)

6'(1.8 m)

8'(2.4 m)

6'(1.8 m)

5'(1.5 m)

76"(2 m)

The BUG-O DC IV is a dual speed range, positive rack & pinion drive, ready for mounting welding orcutting attachments and accessories. It consists of a DC IV Drive unit mounted on a 12" (305 mm)Carriage. This unit runs on standard Aluminum Rigid Rail & Aluminum Flex Rail.

PATENTS WORLDWIDE

Powerful Solutions For Welding And Cutting Automation.

Powerful Welding Travel CarriagesWill Handle The Toughest Applications.The DC IV Tractor is the basic drive for many Bug-O systems.There are six speed ranges available on the DC IV.



BUG-O DC IV

Features:Two pinion gears are provided. The factoryinstalled pinion engages the bull gear toprovide a high torque, low speed range (A).The user can easily install the alternatepinion to bypass the bull gear and obtain alow torque, high speed range (B).

C. Wing nut locks clutch.

D. Cam Clutch engages anddisengages the drive.

E. Power Cord.

F. Power Indicator Light.

G. Forward-Off-Reverse Switch.

H. Infinitely variable speedcontrol.

J. Circuit Breaker.

K. Carriage.

Dimensions:

Technical Data:

PowerRequirement: -60 watts at rated voltage:

DC IV: BUG-034_ 120 VAC/50-60/1BUG-044_ 240 VAC/50-60/1BUG-054_ 42 VAC/50-60/1

Net Weight: 18 lbs. (8 kg)

ShippingWeight: 20 lbs. (9 kg)

Drive Load Chart

Pinion Gear Speed Range Vert. Load GearUsed in/min mm/min LBS. KG Ratio 120/50-60/1 240/50-60/1 42/50-60/1

Low Speed 1.5-30 38-750 50 2250:1 BUG-0343 BUG-0443 BUG-0543

High Speed 8-160 200-4000 3 1.4

Low Speed .7-15 19-380 75 34100:1 BUG-0345 BUG-0445 BUG-0545

High Speed 4-80 100-2000 15 7

Low Speed .5-10 12-255 100 45150:1 BUG-0346 BUG-0446 BUG-0546

High Speed 2-50 50-1250 30 14

Continuous Model Number

CD

K

E

G

H

JF

B

A8.13"

207 mm

12"305 mm

8.13"207 mm

A QUALITY PRODUCT FROM BUG-O SYSTEMS • 280 TECHNOLOGY DRIVE • CANONSBURG, PA 15317-9564 USALitho in U.S.A. LIT-DCIV-BRO-0708A DIVISION OF WELD TOOLING CORPORATION © Weld Tooling Corp. ROM 1:16

Flexible Automation of Cutting& Welding Applications

Flexible Automation vonSchweiß- und Schneidarbeiten

Automatización flexible paracorte y soldadura

Automatisation Flexibled’applications de Soudure etde Coupe

Plug in a Bug-OFor more detailedinformation on anyproduct, visit ourwebsite where youcan download a fullproduct brochure.

Phone: 1-412-331-1776Fax: 1-412-331-0383

www.bugo.com

OVERLAY SYSTEMCustom ConfiguredSystem for Rebuildingand Resurfacing Materialsuch as Vessel Walls andBoiler Tubes.110, 220 or 42 voltTravel Speed: 50-3000 mm,

2-20 ipmAvailable in Programmableor Manual IndexingVersions and WorkingEnvelopes.

BUG-O GANTRYWELDING SYSTEMCustom DesignedSystems for a Varietyof Applications such asSeam Welding andBeam Fabrication.

BUG-O GANTRYSIDE BEAMCARRIAGECustom DesignedSystems for a Varietyof Applications suchas Seam Welding andBeam Fabrication.

Fixture Building Equipment& Complete Fixtures

A QUALITY PRODUCT FROM BUG-O SYSTEMSA DIVISION OF WELD TOOLING CORPORATION Litho in U.S.A.

• 280 TECHNOLOGY DRIVE • CANONSBURG, PA 15317 USA© Weld Tooling Corp. LIT-BRO-ESS-1208

For more information visit our website at:www.bugo.com

ROM 1:16

2

MM1Programmable PipeCutter With Pipe Bed120 or 220 VACCutting Diameters100-400 mm, 4"-16"Pipe Length Capacityup to 9.14 m, 30'Process: Oxyfuel or

PlasmaCutting Diameter:

100-400 mm, 4"-16" O.D.

Cypress Pipe Cutting& End Preparation Units

Capabilities of Cypress Pipe Cutting & EndPreparation Units. Pre-programmed andCustom Cuts.

TYPE 1

SaddleNozzleCuts

TYPE 2OffsetSaddleNozzleCuts(Hillside)

TYPE 4

MiterCut

TYPE 5HoleCuttingat VariousAngles

ShapeProgramCustomIrregularShapes

TYPE 3LateralNozzleCuts

15

Six Ways Automating Your Welding& Cutting Can Save You Money!

IncreaseProductionThe machine replacesthe operator's hand tocontrol the process.

Improve QualityPrecise speed and path controlimprove appearance and quality.

Reduce MaterialHandling

Take the small light-weight machine to

the work. Workin all positions.

Reduce DistortionProvides uniform heat input, puts the right amount ofweld in the right place.

Improve Worker'sEnvironmentKeeps the worker further awayfrom the arc and reducesoperator fatigue.

AdaptableFlexible Modular Construction that adapts to your job.

314

SE-2 PTDPROGRAMMABLEPIPE CUTTER / PASSTHROUGHPass Through PipeCutting Diameters25-100 mm, 1"-4"External Chuck of 100-355 mm, 4"-14"120 or 220 VACProcess: Oxyfuel or

PlasmaNet Weight: 157 kg,346 lbs.

SE-4PDPROGRAMMABLE PIPECUTTERCutting Diameters:

25-300 mm. 1"-12"Maximum Pipe Length:

450 mm, 18"115 VACProcess: Oxyfuel or

PlasmaWeight: 91 kg, 201 lbs.

SE-4PTDPROGRAMMABLE PIPECUTTER / PASSTHROUGHPass Through PipeCutting Diameters:

100-325 mm, 4" to 12-3/4"External Chuck up to

500 mm, 20"120 or 220 VACProcess: Oxyfuel or



MINI VERT IIICompact Fillet WelderBattery Powered4 Wheel Drive110 or 220 volt chargerSpeed: 100-990 mm/min.

3.9-39 ipmWeight: 7.2 kg, 16 lbs.

BUG-GY-VERT IIFillet Welderwith OscillationBattery Powered4 Wheel Drive110 or 220 volt chargerWelds in all PositionsSpeed: 50-760 mm/min.

2-30 ipmWeight: 14 kg, 28 lbs.

BUG-GYFillet Welder withProgrammable StitchWelding and ReverseCrater FillOptional Dual TorchAttachment Available110, 220 or 42 voltSpeed: 101-1524 mm/min.


Trackless Mechanizationfor Cutting & Welding

4 13

CB-1PPlasma Circle BurnerFor Cutting BeveledHoles 11-300 mm,1/2"-12" in Pipe up to7 mm, 3/8" WallThicknessIncludes Plasma PowerSource. 60% Duty CycleRise and Fall Cam:

127 mm, 5"Speed: .2-11 rpmWeight: 77 kg, 170 lbs.

CB-2Circle Burner withMagnetic BaseCutting Diameter:40-1066 mm, 1.5"-42"

beveled holes100-1220 mm, 4"-48"

square cutProcess: OxyfuelRise and Fall Cam:

0-175 mm, 0-7"Weight: 102 kg, 225 lbs.

Cypress Circle Cuttersand Welders

CIRCLE WELDERSNozzle Welding UnitsAvailable for MIG/MAGand Submerged Arc.Multiple Versions Availablefor Nozzle Diameters of25-1270 mm, 1"-50". ForMulti-pass and Multi-layerWelding.

UNI-BUG IIIProgrammable StitchWelder. Runs Directly onthe Work Piece. CarriageOptions for the followingstructural profiles:• Flat Bar • Bulb Angle• T Profiles • L Profiles110, 220 or 42 voltSpeed: 102-1905 mm/min.

4-75 ipmWeight: 8.2 kg, 18 lbs.

STIFFENER WELDERDual Sided Fillet Welderwith Wire Feeders andProgrammable StitchFunctionStiffener Capacities:

102-457mm, 4''-8'' High102-305mm, 4''-12'' Wide

Speed: 0-900 mm/min. 0-36 ipm

Weight: 113 kg, 250 lbs.


SUB-ARC TRACTORHeavy Duty Submerged-arctractor for fillet and buttjoints. Optional flux recoveryunit is available.4 Wheel DriveSpeed: 127-2,540 mm/min.


AUTOMATICGIRTH WELDERSelf-propelled submergedarc welding system.Applicable for bottom-upor jack-up constructedsingle or double wallstorage tanks.Speed: 10-290 cm/min.

4-114 ipm

512

DC HOB-O HOLEBORERLightweight PrecisionHole Borer, Bevelerand Welder.120, 240 and 42 VoltCutting Diameter:

25-1200 mm, 1''-47''Weight: 13.6 kg, 30 lbs.

CIR-O IIIPrecision Circle Burner,Beveler and Welder.120, 240 and 42 VoltCutting Diameter:

75-1422 mm, 3''-56''Weight: 48 kg, 106 lbs.

CIR-O IVPrecision Circle Burner,Beveler and Welder.120, 240 and 42 VoltCutting Diameter:

75-1626 mm, 3"-64"Weight: 65 kg, 143 lbs.

CIR-O VPrecision Circle Burner,Beveler and Welder.120, 240 and 42 VoltCutting Diameter:

75-1830 mm, 3"-72"Weight: 90 kg, 198 lbs.

Hole & Circle Cutters

PIPE-BUGChain Driven PipeCutting MachineManually Driven orMotorized, 110 or 220 voltPipe Capacities: 76mm+

3''+Weight:(Manual) 16 kg, 34 lbs(Motorized) 26 kg, 56 lbs

GO-FER CUTTINGKIT-OXY-FUELStraight Line Cutting andBeveling for Oxy-Fuel120, 240 or 42 voltSpeed: infinitely variable

from 200-2500 mm/min.8-100 ipm

Weight: 17.7 kg, 39 lbs.

GO-FER WELDINGKITStraight Line Semi-Automatic Welding120, 240 or 42 voltSpeed: infinitely variable



GO-FER CUTTINGKIT-PLASMAStraight Line Cutting andBeveling Machine forPlasma120, 240 or 42 voltSpeed: infinitely variable



Straight Line Cutting& Welding with Rails

6 11


MDS-1050Machined RackCutting Group

MDS-1040Machined RackWelding Group

PAN-1000PanographTorch Floater

PAN-1008Welding Panograph

SUPPORTS & ACCESSORIES

MDS-1075Dual Torch WeldingGroup

MDS-1090Dual Torch CuttingGroup

PAN-2145-L, RMechanical CornerFollower

PAN-2160Mechanical SeamFollower

PAN-1072Double TorchPanograph

TRAC-BUGOXY-FUELStraight Line TrackBurning Machine forOxy-Fuel120, 240 or 42 voltSpeed: infinitely variable



MODULAR DRIVESYSTEMStraight Line Welding110, 220 or 42 voltRuns on all types ofBug-O RailSpeed: 51-3048 mm/min


TRAC-BUG-PLASMAStraight Line TrackBurning Machine forPlasma120, 240 or 42 voltSpeed: infinitely variable




710

Releasable CarriageMPD-1065

Hi-Flex CarriageFMD-1105

Swivel MagnetFor Rigid RailARM-2325

Magnet w/ReleaseFor Semi-Flex RailARM-2425

On/Off MagnetFor Rigid RailARM-2500

Screw FeetAssembliesFor Bent RailARM-2380

Vacuum BarAssemblyFor Nonferrous MaterialARV-1036

Vacuum Pump KitARV-20201100 Volt/50-60 Hz

ARV-2030220 Volt/50-60 Hz

Carriages - Rails - MagnetBars - Vacuum Support

UNIVERSALBUG-O-MATICCompact Drive andWeaver Combination.Adapts to all Bug-O Rail.120, 240 or 42 VoltsSpeed: 70-1670 mm/min.


MODULAR DRIVESYSTEMLinear Weaver110, 220 or 42 VoltAdapts to all Bug-O Rail.Speed: 51-3048 mm/min


MODULAR DRIVESYSTEMPendulum Weaver110, 220 or 42 VoltAdapts to all Bug-O RailSpeed: 51-3048 mm/min


Straight Line Weldingwith Oscillation

8 9

Rigid RailsHeavy DutyARR-10802.37 m, 8' long sections

ARR-10851.18 m, 4' long sections

Extra Heavy DutyARR-12502.37 m, 8' long sections


Semi-FlexFlexes to 5 m, 15' RadiusAFR-30002.4 m, 8' long sections

Hi-FlexFlexes to 760 mm, 30''RadiusFMD-10501.47 m, 57.7'' longsections

Ring RailsMinimum Work Diameterof 230 mm, 9''BRR-11801.20 m - 6.23 m3'-11'' - 21'-5''


Special Units

PORTABLE PLATEBEVELING MACHINEMachines bevel angles onplate120 or 220 voltChamfering capacity up to

3/4'' (20 mm)Adjustable bevels from 30°

to 60°Weight: 19 kg, 42 lbs.

PROGRAMMABLESHAPE MACHINE2 Axis PortableProgrammable Cuttingand Welding Machine120, 240 and 42 voltSpeed: 63-1250 mm/min

2.5-50 ipmNet Weight: 17 kg, 37 lbs.

PROGRAMMABLEGANTRY SYSTEM2 Axis Cutting Machine120 or 240 VoltAvailable in 2451 mm

(97''), 3048 mm (120'')and 3632 mm (143'')widths.

Process: Oxyfuel orPlasma

Speed: 100-2000 mm/min4-80 ipm

8 9

Rigid RailsHeavy DutyARR-10802.37 m, 8' long sections


Extra Heavy DutyARR-12502.37 m, 8' long sections


Semi-FlexFlexes to 5 m, 15' RadiusAFR-30002.4 m, 8' long sections

Hi-FlexFlexes to 760 mm, 30''RadiusFMD-10501.47 m, 57.7'' longsections

Ring RailsMinimum Work Diameterof 230 mm, 9''BRR-11801.20 m - 6.23 m3'-11'' - 21'-5''


Special Units

ARC GOUGINGSYSTEMAutomatic GougingSystem. Automatic feedof jointed carbon rods.120 VoltSpeed: 51-3048 mm/min.

2-120 ipmWeight: 127 kg, 57.5 lbs.

PROGRAMMABLESHAPE MACHINE2 Axis PortableProgrammable Cuttingand Welding Machine120, 240 and 42 voltSpeed: 63-1250 mm/min

2.5-50 ipmNet Weight: 17 kg, 37 lbs.

PROGRAMMABLEGANTRY SYSTEM2 Axis Cutting Machine120 or 240 VoltAvailable in 2451 mm

(97''), 3048 mm (120'')and 3632 mm (143'')widths.

Process: Oxyfuel orPlasma

Speed: 100-2000 mm/min4-80 ipm

710

Releasable CarriageMPD-1065

Hi-Flex CarriageFMD-1105

Swivel MagnetFor Rigid RailARM-2325

Magnet w/ReleaseFor Semi-Flex RailARM-2425

On/Off MagnetFor Rigid RailARM-2500

Screw FeetAssembliesFor Bent RailARM-2380

Vacuum BarAssemblyFor Nonferrous MaterialARV-1036

Vacuum Pump KitARV-20201100 Volt/50-60 Hz

ARV-2030220 Volt/50-60 Hz


UNIVERSALBUG-O-MATICCompact Drive andWeaver Combination.Adapts to all Bug-O Rail.120, 240 or 42 VoltsSpeed: 70-1670 mm/min.


MODULAR DRIVESYSTEMLinear Weaver110, 220 or 42 VoltAdapts to all Bug-O Rail.Speed: 51-3048 mm/min


MODULAR DRIVESYSTEMPendulum Weaver110, 220 or 42 VoltAdapts to all Bug-O RailSpeed: 51-3048 mm/min


Straight Line Weldingwith Oscillation

6 11


MDS-1050Machined RackCutting Group

MDS-1040Machined RackWelding Group

PAN-1000PanographTorch Floater


SUPPORTS & ACCESSORIES

MDS-1075Dual Torch WeldingGroup

MDS-1090Dual Torch CuttingGroup

PAN-2145-L, RMechanical CornerFollower

PAN-2160Mechanical SeamFollower

PAN-1072Double TorchPanograph

TRAC-BUGOXY-FUELStraight Line TrackBurning Machine forOxy-Fuel120, 240 or 42 voltSpeed: infinitely variable



MODULAR DRIVESYSTEMStraight Line Welding110, 220 or 42 voltRuns on all types ofBug-O RailSpeed: 51-3048 mm/min


TRAC-BUG-PLASMAStraight Line TrackBurning Machine forPlasma120, 240 or 42 voltSpeed: infinitely variable




512

DC HOB-O HOLEBORERLightweight PrecisionHole Borer, Bevelerand Welder.120, 240 and 42 VoltCutting Diameter:

25-1200 mm, 1''-47''Weight: 13.6 kg, 30 lbs.

CIR-O IIIPrecision Circle Burner,Beveler and Welder.120, 240 and 42 VoltCutting Diameter:

75-1422 mm, 3''-56''Weight: 48 kg, 106 lbs.

CIR-O IVPrecision Circle Burner,Beveler and Welder.120, 240 and 42 VoltCutting Diameter:

75-1626 mm, 3"-64"Weight: 65 kg, 143 lbs.

CIR-O VPrecision Circle Burner,Beveler and Welder.120, 240 and 42 VoltCutting Diameter:

75-1830 mm, 3"-72"Weight: 90 kg, 198 lbs.

Hole & Circle Cutters

PIPE-BUGChain Driven PipeCutting MachineManually Driven orMotorized, 110 or 220 voltPipe Capacities: 76mm+

3''+Weight:(Manual) 16 kg, 34 lbs(Motorized) 26 kg, 56 lbs

GO-FER CUTTINGKIT-OXY-FUELStraight Line Cutting andBeveling for Oxy-Fuel120, 240 or 42 voltSpeed: infinitely variable



GO-FER WELDINGKITStraight Line Semi-Automatic Welding120, 240 or 42 voltSpeed: infinitely variable



GO-FER CUTTINGKIT-PLASMAStraight Line Cutting andBeveling Machine forPlasma120, 240 or 42 voltSpeed: infinitely variable




4 13

CB-1PPlasma Circle BurnerFor Cutting BeveledHoles 11-300 mm,1/2"-12" in Pipe up to7 mm, 3/8" WallThicknessIncludes Plasma PowerSource. 60% Duty CycleRise and Fall Cam:

127 mm, 5"Speed: .2-11 rpmWeight: 77 kg, 170 lbs.

CB-2Circle Burner withMagnetic BaseCutting Diameter:40-1066 mm, 1.5"-42"

beveled holes100-1220 mm, 4"-48"

square cutProcess: OxyfuelRise and Fall Cam:

0-175 mm, 0-7"Weight: 102 kg, 225 lbs.

Cypress Circle Cuttersand Welders

CIRCLE WELDERSNozzle Welding UnitsAvailable for MIG/MAGand Submerged Arc.Multiple Versions Availablefor Nozzle Diameters of25-1270 mm, 1"-50". ForMulti-pass and Multi-layerWelding.

UNI-BUG IIIProgrammable StitchWelder. Runs Directly onthe Work Piece. CarriageOptions for the followingstructural profiles:• Flat Bar • Bulb Angle• T Profiles • L Profiles110, 220 or 42 voltSpeed: 102-1905 mm/min.


STIFFENER WELDERDual Sided Fillet Welderwith Wire Feeders andProgrammable StitchFunctionStiffener Capacities:

102-457mm, 4''-8'' High102-305mm, 4''-12'' Wide

Speed: 0-900 mm/min. 0-36 ipm



SUB-ARC TRACTORHeavy Duty Submerged-arctractor for fillet and buttjoints. Optional flux recoveryunit is available.4 Wheel DriveSpeed: 127-2,540 mm/min.


AUTOMATICGIRTH WELDERSelf-propelled submergedarc welding system.Applicable for bottom-upor jack-up constructedsingle or double wallstorage tanks.Speed: 10-290 cm/min.

4-114 ipm

314

SE-2 PTDPROGRAMMABLEPIPE CUTTER / PASSTHROUGHPass Through PipeCutting Diameters25-100 mm, 1"-4"External Chuck of 100-355 mm, 4"-14"120 or 220 VACProcess: Oxyfuel or

PlasmaNet Weight: 157 kg,346 lbs.

SE-4PDPROGRAMMABLE PIPECUTTERCutting Diameters:

25-300 mm. 1"-12"Maximum Pipe Length:

450 mm, 18"115 VACProcess: Oxyfuel or


SE-4PTDPROGRAMMABLE PIPECUTTER / PASSTHROUGHPass Through PipeCutting Diameters:

100-325 mm, 4" to 12-3/4"External Chuck up to

500 mm, 20"120 or 220 VACProcess: Oxyfuel or



MINI VERT IIICompact Fillet WelderBattery Powered4 Wheel Drive110 or 220 volt chargerSpeed: 100-990 mm/min.

3.9-39 ipmWeight: 7.2 kg, 16 lbs.

BUG-GY-VERT IIFillet Welderwith OscillationBattery Powered4 Wheel Drive110 or 220 volt chargerWelds in all PositionsSpeed: 50-760 mm/min.


BUG-GYFillet Welder withProgrammable StitchWelding and ReverseCrater FillOptional Dual TorchAttachment Available110, 220 or 42 voltSpeed: 101-1524 mm/min.



2

MM1Programmable PipeCutter With Pipe Bed120 or 220 VACCutting Diameters100-400 mm, 4"-16"Pipe Length Capacityup to 9.14 m, 30'Process: Oxyfuel or

PlasmaCutting Diameter:

100-400 mm, 4"-16" O.D.


Capabilities of Cypress Pipe Cutting & EndPreparation Units. Pre-programmed andCustom Cuts.

TYPE 1

SaddleNozzleCuts

TYPE 2OffsetSaddleNozzleCuts(Hillside)

TYPE 4

MiterCut

TYPE 5HoleCuttingat VariousAngles

ShapeProgramCustomIrregularShapes

TYPE 3LateralNozzleCuts

15

Six Ways Automating Your Welding& Cutting Can Save You Money!

IncreaseProductionThe machine replacesthe operator's hand tocontrol the process.

ImprovQualityPrecise speed and path controlimprove appearance and quality.

Reduce MaterialHandling

Take the small light-weight machine to

the work. Workin all positions.

Reduce DistortionProvides uniform heat input, puts the right amount ofweld in the right place.

Improve Worker'sEnviornmentKeeps the worker further awayfrom the arc and reducesoperator fatigue.

AdaptableFlexible Modular Construction that adapts to your job.

Flexible Automation of Cutting& Welding Applications

Flexible Automation vonSchweiß- und Schneidarbeiten

Automatización flexible paracorte y soldadura

Automatisation Flexibled’applications de Soudure etde Coupe

Plug in a Bug-OFor more detailedinformation on anyproduct, visit ourwebsite where youcan download a fullproduct brochure.

Phone: 1-412-331-1776Fax: 1-412-331-0383

www.bugo.com

OVERLAY SYSTEMCustom ConfiguredSystem for Rebuildingand Resurfacing Materialsuch as Vessel Walls andBoiler Tubes.110, 220 or 42 voltTravel Speed: 50-3000 mm,

2-20 ipmAvailable in Programmableor Manual IndexingVersions and WorkingEnvelopes.

BUG-O GANTRYWELDING SYSTEMCustom DesignedSystems for a Varietyof Applications such asSeam Welding andBeam Fabrication.

BUG-O GANTRYSIDE BEAMCARRIAGECustom DesignedSystems for a Varietyof Applications suchas Seam Welding andBeam Fabrication.


A QUALITY PRODUCT FROM BUG-O SYSTEMSA DIVISION OF WELD TOOLING CORPORATION Litho in U.S.A.

• 280 TECHNOLOGY DRIVE • CANONSBURG, PA 15317 USA© Weld Tooling Corp. LIT-BRO-ESS-1208

For more information visit our website at:www.bugo.com

ROM 1:16

Fixtures & PositioningEquipment from Bug-O Systems

Welding And Cutting SolutionsSince 1948

www.bugo.com

CDS-6350Stand Alone Linear Weaver

BUG-6350Stand Alone Pendulum Weaver

Positioning Equipment - Weavers

The Stand Alone Weavers are compact lightweight oscillating weld weavers designed to be mounted on Manipulators and Fixtures.They offer the ability to perform weave welds or straight-line stringer welds and can be used to steer the torch during weldingoperations. They also feature adjustable independent dwell settings for controlled penetration and undercut elimination.

TECHNICAL DATA:

Specifications:

Power Requirement:CDS-6350 120 VAC/50-60 HzCDS-6352 240 VAC/50-60 HzCDS-6354 42 VAC/50-60/1

Weave Speed: 4-100 ipm (102-2540 mm/min)

Dwell: 0-3 seconds each side

Weave Width: 0-2'' (0-50 mm)

Steering: 4'' - 2'' (100-50 mm)each side of center


Weaver Dimensions: 6.75''L x 5.00''W x 3.88''H(171 x 127 x 99 mm)

TECHNICAL DATA:

Specifications:

Power Requirement:BUG-6350 120 VAC/50-60 HzBUG-6352 240 VAC/50-60 HzBUG-6354 42 VAC/50-60/1





Net Weight of System: 21 lbs. (9.5 kg)


WeldContact Cable

Steering Knob

OscillationSpeed Control

OscillationWidth Control

RightDwell

LeftDwell

Power Switch

PatternSelection

WeldTriggerContactSwitch

A QUALITY PRODUCT FROM BUG-O SYSTEMS • 3001 WEST CARSON STREET • PITTSBURGH, PA USA 15204-1899A DIVISION OF WELD TOOLING CORPORATION © Weld Tooling Corp. ROM 1:16 Litho. in U.S.A. LIT-PE-BRO-1007

Welding Positioners Turning Roll Assembly• DC Drive protected against

high frequency.• Turn Table tilts from 0-1200.• Spindle has 1.38" through

hole for pipe work or gaspurge.

F

C

B

D

A

• DC Drive protected againsthigh frequency.

• Remote foot switch run/stopcontroller.

• Forward/stop/reverseswitch with potentiometerfor stepless speedadjustment.

Positioning Equipment

E

A

E

C

D

B

• 8 slot turntable providesquick mounting for holdingfixture.

• Timer controlled weldperiod.

• Includes foot pedal.

BPG-450L Chuck sold separately.Chuck capacity 1/4"-17 1/2" (4 mm-450 mm)

Part # Part #BPT-100A BPT-200A BPT-450M

Item BPT-100B BPT-200B

Power Input 1 Phase 110V 60 Hz 1 Phase 220V

Capacity (lb) (Horiz./Vert) 220/165 440/330 990/660

Rated Center of Gravity 4 2 (Max)

Rated Eccentricity (in) 4 6 (Max)

Table Dimension D (in) 12-5/8 17-11/16

Rotation Speed (rpm) A: 1~15/B: 0~4 0.12-2.5

Spindle Thru Hole (in) 1/1/2 1

Table Slot Bolt Size (in) 3/8 1/2

Earthing (amp) 300 300

Rotation Motor (hp) 1/20 1/12 1/6

Tilt Range (degree) 0-120 0-135

Welding Timer (second) 0-60 0-60

Overall Length A (in) 16-1/4 25

Overall Width B (in) 16-1/4 24

Overall Height C (in) 13-3/8 25

Center to Floor E (in) 10 21-1/4

Weight (lb/kg) A: 82/37 B: 88/40 280/127

Positioning Equipment

Torch SupportsFreestanding Torch Support

FTS-1020 & FTS-1025

Mini-MinipulatorBUG-1965

The Freestanding Torch Support FTS-1020 is a small manually operated torchmanipulator. Rack and pinion movement on hardened “V” ways provides effortlessand smooth positioning of cutting torch or welding gun. The “T” base comes withpre-drilled holes for quick installation into your fixture.

The NEW FTS-1025 Free Standing Torch Support with Automatic HeightControl is a compact, easy to use system, designed to maintain a constant torch-to-work distance automatically. This system can be used for Sub-Arc, Innershieldand MIG welding The actual weld current is sensed continuously using a shunt.The signal is filtered, amplified andcompared to a set point value. Anyerror from the set point is noticedby the controller and it will raisethe torch up or down to maintainprecise torch to work distanceautomatically.

Total VerticalAdjustment: 25'' (635 mm)

Total HorizontalAdjustment: 25'' (635 mm)

Net Weight: 35 lbs. (11.34 kg)40.42''

(1.03 m)

35.5''(902mm)

2 3

100''(2.54 m)

93-1/2"(2.37 m)

The MINI-MINIPULATOR II includes solid state variable speed, verticaland horizontal DC drives, pendant control of “up-off-down” and “forward-off-reverse,” limit switches on both drives, and a counterweight in columncenter. The base rotates 360 degrees.

TECHNICAL DATA:

Specifications:

Power Requirement:BUG-1965 120 VAC/50-60/1BUG-1966 220 VAC/50-60/1BUG-1967 42 VAC/50-60/1

Vertical Travel: 65'' (1651 mm)

Minimum Height: 21-1/2'' (546 mm)From Centerline of Horizontal Rail toMounting Surface (Floor)

Maximum Height: 86-1/2'' (2197 mm)

Horizontal Travel: 64'' (1626 mm)Measured from Centerline of Column toEnd of Horizontal Rail

Load Capacity: 20 lbs. (10kg)


Shipping Weight: 500 lbs. (227 kg)

Dimensions: 93-1/2''L x 15''W x 100''H(2375 mm x 380 mm x 2540 mm)

FTS-1020 shown above.

Application of FTS-1025 Automatic HeightControl with Linear Weaver shown above.

Part # Part #

Item BTR-0100 BTR-3504

Power Input 1 Phase 110V 60 Hz 1 Phase 220V 60 Hz

Turning Capacity (lb) 2200 7700

Load Capacity (lb)

(Drive & Idler) 2200 7700

Diameter Range, F (in) 1~31-3/8 3/8~55

Speed Range (in/min) 3-1/8~63 3~47

Rotation Motor (hp) 1/12 1/2

Roller Dia., D (in) 8 8

Roller Width, E (in) 2 4

Overall Length, A (in)

(Drive/Idler) 12-5/8 / 6-5/16 17/11

Overall Width, B (in)

(Drive Idler) 18-1/2 31-1/2/28

Overall Height, C (in) 13-5/16 20

Net Weight (lb)

(Drive/Idler) 81.5/37.5 242.3/121

Fixtures & PositioningEquipment from Bug-O Systems

Welding And Cutting SolutionsSince 1948

www.bugo.com

CDS-6350Stand Alone Linear Weaver

BUG-6350Stand Alone Pendulum Weaver

Positioning Equipment - Weavers

The Stand Alone Weavers are compact lightweight oscillating weld weavers designed to be mounted on Manipulators and Fixtures.They offer the ability to perform weave welds or straight-line stringer welds and can be used to steer the torch during weldingoperations. They also feature adjustable independent dwell settings for controlled penetration and undercut elimination.

TECHNICAL DATA:

Specifications:

Power Requirement:CDS-6350 120 VAC/50-60 HzCDS-6352 240 VAC/50-60 HzCDS-6354 42 VAC/50-60/1







TECHNICAL DATA:

Specifications:

Power Requirement:BUG-6350 120 VAC/50-60 HzBUG-6352 240 VAC/50-60 HzBUG-6354 42 VAC/50-60/1





Net Weight of System: 21 lbs. (9.5 kg)


WeldContact Cable

Steering Knob

OscillationSpeed Control

OscillationWidth Control

RightDwell

LeftDwell

Power Switch

PatternSelection

WeldTriggerContactSwitch

A QUALITY PRODUCT FROM BUG-O SYSTEMS • 3001 WEST CARSON STREET • PITTSBURGH, PA USA 15204-1899A DIVISION OF WELD TOOLING CORPORATION © Weld Tooling Corp. ROM 1:16 Litho. in U.S.A. LIT-PE-BRO-1007

FLAMECUTTING

HANDBOOK

Flame Cutting Handbook.p65 5/9/2007, 8:06 AM1

2


3

BUG-O SYSTEMSBUG-O Systems’ Kits are assembled from modularcomponents. Each kit was originally an adaptation tomeet an actual problem. The concept is both practicaland economical, and is quickly and easily adaptedon the job site.

Initially developed to carry cutting torches in a precisework path, the primary aim of the BUG-O System ismovement at controlled speed and direction in anyposition. The secondary function is to provide suitableholding or clamping devices to make BUG-O integralwith both the workpiece and the cutting or weldingtool.

BUG-O is more than a flame cutting system- it’s arevolution in welding procedures. Ingenious customershave developed hundreds of ways to cut time andcosts by putting this system to work for them, andmost of the these applications have saved the cost ofthe unit on the first job.

With BUG-O Systems you can double your weldingproduction!

The nucleus of the BUG-O System of modular pathand rate control components is the BUG-O. It is aself-propelled multipurpose carriage and rail systemwith infinitely variable speeds. A steel pinion mesheswith a machine-cut steel rack to provide a positivedrive. The BUG-O is locked onto a rail, which ismounted on the work.

The BUG-O unit is suitable for use with the mostadvanced electric welding processes. It is also thepractical way to carry any process requiring precisionmovement; in applications such as gouging, spraying,guiding ultrasonic inspection and others.


4

PRECISION HOLE BORING,BEVELING AND WELDING

HOB-O cuts, bevels or welds in any position….. anyplane or angle. Carry the tool to the work. HOB-Oweighs only 30 lbs. (18.6 kg)… can be moved andplaced in minutes by one man. Powerful magnetslock it to the workpiece …. exactly where you want it.Easily adjustable, the HOB-O flame bores holes from1'' to 8'' (25-200mm) diameter, inside the machineand 14-1/2'' to 48'' (368-1220mm) diameter, outside.Self-propelled, it has an infinitely variable speed controlto suit any application. HOB-O gives you the precisionof drilling … the speed of flame boring … and theconvenience of a portable tool costing less than one4'' high speed drill bit.


5

PREFACEThis booklet has been prepared to show how tooperate and maintain “Gas Cutting” equipment.Specifically, it shows how to set up, light, set travelspeed and position the “Cutting Torch” for a qualitycut.

WELD TOOLING CORPORATION. 2007

3001 WEST CARSON STREET

PITTSBURGH, PA 15204 U.S.A.

PHONE: (412) 331-1776

FAX: (412) 331-0383

For Additional Information Please

Go to Our Website: www.bugo.com


3001 WEST CARSON STREET PITTSBURGH, PA USA 15204 PHONE: 1-800-245-3186 www.bugo.com FAX: 1- 412-331-0383


6


7

INTRODUCTION

GAS CUTTING OF FERROUS(CARBON STEEL) METALS

Gas cutting is a process of preheating carbon steel toits combustion temperature, then burning it rapidly bymeans of a regulated jet of oxygen. A cutting torch isused for this operation.

The process is primarily a chemical one. It is basedon the chemical relationship of oxygen to iron metalsthat have been heated to a temperature of 1400° to1600° F (760° to 871° C). Only the metal within thedirect path of the oxygen jet is affected.

In cutting, a “kerf” is formed. This is a narrow slit havinguniformly smooth and parallel walls. A skilled workmanusing a BUG-O and a machine cutting torch canmaintain the following tolerances with respect tosquareness and straight alignment of the cut surface:1/32nd of an inch (.79mm) on plate thickness up to 4inches (100mm) and 1/16th of an inch (1.58mm) onplate thicknesses from 4 to 12 inches (100 to 300 mm).

In actual gas cutting, the iron or steel removed fromthe “kerf” is not entirely burned or consumed by theoxygen. About 30 to 40 percent of the metal is washedout of the cut as unconsumed or metallic iron due tothe eroding effect of the oxygen jet.


8


9

CONTENTS

BUG-O Systems ................................................. 3

HOB-O................................................................ 4

Preface ............................................................... 5

Introduction ......................................................... 7

Safety Instructions ........................................ 10-11

Instructions and Precautions for Gas Cutting

A. Safety ........................................................... 12

B. Burning Equipment ....................................... 12

1. Torches ................................................. 12

2. Hoses ................................................... 13

3. Regulators ............................................ 14

4. Tips ....................................................... 15

5. BUG-O Machine .................................... 16

C. Start-Up Procedure ....................................... 17

1. Hooking-Up ........................................... 17

2. Burning Tips .......................................... 18

3. BUG-O Machine .................................... 18

4. Lighting the Torch and Setting

the Preheat Flame ................................. 19

5. Adjusting the Preheat Flame

for Making a Square Edge Cut ............. 19

6. Starting Cut ........................................... 20

7. Observing the Cut ................................. 21

D. Procedure for Making a Starting Hole ........... 24

E. Observing a Cut Being Made ........................ 24

F. Bevel Cutting ................................................. 29

Cutting Notes .................................................... 33

Machine Cutting Tip Chart ................................. 34

LIT-FCH-IPM-0507


10

SAFETY INSTRUCTIONSEVERY TIME a machine cutting torch is used thefollowing safety and operation precautions MUST BEPRACTICED! Deviation from the following safety andoperation instructions can result in fire, explosion,damage to the apparatus or injury to the operator.

1. Inspect the inlet connections, valves, and torchhead for dirt, dust, oil, grease, or damaged parts.Dirt or dust can be removed with a clean cloth.DO NOT USE THE CUTTING TORCH IF OILOR GREASE IS PRESENT! Have yourmanufacturer’s repair center clean the torch orrepair any damage.

2. Inspect the torch head. The tapered seatingsurface must be in good condition. If dents, burrsor burned seats are present, the seat must beresurfaced. If the torch is used with poor settingsurface, backfire or backflash may occur anddamage the equipment.

3. Select the required size and type of cutting tip.Inspect the tip seating surface for damage.REMEMBER- these seating surfaces preventpremature mixing of gases that can cause fireand explosions. If the tapered seats on the tipare damaged, DON’T USE IT! Inspect the preheatand cutting oxygen holes. Spatter can stick on orin these holes but can be removed with a tipcleaner.

4. Insert the tip in the Cutting Torch head and tightensecurely.

5. Adjust the regulator delivery pressures accordingto the size and type of tip being used.

6. IMPORTANT: Always purge out the cutting oxygenpassages by opening the cutting oxygen valve(at least five seconds before lighting the torch.)Open the fuel valve approximately one-half turnand ignite the gas with a spark lighter. Adjust thefuel valve until the flame clears the end of the tipabout ½ inch (13mm), then reduce slightly toreturn the flame to the tip.


11

7. Slowly open the preheat oxygen valve until aneutral flame is established (a sharp inner cone).SPECIAL NOTE FOR TWO HOSE MACHINETORCHES ONLY: After the neutral flame hasbeen established as described, open the cuttingoxygen valve. Note that the preheat flameschange slightly from neutral to a carburizing flamewith a feather. With the cutting oxygen flowing,adjust the preheat oxygen valve until the preheatflames are again neutral.

8. If you experience a backfire or backflash (a hissingsound when the flame is burning inside the cuttingtorch) IMMEDIATELY turn off the preheat oxygenvalve, then shut off the torch fuel valve. Allow thecutting torch to cool before attempting to re-use it. Iftrouble persists, call your manufacturer’s repair center.

9. WHEN YOU FINISH YOUR CUTTINGOPERATION:a. First shut off the oxygen preheat valve, then

shut off the torch fuel valve. If this procedureis reversed, a “pop” may occur. The “pop”throws carbon soot back into the torch andmay in time partially plug it.

b. Close both cylinder valves.c. Open the torch oxygen preheat valve, and

release the pressure in the hose and regulator.Close the torch valve.

d. Turn the adjusting screw on the oxygenregulator counter-clockwise until the adjustingspring pressure is released.

e. Open the torch fuel valve and release thepressure in the hose.

f. Repeat “d” using fuel regulator.g. Close all valves on torch handle and the

cutting attachment.

NOTE: The use of Reverse Flow Check Valves isstrongly recommended to reduce the possibility ofmixing gases in the hoses and regulator. Mixed gaseswill rapidly burn once the torch is lighted. Thesecombustible gases can explode in the hoses, regulatorsor cylinders, resulting in serious injury to the operator.


12

INSTRUCTIONS AND PRECAUTIONSFOR GAS CUTTING

A. SAFETY

1. Before handling or using any flame cuttingequipment, understand and apply at all timesthe safe-practice instructions in this manual.

a. Be sure work areas are free of flammableand combustible or explosive materials.

b. Always wear protective personalequipment.

(1) A close-fitting hat with hair tucked in.

(2) Flame retardant clothing. Shirt- collarbuttoned close around neck; pocketswith flaps buttoned; full lengthsleeves, fastened at the wrist.Trousers- must cover top of shoes-no cuffs!

(3) Hightop work shoes.

(4) Approved eye protection.

(5) Leather work gloves.

B. BURNING EQUIPMENT

1. Torches

a. A 2- or 3-hose machine torch 8 to 15inches (203 to 381 mm) long is generallyused on BUG-O machines.

b. 3-hose torches are recommended forheavy cutting on steel thicknesses up to36 inches (914mm).

c. Torch valves, bodies and racks shouldbe in good condition and have no gasleaks.

(If a torch is damaged in any way, itshould be sent to the supplier for repair.)


13

2. HOSES

a. Use ¼ inch (6.4mm) twin and singlehose (red for gas and green foroxygen) with “B” size fittings. The(notched) fitting is for gas and thesmooth fitting is for oxygen.

b. Fitting should be clamped tightly sothere will be no gas or oxygenleakage. However, avoid stripping thethreads of the clamps and fittings.

c. Hoses with kinks, burned spots orsmall cuts are very dangerous, andwill affect the quality of the cut.

d. If hose is damaged, should be splicedor scrapped. NEVER USE TAPE TOSTOP A LEAK. It is dangerous, andcould cause a fire or explosion whichcould seriously injure the operator orothers.

e. For a three-hose torch, the oxygenhose has a 3/8 (10mm) to ½'' (13mm)inside diameter to allow a greatervolume of oxygen flow for cutting.

f. The 50-foot (15.2m) standard lengthof hose should be used. Additionallengths of 25 feet (7.6m) can beadded. It is important for the operatorto know the exact total length of hoseconnected to the torch so the regulatorgage can be set with the correctpressure. Increase oxygen pressure5 pounds (3515 Kg/M²) and gaspressure 1 pound (703 Kg/M²) foreach additional 25 feet (7.6m) of hose.


14

3. REGULATORS

a. Regulators are reducing valves used to reducethe high supply pressure to that which is desired.The gage on the regulator indicates thepressure at which gas is supplied to the torch.

b. The Regulators should be handled with care.Damaged regulators will give inaccuratepressure readings which will affect the qualityof the cut. The needle should read 0 beforepressure is applied.

c. Grease or oil should never be used onregulator fittings because they can causeburning or explosion of lines.

d. Gas and oxygen outlets should be blown outto remove grit or dust, before attaching to theregulator.

e. If needle on gage appears to be stuck whenpressure is applied, tap lightly with your finger.If this does not cause the needle to move, thegage should be sent to the repair department.


15

4. TIPS

a. The proper care of a tip will allow many feetof burning before it wears out.

b. Tip cleaners should be used periodically toinsure that holes are not plugged and thatthere are no burrs to deflect the gas.

c. The seat of the tip should be smooth to makea tight seal. If the seat is damaged, it will havea nick or nicks. This allows gas to escape andproduces a flame around the top of the tip.

d. Tips should never be thrown in a tool box.They should be kept in their boxes or placedin special holding racks.


16

5. BUG-O SYSTEM (PORTABLE)

a. The BUG-O should be in good conditionso it will travel smoothly and at a steady speed.

(1) Check the wheels to make sure there are noburrs or spatter stuck to them. They shouldbe smooth and clean and rotate freely.

(2) The speed adjustment knob should turnsmoothly to allow speed-up or slow-down fromone setting to the other.

(3) The track ways or “grooves” should beperiodically brushed clean. This removesparticles that could obstruct the wheels andruin the cut. The track should be straight withno burrs or nicks in the grooves.

(4) If the BUG-O or track is damaged or does notwork well, have it repaired.


17

(5) The gears in the machine may eventuallybecome worn, permitting excessive backlash.With the machine on the track, and the clutchengaged the BUG-O should not move morethan 1/8 inch (3mm) back and forth when handpressure is applied in these directions.

C. START UP PROCEDURE

1. HOOKING UP

a. Secure cylinders in upright position. Blow outgas and oxygen supply station outlets toremove any dust and grit particles.

b. Attach regulators to outlet. Finger tightenconnections. Use a wrench to make snug.Be careful not to strip the threads.

c. Attach hoses to regulators. Finger tightenconnections. Use a wrench to make snug. Becareful not to strip the threads.

d. Place BUG-O in approximate position to makecut.

e. Insert torch into holder on the BUG-O.

f. Attach hoses to the torch. Finger tightenconnections. Use a wrench to make snug.Be careful not to strip the threads.


18

g. (1) Valves on torch should be closed.

(2) Turn valve on regulators counterclockwiseuntil it moves freely so no pressure willregister.

(3) Open acetylene cylinder valve ½ turn.Open oxygen cylinder valve all the way.

(4) Slowly open gas and oxygen valves ontorch and turn wide open.

(5) Slowly turn in regulator valve until desiredpressure is reached on gas and oxygen.(See torch manufacturer’s tables forrecommended oxygen and gaspressures.)

(6) Close valves on torch.

2. BURNING TIPS

a. Select tip (see torch manufacturer’s tablefor recommended tip sizes).

b. Inspect tip.

c. Use tip cleaners to insure holes are cleanand square on used tips.

3. BUG-O

a. Brush off dust/dirt form track grooves,work surfaces and magnet plates.

b. Place rail on work parallel to cut-line.Position torch over cut-line.

c. Adjust speed to approximate burningspeed.

(1) Set indicator on 20, 30 or 40 on dial.

(2) Place torch tip ¼ inch (6.4mm) aboveplate and mark with soap stone. This isthe starting point.

(3) Using the second hand on a watch, startthe travel machine when the second handis on 12.. Let the machine travel for oneminute, then stop by throwing the switch.


19

(4) Using a soap stone, mark the spot wherethe tip stopped. Measure the distancebetween the two marks-“This is inches(mm) per minute travel.”

(5) Repeat a different dial positions toestablish correct speed settings.

(6) See tables for recommended travelspeed settings.

4. LIGHTING THE TORCH AND SETTING THEPREHEAT FLAME

a. Adjust cutting goggles over eyes.

b. Put on gloves.

c. Open gas valve ¼ turn.

d. Open preheat oxygen valve 1/8 turn.

e. Put striker at tip end and light torch.

f. Adjust preheat flame to neutral by turningoxygen and gas valves one at a time andwatching the blue flame cones forsharpness.

5. ADJUSTING THE PREHEAT FLAME FORMAKING A SQUARE EDGE CUT

a. A simple rule to follow when a square edge isdesired is to have the preheat flame comeout as a whisper or a shoooosh rather thanhaving a rush of gas and oxygen come outwith such a force that the preheat flame hasa shrill whistling sound. The whisperingpreheat flame has just enough heat to keepthe leading edge and sides of the cut barelymelting. Little sparkles will be present aroundthe top surface of the hole which indicatesthat a correct preheat flame is used to give asquare edge to the top of the cut. Thewhistling preheat flame has too much heatthat keeps the leading edge and sides meltingand will cause a rolled edge to the top of thecut.


20

b. Place tip half over the edge of plate.

c. Plate edge should start to get red.

1) If the plate edge does not start to melt(making fluid puddle), preheat flame istoo cold.

2) If edge starts to melt too much (a fluidpuddle the same diameter as the tip end),the preheat flame is too hot.

c) To adjust the too hot preheatflame (so that just enoughheat is put into the plate tohave a square edge on top ofcut):

(1) Both the oxygen and gasvalves must be slowly closedto reduce the preheat flame.First, close the oxygen valveslightly until the blue flamegets longer. Then close thegas valve until the blue flameshortens to the correct originallength.

(2) Watch plate edge until fluidpuddle is approximately ½ thesize of the torch tip.

d. It is better to start with a cold preheat flame andslowly increase the oxygen and gas flow until asmall molten fluid puddle appears on the startingedge of the plate.

6. START CUTTING (See para. C for detailedprocedure for making a starting hole.)


21

a. With acetylene, natural of propane gas thetip end should be placed about 1 to 3 timesthe length of the blue flame cones away fromthe plate surface (about 1/8 or 3/8'' [3 or 10mm] high). For MAPP gas the tip should bemaintained from ¼ to 3/4'' (6 to 19mm) fromthe plate.

b. The torch should be square with the plate.Do not tilt torch.

c. The top of the plate should be preheated fora distance of 1-1/2'' to 2'' (38 to 50mm) bymoving the torch slowly back and forth overthe area.

d. Bring torch to edge of plate so ½ of the preheatflame is touching the plate.

e. Hold at this position until a molten puddle startsto form (a little extra preheat oxygensometimes is necessary to start this actionand should be reduced after the cut is started).

f. Open cutting oxygen valve and start to cut.

g. Throw the travel machine switch to start travelalong plate and immediately open the cuttingoxygen valve to start cut.


22

h. If travel is not started immediately, the bottom1/3 of the cut will pocket and gouge due tothe expanding oxygen gas and the moltenslag, the same as too slow a travel speedwould make. The top of the cut should alwayslead the bottom of the cut even if it’s only 1/16(1.6mm) on an inch. This prevents theopening or kerf from being clogged with slag.

It is better that the cut be made a little on thefast side, which would give a rippled waveappearance, rather than on the slow sidewhich would require repairing or reburning.

7. OBSERVING THE CUT

a. Minor adjustments may have to be made toinsure good smooth cut.

(1) The “high quality” cut is shown in Sketch #1.Top edge is square, face smooth, side scalepulls away from the sides, bottom slag comesoff clean with a little tap, torch tip height andtravel speed is correct.


23

(2) In sketch #2 the top edge has a roll. Too hota preheat flame has melted away the edgeand rounded the corners. To avoid this, thepreheat flame must be reduced by slightlyclosing the preheat oxygen valve and the gasvalve. Keep repeating this procedure untiledge cut is square.


24

(3) Gouges or pockets have formed at the bottom½ or 1/3 of cut shown in Sketch #3. This wascaused by using too high a pressure on thecutting oxygen or too slow travel. Pressureshould be reduced or travel speed increased.Excess oxygen will expand and gouge the hotarea of burn towards the bottom of the cut.

D. PROCEDURES FOR MAKING A STARTINGHOLE WITH A MACHINE BURNING TORCH

a. A 2- or 3- hose torch can be used with a 3/8''(10mm) dia. oxygen hose, for volume, with aregulator setting of 80 to 85 PSI (KG/M²).

b. The pre heat flame should be set a little hotterthan for the normal cut to get the surfaceheated and melting faster.


25

c. The tip of the torch should be no less than 5/8'' (16mm) from the surface.

d. As soon as the surface area starts to form amolten puddle from the preheat flame, thecutting oxygen valve is opened and the torchraised to 1-1/2 to 2'' (38 to 50mm) above thesurface to prevent the molten metal fromclogging the cutting nozzle or tip.

e. CAUTION: The torch holder should be firmwithout play, so that the torch will not vibrateduring the raising motion.

f. As soon as the material is pierced, lower torchto cutting position (3/8'' to ½'' 10mm-13mm)and start carriage travel.

E. OBSERVE THE CUT BEING MADE

In this series for sketches, a correct cut aswell as undesirable cuts and their causes areillustrated.

1. This sketch shows the result of using correctcutting techniques. The face of the cut is flatand regular, and the draglines are smooth,uniform and practically vertical. This is anexcellent surface which can be welded withoutmachining.


26

2. The travel speed was a little too fast in this cut.This is shown by the angle (or rake) of thedragline. The surface of such a cut is rippledbut reasonably smooth. It required a minimumof grinding to be welded without machining.

3. In this cut, the travel speed was a little too slow.This caused an accumulation and sticking ofmolten slag which resulted in the irregularsurface. Gouging and pockets such as thesewill have to be built back by welding. They mustthen be machined or hand ground before thecut surface can be used as a proper weld joint.


27

4. The torch was too far from the work in this cut.It produced excessive melting at the top edgeof the cut. A thin layer of scale will stickapproximately 1/3 to 1/2 the depth of the cut.Slag will also stick to the bottom edge of the cut.The scale and slag must be vibrated or chippedto make the surface suitable for welding.

5. Here the torch top was too close to the work.It caused a portion of the inner cone of thepreheat flame to burn inside the top portionof the cut. This produced an unstable cuttingaction and resulted in the rough (small pocketsor gouges) edges at the top quarter of thecut. Areas such as these must be machinedor ground to make them suitable for welding.


28

6. Too much pressure on the cutting oxygenproduces a cut of this type. The combustionand melting of the steel always follows thepattern of the oxygen jet. Excessive or highoxygen pressure causes undue expansion ofthe gas as it leaves the torch tip. This resultsin excessive turbulence which gives thedistorted and unsightly cut shown. Scale isthick and sticks to the surface. Top portion ofcut is undercut. Slag is stuck to the bottom ofthe cut. A cut such as this also must bemachined or ground to make it suitable forwelding.


29

7. High preheat flame was used in this cut. Thetop surface is melted and rolls over the edgeas small globs of metal. This cut must bemachined of ground to make it suitable forwelding.

8. A dirty or slag-clogged tip was used in thiscut. It caused the oxygen stream to lose itsparallel form. As a result, the surface of thecut is no longer clear and regular. This surfacewill require machining or grinding to make itsuitable for welding.


30

F. BEVEL CUTTING

In this series of sketches a 3-inch (76.2mm)carbon steel plate was beveled to show whatcan happen when proper and impropertechniques are used in Bevel Cutting. Morepreheat is required for beveling than for verticalcutting. That’s because the angle of the tip tothe plate surface causes the heat to bounceoff. When selecting a tip for Bevel Cutting,the depth of the cut rather than just the platethickness should be considered.

The PAN-1000 Panograph Torch Floater isrecommended for bevel cutting on both “flat”and “wavy” material. The Panograph TorchFloater maintains constant nozzle-to-workdistance which assures a uniform bevel!


31

1. This section is uniformly smooth on edges andsurface and represents a quality cut.


32

2. This section is very bad. (a) Very high preheathas melted and rolled the top edge. (b) Travelspeed was too slow causing gouges and slagsticks to the bottom of the cut.

3. This section is slightly cupped just below thetop edge because of excess oxygen pressure.The slight beading along the top edgeindicated that a little too much preheat wasused.


33

CUTTING NOTES:


34

MACHINE CUTTING TIP CHART

(Fill in figures from torch manufacturer’s literature.)

IN. MM.

PLA

TE

TH

ICK

NE

SS

TIP

SIZ

E

CU

TT

ING

O2

PR

ES

SU

RE

FU

EL

GA

SP

RE

SS

UR

E

KE

RF

WID

TH

CU

TT

ING

SP

EE

D

© WELD TOOLING CORP. 2007

1/16 2

1/8 3

1/4 6

3/8 10

1/2 13

3/4 19

1 25

1-1/4 32

1-1/2 38

2 51

2-1/2 64

3 76

4 102

5 127

6 152

7 178

8 203

9 229

10 254

11 279

12 305


Powerful Solutions For Welding And Cutting Automation

CNC Cutting Machine Burns VirtuallyAny Shape Or Pattern.

Download NC or CAD drawings into theProgrammable Gantry System.

The Programmable Gantry System provides coordinated motion in two axis, using three drives: twosynchronized motors drive the main carriages along the X-axis, and one drives the Y-axis crossbeamcarriage. The machine can be easily programmed to repeat any contour or pattern for either cutting orwelding applications. A handheld terminal supplied with the machine is used to program the requiredshape and operation sequence. Other functions besides moves can be programmed, such as starts,stops, delays, repeats and rapid traverse. Ten programs can be stored in machine memory at any onetime.

A PC option is available which includes a connecting cable and a software program. With this, theoperator can create any number of shapes on a PC and store them on disk. Selected shapes can thenbe downloaded into the machine as needed.

The Programmable Gantry System is shipped in major subassemblies that are easy to assemble andinstall on your burning table.

PATENTS WORLDWIDE



Programmable Gantry System

Features:

ENCODER

WEST DRIVE

CARRIAGE36" (914 mm)

ENCODER

EAST DRIVE


HANDHELDPENDANT

XXYCONTROLS

CABLECARRIER

SUPPORT

ENCODER

CABLECARRIER

HEAVY DUTYALUMINUMRIGID RAIL

FACE RAIL

COLUMN18" (457 mm)


CROSS DRIVE

HEAVY DUTYRACKINGGROUP

A QUALITY PRODUCT FROM BUG-O SYSTEMS • 280 TECHNOLOGY DRIVE • CANONSBURG, PA 15317-9564 USALitho in U.S.A. LIT-PGS-BRO-1108A DIVISION OF WELD TOOLING CORPORATION © Weld Tooling Corp. ROM 1:16

2


Handheld Terminal Functions:

The CNC Gantry System is a two-axis gantry that hasdual side synchronized drives running on paralleltracks, and a second axis drive carrying a cuttingtorch that runs on a crossbeam. It can be used forflame or plasma cutting, or for welding, of a variety ofshapes which are programmed and stored inmemory.

The machine memory stores ten different programmedshapes, numbered 0 to 9. At any time, one of theseshapes is current, and will stay current even when thepower is shut off and turned back on, until the shapenumber is changed by the operator.

All programming is done with the handheld terminalprovided, or by downloading from a PC using the PCoption. The terminal plugs into a connector on thecontrol box, and can be removed at any time. It is notneeded to run the machine.

Shapes or patterns are constructed using segments.To do this, select the type of segment required and itsquadrant from the programming chart, and enter it onthe terminal keypad. Any one shape can have up to50 segments. Other functions such as weld/oxygen,on/off, time delay, or repeat another shape a numberof times, also count as one segment each if used.

The programming operation is selected by pressing keys A, B, C, D, or E.A. ALL SEGMENTS; press "A" on the terminal to program a new shape; enter

the total number of segments and data for each segment.

B. REVISE 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 that the wholeshape does not have to be re-entered.

C. CHANGE SHAPE NUMBER; press "C" on the terminal to change the currentshape number. The program switches to the new number in memory, and towhatever shape is stored there.

D. DISPLAY SHAPE DATE; press "D" to display the data for the current shape.The terminal display shows the total number of segments, and data for eachsegment one by one each time you press enter.

E. END OF SEGMENT SLOWDOWN; press "E" to set the value of decelerationfor the shape, when the machine approaches the end of each segment. This isuseful when the shape has sharp corners, to prevent overshoot. 99 is maximumslowdown, 0 is no slowdown.

The different types of segments that can be loaded into the machine are as follows:

Other functions besides the moves shown above are: Weld Contact/Solenoid On/Off,Pause, Delay, Repeat another shape, Full ellipse and Rapid Traverse.

Clockwise 90

CounterClockwise 90

X or Y Axis

ClockwisePartial Arcs

Counter ClockwisePartial Arcs

Inclined Lines

3


Operation:

Technical Data:

When the machine is plugged in and the power turnedon, this is the reference, start or home position.

There are three options (the handheld terminal is notneeded for the first two):

1. MOVE: To change the start position, pushthe STOP/PAUSE button (A), move themachine manually to the required position usingtoggle switches (B) and (C), and push the resetbutton (D).

2. RUN: Set the speed knob (E) and push theSTART/RUN button (F) to cut/weld a shape.

3. PROGRAM: The programming operationrequires the use of the handheld terminal ordownloading from a PC.

PowerRequirements: PGS-1000-_*120 VAC/50-60 Hz/1

PGS-1002-_*240 VAC/50-60 Hz/1

Travel Speed: 4-80 in/min (100-2000 mm/min)

Maximum SegmentDimension: 72" (1800 mm)

Within Limits of Travel

Minimum DimensionIncrement: Inches: 0.01"

Metric: 0.1 mm

Delay Increment: 0.01 seconds

Maximum Delay: 99.99 seconds

* Available in 3 Standard Sizes: 8, 10 and 12 ft.

PGS-100_-8 Actual to is 96.5'' (2451 mm)PGS-100_-10 Actual to is 120'' (3048 mm)PGS-100_-12 Actual to is 143'' (3632 mm)


The gantry can be programmed from a PC,using either of two software packages describedbelow. Shapes can be created off-line, anddownloaded to the machine when required.Each program is supplied with a cable to con-nect to the serial port of the PC.

1. PC Option.This runs under MS-DOS, and allows you to:

• Create shapes on the PC.• Save any number of shapes to disk, and

retrieve them as necessary.• View a programmed shape on screen -

which helps program verification.• Download programmed shapes from the

PC to the Gantry.

2. BESTNEST Program.These are full fledged CAD interface programs,available in three different levels, each addingfurther capabilities to those listed above.

A. Basic: enables you to• Read and convert standard DXF files

generated by CAD programs.• Draw and edit shapes graphically on

screen.• Specify parameters like kerf, lead in,

lead out, or use defaults.• Specify different materials to save

shapes.B: Manual Nesting: allows interactive

nesting of parts.C: Auto-nesting: full auto-nesting and

multiple torch nesting.

COMPUTER SOFTWARE

AF

E

D

B

CGantry Control Box

CL CL

CL CL

CL CL

BUG-O

Ready

2



The CNC Gantry System is a two-axis gantry that hasdual side synchronized drives running on paralleltracks, and a second axis drive carrying a cuttingtorch that runs on a crossbeam. It can be used forflame or plasma cutting, or for welding, of a variety ofshapes which are programmed and stored inmemory.

The machine memory stores ten different programmedshapes, numbered 0 to 9. At any time, one of theseshapes is current, and will stay current even when thepower is shut off and turned back on, until the shapenumber is changed by the operator.

All programming is done with the handheld terminalprovided, or by downloading from a PC using the PCoption. The terminal plugs into a connector on thecontrol box, and can be removed at any time. It is notneeded to run the machine.

Shapes or patterns are constructed using segments.To do this, select the type of segment required and itsquadrant from the programming chart, and enter it onthe terminal keypad. Any one shape can have up to50 segments. Other functions such as weld/oxygen,on/off, time delay, or repeat another shape a numberof times, also count as one segment each if used.

The programming operation is selected by pressing keys A, B, C, D, or E.A. ALL SEGMENTS; press "A" on the terminal to program a new shape; enter

the total number of segments and data for each segment.

B. REVISE 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 that the wholeshape does not have to be re-entered.

C. CHANGE SHAPE NUMBER; press "C" on the terminal to change the currentshape number. The program switches to the new number in memory, and towhatever shape is stored there.

D. DISPLAY SHAPE DATE; press "D" to display the data for the current shape.The terminal display shows the total number of segments, and data for eachsegment one by one each time you press enter.

E. END OF SEGMENT SLOWDOWN; press "E" to set the value of decelerationfor the shape, when the machine approaches the end of each segment. This isuseful when the shape has sharp corners, to prevent overshoot. 99 is maximumslowdown, 0 is no slowdown.


Other functions besides the moves shown above are: Weld Contact/Solenoid On/Off,Pause, Delay, Repeat another shape, Full ellipse and Rapid Traverse.

Clockwise 90

CounterClockwise 90

X or Y Axis


Counter ClockwisePartial Arcs

Inclined Lines

3


Operation:

Technical Data:

When the machine is plugged in and the power turnedon, this is the reference, start or home position.

There are three options (the handheld terminal is notneeded for the first two):

1. MOVE: To change the start position, pushthe STOP/PAUSE button (A), move themachine manually to the required position usingtoggle switches (B) and (C), and push the resetbutton (D).

2. RUN: Set the speed knob (E) and push theSTART/RUN button (F) to cut/weld a shape.

3. PROGRAM: The programming operationrequires the use of the handheld terminal ordownloading from a PC.

PowerRequirements: PGS-1000-_*120 VAC/50-60 Hz/1

PGS-1002-_*240 VAC/50-60 Hz/1

Travel Speed: 4-80 in/min (100-2000 mm/min)

Maximum SegmentDimension: 72" (1800 mm)


Minimum DimensionIncrement: Inches: 0.01"

Metric: 0.1 mm

Delay Increment: 0.01 seconds

Maximum Delay: 99.99 seconds

* Available in 3 Standard Sizes: 8, 10 and 12 ft.

PGS-100_-8 Actual to is 96.5'' (2451 mm)PGS-100_-10 Actual to is 120'' (3048 mm)PGS-100_-12 Actual to is 143'' (3632 mm)


The gantry can be programmed from a PC,using either of two software packages describedbelow. Shapes can be created off-line, anddownloaded to the machine when required.Each program is supplied with a cable to con-nect to the serial port of the PC.

1. PC Option.This runs under MS-DOS, and allows you to:

• Create shapes on the PC.• Save any number of shapes to disk, and

retrieve them as necessary.• View a programmed shape on screen -

which helps program verification.• Download programmed shapes from the

PC to the Gantry.

2. BESTNEST Program.These are full fledged CAD interface programs,available in three different levels, each addingfurther capabilities to those listed above.

A. Basic: enables you to• Read and convert standard DXF files

generated by CAD programs.• Draw and edit shapes graphically on

screen.• Specify parameters like kerf, lead in,

lead out, or use defaults.• Specify different materials to save

shapes.B: Manual Nesting: allows interactive

nesting of parts.C: Auto-nesting: full auto-nesting and

multiple torch nesting.

COMPUTER SOFTWARE

AF

E

D

B

CGantry Control Box

CL CL

CL CL

CL CL


CNC Cutting Machine Burns VirtuallyAny Shape Or Pattern.

Download NC or CAD drawings into theProgrammable Gantry System.

The Programmable Gantry System provides coordinated motion in two axis, using three drives: twosynchronized motors drive the main carriages along the X-axis, and one drives the Y-axis crossbeamcarriage. The machine can be easily programmed to repeat any contour or pattern for either cutting orwelding applications. A handheld terminal supplied with the machine is used to program the requiredshape and operation sequence. Other functions besides moves can be programmed, such as starts,stops, delays, repeats and rapid traverse. Ten programs can be stored in machine memory at any onetime.

A PC option is available which includes a connecting cable and a software program. With this, theoperator can create any number of shapes on a PC and store them on disk. Selected shapes can thenbe downloaded into the machine as needed.

The Programmable Gantry System is shipped in major subassemblies that are easy to assemble andinstall on your burning table.

PATENTS WORLDWIDE




Features:

ENCODER

WEST DRIVE


ENCODER

EAST DRIVE


HANDHELDPENDANT

XXYCONTROLS

CABLECARRIER

SUPPORT

ENCODER

CABLECARRIER

HEAVY DUTYALUMINUMRIGID RAIL

FACE RAIL

COLUMN18" (457 mm)


CROSS DRIVE

HEAVY DUTYRACKINGGROUP

A QUALITY PRODUCT FROM BUG-O SYSTEMS • 280 TECHNOLOGY DRIVE • CANONSBURG, PA 15317-9564 USALitho in U.S.A. LIT-PGS-BRO-1108A DIVISION OF WELD TOOLING CORPORATION © Weld Tooling Corp. ROM 1:16

Features:

A. BUG-O DC IVB. Cable Mounting AssemblyC. Machined Rack Welding GroupD. Heavy Duty Rigid RailE. Magnet Bar Swivel w/ReleaseF. Tool Kit

Technical Data:

Power Requirements: BUG-1950 120VAC/50-60/1BUG-1951 240VAC/50-60/1BUG-1952 42VAC/50-60/1

Travel Speed: *1.5-30 ipm (38-760 mm/min)

Load Capacity: 50 lbs (22.7 kg) Vertical120 lbs (54.4 kg) Horizontal

Net Weight of Kit: 60 lbs. (27.3 kg)

Shipping Weight of Kit: 79 lbs. (36 kg)

BUG-1950 DC IV General Welding Kit120 VAC (120/50-60/1)

Includes:1 BUG-0343 BUG-O DC IV

*1.5-30 ipm (38-760 mm/min)Includes:

1 BUG-9444 Tool Kit

1 BUG-2975 Cable Mounting Assembly1 BUG-5440 Machined Rack Welding Group1 ARR-1080 Heavy-Duty Rigid Rail 8' (2.37 m)1 ARR-1085 Heavy-Duty Rigid Rail 4' (1.18 m)5 ARM-2325 Swivel Magnet Plate w/Release

BUG-1951 DC IV General Welding Kit 240 VACSame as above except with BUG-0443

BUG-1952 DC IV General Welding Kit 42 VACSame as above except with BUG-0543

*NOTE: With the bypass pinion installed, the DC IV will have an increased speedrange (8-160 ipm: 200-4000 mm/min), however, vertical load carryingcapability will be reduced to 3 lbs. (1.4 kg).

E

D

A

C

B

F



DC General Welding Kit

Factory Installed Options:BUG-1635-_ Pendant Control with Weld Starter(Specify Length Desired). Available in 10.0" (3.0 m) and 25.0'(7.6 m) lengths. Includes: Speed Control Knob and Forward-Off-Reverse Travel Switch and Weld Contactor Switch.

BUG-9865Stepping module bolts to DC Drive.When limit switch is tripped, moduleprovides adjustable-timed power (0-3seconds) to the DC Drive.

Available Separately:


280 TECHNOLOGY DRIVE CANONSBURG, PENNSYLVANIA USA 15317-9564 PHONE: 1- 800-245-3186 http://www.bugo.com FAX: 1- 412-331- 0383

BUG-9770 LimitSwitch KitWill stop the driveat end of travel.

BUG-2205 CarriageTrailer with Hitch

Technical Data:

Power Requirements: BUG-1950-HD 120VAC/50-60/1BUG-1951-HD 240VAC/50-60/1BUG-1952-HD 42VAC/50-60/1

Travel Speed: *1.5-30 ipm (38-760 mm/min)

Load Capacity: 50 lbs (22.7 kg) Vertical120 lbs (54.4 kg) Horizontal

Net Weight of Kit: 60 lbs (27.3 kg)

Shipping Weight of Kit:79 lbs (36 kg)

Features:

A. BUG-O DC IVB. Cable Mounting AssemblyC. H.D. Welding GroupD. Heavy Duty Rigid RailE. Magnet Bar Swivel w/ReleaseF. Tool Kit

BUG-1950-HD DC IV Heavy Duty Welding Kit(120/50-60/1)

Includes:1 BUG-0343 BUG-O DC IV

*1.5-30 ipm (38-760 mm/min)Includes:

1 BUG-9444 Tool Kit

1 BUG-2975 Cable Mounting Assembly1 BUG-5275 H.D. Welding Group1 ARR-1080 Heavy-Duty Rigid Rail 8' (2.37 m)1 ARR-1085 Heavy-Duty Rigid Rail 4' (1.18 m)5 ARM-2325 Swivel Magnet Plate w/Release

BUG-1951-HD DC IV General Welding Kit-HD 240 VACSame as above except with BUG-0443

BUG-1952-HD DC IV General Welding Kit 42 VACSame as above except with BUG-0543

D

E

CA

B

*NOTE: With the bypass pinion installed, the DC IV will have an increased speedrange (8-160 ipm: 200-4000 mm/min), however, vertical load carryingcapability will be reduced to 3 lbs. (1.4 kg).



Factory Installed Options:BUG-1635-_ Pendant Control with Weld Starter(Specify Length Desired). Available in 10.0" (3.0 m) and 25.0'(7.6 m) lengths. Includes: Speed Control Knob and Forward-Off-Reverse Travel Switch and Weld Contactor Switch.

BUG-9865Stepping module bolts to DC Drive.When limit switch is tripped, moduleprovides adjustable-timed power (0-3seconds) to the DC Drive.

Available Separately:

DC Heavy-Duty Welding Kit

A QUALITY PRODUCT FROM BUG-O SYSTEMS • 280 TECHNOLOGY DRIVE • CANONSBURG, PA USA 15317-9564A DIVISION OF WELD TOOLING CORPORATION © Weld Tooling Corp. ROM 1:16 Litho. in U.S.A. LIT-GW-BRO-0108

F

BUG-9770 LimitSwitch KitWill stop the driveat end of travel.

BUG-2205 CarriageTrailer with Hitch



PHONE: 1- 800-245-3186 http://www.bugo.com TELEFAX: 1- 412-331- 0383

Self-propelled welding system for field storage tank welding.

BUG-O ALL TIME GIRTH WELDERS


The Bug-O All Time Girth Welder is a self-propelled welding system for horizontal welding. It can reduce

field storage tank welding time up to 40%. Weld defects are greatly reduced saving tank erection costs. This

machine is available as dual or single sided. The Lincoln NA-3 control and welding head are fitted with wire

feed rolls, nozzles, straighteners and 50 lbs (22.7 kg) wire reels. A flux recovery system is equipped with the

machine for the recycling of flux. An adjustable frame allows for plates 6' (1.8m) to 10' (3m) tall.

BUG-O ALL TIME GIRTH WELDERS

• Submerged arc welding process with

Lincoln Electric welding equipment as

standard.

• Laser pointer on weld head for easy

positioning of wire tip.

• Operator seat with platform, weatherproof

curtain and handrail.

• Integrated control panel for sequence

control and easy operation.

• Enclosed dual motors with AC inverter

drive for steady travel along the

circumference of the tank shell.

• Vacuum with flux roller belt for flux

recovery.

• Electric flux winch to lift flux off the ground.

A QUALITY PRODUCT FROM BUG-O SYSTEMS • 3001 WEST CARSON STREET • PITTSBURGH, PA USA 15204-1899

Litho in U.S.A. LIT-GIRTHW-BRO-0707A DIVISION OF WELD TOOLING CORPORATION© Weld Tooling Corp. ROM 1:16

• Optional LPG torch pre-mounted on BGW

frame with gas bottle platform.

• Special models available for welding double

shell LPG/LNG tanks and top down

constructed storage tanks.

Model Application Tank Welding Travel Shell Plate Wire Approx.

Diameter Thickness Speed Height Weight

BGW-1000 6'-10' 3/32'' 2,094 lbs.

Single Side Weld Conventional (1.8 - 3.0 m) (2.4mm) 950 kg

Storage Tanks

BGW-2000 Min. 15' 5/16''-1 9/16'' 4-114 ipm 1/8'' 3,968 lbs.

Double Side Weld (4.5m) (8-40mm) (100-2900 (3.2mm) 1800 kg

mm/min)

BGW-1000-LNG Double Shell

Single Side Weld Cryogenic 7'-13' 2 x 1/16" 1,984 lbs.

Storage Tanks (2-4 m) (2 x 1.6mm) 900 kg

BGW-1000-D Top Down 6'-10' (Tinytwin Arc) 2,425 lbs

Single Side Weld Constructed (1.8-3.0m) 1100 kg

Storage Tanks

Specifications

Features:

BGW-1000 shown above.

Bug-O Systems

The versatile GO-FER III Kits make straight line weldingand cutting more efficient and economical.

Affordable Track Cutting andWelding Systems.


Produce machine quality welds and cuts inany plane or position with a portable drive on

magnetic track.

AFR-3000 Semi-Flex Rail can be bent inside oroutside to a minimum radius of 15' (5.0 m) or 30'(10.0 m) diameter without permanent deformation.

GO-FER III ACCESSORIES

BUG-5166-8 H.D. Tube Rack w/Clamp

BUG-9180-4 Rod 7/8 x 4"

CON-1020 Universal Clamp

BUG-2708 Fits All Clamp

BUG-5485 Contactor/Cable Anchor:Provides built-in contactor switch to controlplasma or welding process. The Cable Anchorprovides strain relief for all cables.

The addition of these 4items provides a verticalracking motion for handheld guns.

ARR-1085 4' (1.18 m) Heavy Duty Rigid RailARR-1080 8' (2.37 m) Heavy Duty Rigid Rail

ARM-2505Spacer Barfor ARR Railonly.

ARM-2500On-Off Magnet Plate Assembly for ARR Railonly. Holding power 100 lbs. (45 kg)Can be switched on and off for rapid set-up.

Rails & Attachments

ARM-2425Swivel Magnet for AFR-3000Rail only.250 lbs. Holding Power

Vacuum Systems For Non-Ferrous MetalsStandard Vacuum Support Kits:

ARV-1080 Vacuum KitFor ARR-1080 & AFR-3000 Rails.

ARV-1085 Vacuum KitFor ARR-1085 Rails.

Custom systems are required for Bent Rail.

ARV-1080 Vacuum Kit forARR-1080 8' (203 mm) Rigid Rail.


ARV-2020 120 Volt/50-60 HzARV-2030 220 Volt/50-60 HzThe ARV-2020 (ARV-2030) VacuumPump Kit is recommended for use witha maximum of four (4) pieces of rail,or sixteen (16) vacuum bars.

ARV-1080 Vacuum Kit forAFR-3000 8' (203 mm) Semi-Flex Rail.

A QUALITY PRODUCT FROM BUG-O SYSTEMS • 280 TECHNOLOGY DRIVE • CANONSBURG, PA USA 15317-9564Litho in U.S.A. LIT-GOFER-BRO-0908A DIVISION OF WELD TOOLING CORPORATION © Weld Tooling Corp. ROM 1:16


PAN-1010Cutting Panograph Assembly

PAN-1007Welding Panograph Assembly

MUG-1119-323-Hose Assembly

BUG-98983-Hose Quick-ActingManifold

5

Panograph AssembliesPanographs are spring-loaded devices that maintain torch stand-off and compensate for plate surface irregularities.

CIR-1010-32-Hose Assembly

GOF-30252-Hose Quick-ActingManifold

GOF-3142 Radius Cutting Attachment:Enables GO-FER III to be quicklychanged from a straight line to a circle-cutting machine.

Size Range: 8" to 96"(203 mm to 2438 mm) diameter.

GO-FER III PLASMA KIT / GOF-3250-PL

Each GOF-3250-PL Plasma kit includes the following:1 ARR-1080 Heavy Duty Rigid Rail 93.50"

(2.37 m)2 ARM-2500 On/Off Magnet Plate Assembly2 ARM-2505 Spacer Bar Assembly1 GOF-3240-PL GO-FER III Drive Unit w/Dynamic

braking 8-100 ipm(203-2640 mm/min)

Each GOF-3240-PL Drive Unit includes thefollowing sub assemblies:

1 BUG-5485 Contactor / Cable Anchor1 BUG-5451 Rackholder with Short

Handle1 PAN-1015 Rack 22.62" (574 mm)1 BUG-5462 Right Angle Clamp1 BUG-5188 Torchholder Assembly1 BUG-9444 Tool Kit

GOF-3252-PL Same as above except with240 VAC GO-FER III GOF-3242-PL

GOF-3254-PL Same as above except with42 VAC GO-FER III GOF-3244-PL


Shipping Weight of Kit: 50 lbs. (22.7 kg)

4

The G0-Fer III Plasma Kit is specifically designed to work in conjunction with a plasma machine. It‘s travel speed of 8-100inches per minute (203-2640 mm/min) and it‘s direct rack and pinion drive make it ideal as an all position portable cuttingmachine for a plasma torch. The torch holder will accept any standard 1-3/8" (35 mm) diameter machine torch that has a 32pitch gear rack. A built in trigger contactor for initiating the cut makes the GO-FER a convenient self contained package.

NOTE: A shielded gun and cable assembly must beused to reduce hi-frequency interference.

ConvenientCarrying Handle

Positive Rackand Pinion Drive

On/Off Magnet PlateAssembly (2)

Spacer BarAssembly (2)

TorchholderAssembly

Contactor / CableAnchor

Tool Kit

Heavy Duty 8' (2.37 m)Rigid Rail

GO-FER III WELDING KIT / GOF-3250-WD

Each GOF-3250-WD kit includes the following:1 ARR-1080 Heavy Duty Rigid Rail 93.50"

(2.37 m)2 ARM-2500 On/Off Magnet Plate Assembly2 ARM-2505 Spacer Bar Assembly1 GOF-3240-WD GO-FER III Drive Unit

w/Dynamic braking 2-50 ipm(50-1270 mm/min)

Each GOF-3240-WD Drive Unit includes thefollowing sub assemblies:

1 BUG-5485 Contactor / Cable Anchor1 BUG-5451 Rackholder with Short

Handle1 PAN-1015 Rack 22.62" (574 mm)1 BUG-5462 Right Angle Clamp1 BUG-5188 Torchholder Assembly1 BUG-9444 Tool Kit1 BUG-5166-8 8" Tube Rack w/Clamp1 BUG-2708 Fits-All Clamp1 BUG-9180-4 Rod 7/8" x 4"1 CON-1020 Swivel Clamp

GOF-3252-WD Same as above except with240 VAC GO-FER IIIGOF-3242-WD

GOF-3254-WD Same as above except with42 VAC GO-FER IIIGOF-3244-WD



3

The GO-Fer III Welding Kit is an economical straight-line welding travel carriage. The all position Fits-All Clamp willaccept and accommodate any hand held welding gun and allow the operator to position the torch at any angle theydesire. The racking group allows for in process torch adjustment for the vertical and horizontal plane. A built in torchtrigger contactor allows the operator to activate the wire feeder from a switch on the top of the Drive unit.

Cable Anchor Contactor / CableAnchor


Y-Z Racking Groupw/Fits-All Clamp


On/Off MagnetAssembly (2)

Positive RackAnd Pinion Drive

Tool Kit


GO-FER III OXY-FUEL KIT / GOF-3250-OXThe GO-FER III Oxy-Fuel Kit is used for straight line cuts and weld preparation beveling. The kit comes complete with theexception of a torch. The Bug-O Torch Holder will accept any standard 1-3/8" (35 mm) diameter machine torch with a 32 pitchgear rack. The Quick-Action Gas Manifold mounted to the rear of the machine is used as a strain reliever for the torch andalso gives the operator the ability to turn on and off the pre-heat gases without having to readjust the gas flow of the torch.

Each GOF-3250-OX kit includes the following:1 ARR-1080 Heavy Duty Rigid Rail 93.50"

(2.37 m)2 ARM-2500 On/Off Magnet Plate Assembly2 ARM-2505 Spacer Bar Assembly1 GOF-3240-OX GO-FER III Drive Unit w/Dynamic

braking 8-100 ipm(203-2640 mm/min)

Each GOF-3240-OX Drive Unit includes thefollowing sub assemblies:

1 GOF-3025 2-Hose Manifold1 CIR-1010-3 Twin Hose Assembly1 BUG-5451 Rackholder with Short

Handle1 PAN-1015 Rack 22.62" (574 mm)1 BUG-5462 Right Angle Clamp1 BUG-5188 Torchholder Assembly1 BUG-9444 Tool Kit

GOF-3252-OXSame as above except with240 VAC GO-FER IIIGOF-3242-OX

GOF-3254-OXSame as above except with42 VAC GO-FER IIIGOF-3244-OX



2


Positive Rackand Pinion Drive

On/Off Magnet PlateAssembly (2)


TorchholderAssembly

Quick-ActionManifold

Twin Hose Assembly 32" (812 mm)

Tool Kit


Bug-O Systems


Affordable Track Cutting andWelding Systems.


Produce machine quality welds and cuts inany plane or position with a portable drive on

magnetic track.

AFR-3000 Semi-Flex Rail can be bent inside oroutside to a minimum radius of 15' (5.0 m) or 30'(10.0 m) diameter without permanent deformation.



BUG-9180-4 Rod 7/8 x 4"



BUG-5485 Contactor/Cable Anchor:Provides built-in contactor switch to controlplasma or welding process. The Cable Anchorprovides strain relief for all cables.

The addition of these 4items provides a verticalracking motion for handheld guns.

ARR-1085 4' (1.18 m) Heavy Duty Rigid RailARR-1080 8' (2.37 m) Heavy Duty Rigid Rail

ARM-2505Spacer Barfor ARR Railonly.

ARM-2500On-Off Magnet Plate Assembly for ARR Railonly. Holding power 100 lbs. (45 kg)Can be switched on and off for rapid set-up.

Rails & Attachments

ARM-2425Swivel Magnet for AFR-3000Rail only.250 lbs. Holding Power

Vacuum Systems For Non-Ferrous MetalsStandard Vacuum Support Kits:

ARV-1080 Vacuum KitFor ARR-1080 & AFR-3000 Rails.

ARV-1085 Vacuum KitFor ARR-1085 Rails.

Custom systems are required for Bent Rail.



ARV-2020 120 Volt/50-60 HzARV-2030 220 Volt/50-60 HzThe ARV-2020 (ARV-2030) VacuumPump Kit is recommended for use witha maximum of four (4) pieces of rail,or sixteen (16) vacuum bars.

ARV-1080 Vacuum Kit forAFR-3000 8' (203 mm) Semi-Flex Rail.

A QUALITY PRODUCT FROM BUG-O SYSTEMS • 280 TECHNOLOGY DRIVE • CANONSBURG, PA USA 15317-9564Litho in U.S.A. LIT-GOFER-BRO-0908A DIVISION OF WELD TOOLING CORPORATION © Weld Tooling Corp. ROM 1:16


PAN-1010Cutting Panograph Assembly

PAN-1007Welding Panograph Assembly

MUG-1119-323-Hose Assembly


5

Panograph AssembliesPanographs are spring-loaded devices that maintain torch stand-off and compensate for plate surface irregularities.

CIR-1010-32-Hose Assembly


GOF-3142 Radius Cutting Attachment:Enables GO-FER III to be quicklychanged from a straight line to a circle-cutting machine.

Size Range: 8" to 96"(203 mm to 2438 mm) diameter.


Semi-Automatic Processes.

Heavy Duty Tool Positioning System



The BUG-5275 H.D. WELDING GROUP is designed to carry a welding gun along a smooth flat surface. It will mount on any standard BUG-O carriage. It consists of the following items:

BUG-5275 H.D. Welding Group A BGV-1165 Clamp Block B BUG-2708 Clamp C BUG-3320-8 H.D. Tube Rack 8" (203 mm) D BUG-3320-15 H.D. Tube Rack 15" (381 mm) E BUG-5186 Right Angle Clamp F BUG-5188 Torch Holder Assembly G CON-1020 Swivel Clamp Assembly

The BUG-5285 H.D. CUTTING GROUP is designed to carry a cutting torch along a smooth flat surface. It will mount on any standard BUG-O carriage. It consists of the following items:

BUG-5285 H.D. Cutting Group

A BGV-1165 Clamp Block B BUG-3320-15 H.D. Tube Rack 15" (381 mm) C BUG-5182 Right Angle Clamp D BUG-5188 Torch Holder Assembly

The BUG-5185 H.D. ALL POSITION CUTTING GROUP is designed to carry a cutting torch along a smooth flat surface and allows independent adjustment for 360 x 360 setting of the torch. It will mount on any standard BUG-O carriage. It consists of the following items:

BUG-5185 H.D. All Position Cutting Group

A BUG-3320-15 H.D. Tube Rack 15" (381 mm) B BUG-3310-8 H.D. Tube Without Rack C BUG-5188 Torch Holder Assembly D BUG-5184 Tube Clamp Assembly E BUG-5182 Right Angle Clamp F BUG-5280 Tube Mounted Rackholder

A

B

D

C

E

F

A

B

C

D

A

D E

BG

C

F

The HEAVY DUTY RACK SYSTEM is a series of components which are designed to hold welding guns, cutting torches and other process tools. The system consists of tubes, blocks and clamps which are very rigid and compact. They are easy to use and can be mixed and matched in many different ways. PATENTS WORLDWIDE

HEAVY DUTY TOOL POSITIONING SYSTEM - ACCESSORIES

BUG-2915 Torch holder BUG-5189 Clamp Block Assembly BUG-5280 Tube Mounting Rackholder

1-3/8" (35 mm) 1-3/8" (35 mm)

1-3/8" (35 mm) BUG-5462

Right Angle Clamp Assembly[for 7/8" (22.2 mm) Rods

7/8" (22.2 mm)

7/8" (22.2 mm)

BUG-5182 Right Angle Clamp BUG-5184 Tube Clamp Assembly

1-3/8" (35 mm)

7/8" (22.2 mm)

1-3/8" (35 mm)

PAN-1164 Spacer Block(used w/limit switch)

BUG-5245 Welding Gun Mounting Assembly

1-3/8" (35 mm)

BUG-5186 Right Angle Clamp

1-3/8" (35 mm)

BUG-_3310 1-3/8" (35 mm) H.D. Tube w/o rack. (Specify Length)Additional lengths available.

BUG-9180_ 7/8" (22.2 mm) Rod (Specify Length)Additional lengths available.

CON-1020 Swivel ClampAssembly [for 7/8" (22.2 mm) rod]

Lengths 3" (76 mm) 4" (102 mm) 8" (203 mm) 10" (254 mm) 18" (457 mm)


MUG-1515 Collar7/8" (22.2 mm)

BUG-5188 Torchholder Assemblyw/7/8" (22.2 mm) Rod

BUG-2708 Clamp w/7/8" (22.2 mm) Rod

PAN-1033 Rod Clamp [7/8" (22.2 mm) Rod]

BUG-3320-_H.D. Tube Rack (Specify Length)

At the heart of the Heavy Duty System is the BUG-3320-_H.D. Tube Rack. This rack consists of a 1-3/8" (35 mm) diameter steel tube that has a steel 32 pitch r ack keyed into a machined groove that runs along its side. Choose the length that best suits your application.

The BGV-1165 Clamp Block is made from extruded aluminum with a steel pinion that allows for manually operated positioning of the BUG-3320-_ Heavy Duty Tube Rack. The clamp block also features a ratcheting lock-down lever for quick, easy tightening of the tube rack. It can be bolted to a fixture, or any BUG-O SYSTEMS carriage.

Standard Lengths Available(Specify Length) 8" (203 mm) 12" (305 mm) 15" (381 mm) 24" (609 mm) 30" (760 mm) 44" (1120 mm)

BGV-1165Clamp BlockAssembly3.5" (89 mm)

Litho in U.S.A. LIT-HDTPS-BRO-0608A QUALITY PRODUCT FROM BUG-O SYSTEMS • 280 TECHNOLOGY DRIVE • CANONSBURG, PA 15317-9564 USA

© Weld Tooling Corp. A DIVISION OF WELD TOOLING CORPORATION ROM 1:16

2

HEAVY DUTY TOOL POSITIONING SYSTEM - PANOGRAPHS

A BGV-1165 Clamp Block Assembly 3" (74 mm)B BUG-3320-8 H.D. Tube RackC PAN-1033 Rod ClampD BUG-2915 Torchholder AssemblyE PAN-1140 H.D. Spring Tube AssemblyF PAN-1170 Mounting Arm AssemblyG BGV-1180 Clamp Assembly

The PAN-1160 HEAVY DUTY CUTTING PANOGRAPH is designed to carry a cutting torch along an irregular or wavy surface to maintain nozzle-to-work distance. It will mount on any standard BUG-O carriage. It consists of the following items:

PAN-1150 H.D. WELDING PANOGRAPHPAN-1160 H.D. CUTTING PANOGRAPH

E

A

I

J

H

B

K

G

D FC

H BUG-3310-8 H.D. Tube Without Rack I BUG-5188 Torchholder AssemblyJ BUG-5182 Right Angle ClampK PAN-1145 Swivel Wheel AssemblyL BUG-2708 ClampM CON-1020 Swivel Clamp Assembly

Net Wt: 10 lbs. (4.5 kg)Shipping Wt: 12 lbs. (5.4 kg)

A BGV-1165 Clamp Block Assembly 3" (74 mm)B BUG-3320-8 H.D. Tube RackC BUG-2708 ClampD PAN-1140 H.D. Spring Tube AssemblyE PAN-1170 Mounting Arm AssemblyF BGV-1180 Clamp AssemblyG BUG-3310-8 H.D. Tube Without RackH BUG-5188 Torchholder Assembly I BUG-5182 Right Angle ClampJ CON-1020 Swivel Clamp AssemblyK BUG-3265 Spatter Guard AssemblyL MUG-1515 Collar 7/8'' (22.2m)M BUG-5274 “V” Wheel Assembly

BUG-3340 CORNER FOLLOWER

NOTE: Drawings are for part numbers only! For actual set up see instructions provided with product.

E

I

A B

H

JK

F

Net Wt: 11 lbs. (5.0 kg)Shipping Wt: 13lbs. (5.9 kg)

The BUG-3340 CORNER FOLLOWER is designed to carry a welding gun centered along a corner joint to maintain nozzle-to-work distance. It will mount on any standard BUG-O carriage. It consists of the following items.

C

D

F

A B

G

IL

H

EJ

K, M

G

M

L

3

HEAVY DUTY TOOL POSITIONING SYSTEM - ASSEMBLIES

For those who wish to build their own Heavy Duty Rack System, the following parts are available:

BUG-3320-_" (Specify Length)H.D. Tube RackAt the heart of the Heavy Duty Rack System is the BUG-3320-_" HEAVY DUTY TUBE RACK. This rack consists of a 1-3/8" (35 mm) diameter steel tube that has a steel 32 pitch rack soldered into a machined groove that runs along its side. Choose the length that best suits your application.

BUG-5179Clamp Assembly

BGV-1180Clamp Assembly

BUG-5164Clamp Assembly

Standard Lengths Available(Specify Length)8" (203 mm)15" (381 mm)24" (609 mm)30" (760 mm)44" (1120 mm)

BUG-5169-_" (Specify Length)Rack w/Torchholder

BUG-5138-_" (Specify Length)Rack w/Clamp

BUG-5166-_" (Specify Length)Rack w/Clamp

At one end of the Heavy Duty Tube Rack are four mount-ing holes. These holes are used for mounting Heavy Duty Racker CLAMP ASSEMBLIES onto the end of the rack. Three different types are available as shown to the left.

You can order the above components separately or already assembled using the part numbers below (please specify length of rack when ordering).

Standard Lengths Available(Specify Length)8" (203 mm)15" (381 mm)24" (609 mm)30" (760 mm)44" (1120 mm)

The PAN-1140 HEAVY DUTY SPRING TUBE ASSEMBLY is a 1-3/8" (35 mm) diameter spring-loaded tube that has a 7/8" (22 mm) diameter shaft running through it. A pin in the shaft presses against the spring, which keeps constant pressure on the shaft and allows up to 2" (50 mm) of movement. This accessory is designed to be used when a constant torch-to-work distance must be maintained; i.e. for cutting or welding over an irregular work surface (cutting and welding panographs are shown on page 2 of this brochure).

PAN-1140H.D. Spring Tube Assembly

HEAVY DUTY FOLLOWER ASSEMBLIES mount onto the end of the PAN-1140 and ride on the work surface. The BUG-5274 is for fol-lowing corners and the PAN-1145 is designed for flat surfaces.

BUG-5274"V" Wheel Assembly

PAN-1145Swivel Wheel Assembly


Semi-Automatic Processes.

Heavy Duty Tool Positioning System



The BUG-5275 H.D. WELDING GROUP is designed to carry a welding gun along a smooth flat surface. It will mount on any standard BUG-O carriage. It consists of the following items:

BUG-5275 H.D. Welding Group A BGV-1165 Clamp Block B BUG-2708 Clamp C BUG-3320-8 H.D. Tube Rack 8" (203 mm) D BUG-3320-15 H.D. Tube Rack 15" (381 mm) E BUG-5186 Right Angle Clamp F BUG-5188 Torch Holder Assembly G CON-1020 Swivel Clamp Assembly

The BUG-5285 H.D. CUTTING GROUP is designed to carry a cutting torch along a smooth flat surface. It will mount on any standard BUG-O carriage. It consists of the following items:

BUG-5285 H.D. Cutting Group

A BGV-1165 Clamp Block B BUG-3320-15 H.D. Tube Rack 15" (381 mm) C BUG-5182 Right Angle Clamp D BUG-5188 Torch Holder Assembly

The BUG-5185 H.D. ALL POSITION CUTTING GROUP is designed to carry a cutting torch along a smooth flat surface and allows independent adjustment for 360 x 360 setting of the torch. It will mount on any standard BUG-O carriage. It consists of the following items:

BUG-5185 H.D. All Position Cutting Group

A BUG-3320-15 H.D. Tube Rack 15" (381 mm) B BUG-3310-8 H.D. Tube Without Rack C BUG-5188 Torch Holder Assembly D BUG-5184 Tube Clamp Assembly E BUG-5182 Right Angle Clamp F BUG-5280 Tube Mounted Rackholder

A

B

D

C

E

F

A

B

C

D

A

D E

BG

C

F

The HEAVY DUTY RACK SYSTEM is a series of components which are designed to hold welding guns, cutting torches and other process tools. The system consists of tubes, blocks and clamps which are very rigid and compact. They are easy to use and can be mixed and matched in many different ways. PATENTS WORLDWIDE

HEAVY DUTY TOOL POSITIONING SYSTEM - ACCESSORIES

BUG-2915 Torch holder BUG-5189 Clamp Block Assembly BUG-5280 Tube Mounting Rackholder

1-3/8" (35 mm) 1-3/8" (35 mm)

1-3/8" (35 mm) BUG-5462

Right Angle Clamp Assembly[for 7/8" (22.2 mm) Rods

7/8" (22.2 mm)

7/8" (22.2 mm)

BUG-5182 Right Angle Clamp BUG-5184 Tube Clamp Assembly

1-3/8" (35 mm)

7/8" (22.2 mm)

1-3/8" (35 mm)

PAN-1164 Spacer Block(used w/limit switch)

BUG-5245 Welding Gun Mounting Assembly

1-3/8" (35 mm)

BUG-5186 Right Angle Clamp

1-3/8" (35 mm)

BUG-_3310 1-3/8" (35 mm) H.D. Tube w/o rack. (Specify Length)Additional lengths available.

BUG-9180_ 7/8" (22.2 mm) Rod (Specify Length)Additional lengths available.

CON-1020 Swivel ClampAssembly [for 7/8" (22.2 mm) rod]



MUG-1515 Collar7/8" (22.2 mm)

BUG-5188 Torchholder Assemblyw/7/8" (22.2 mm) Rod

BUG-2708 Clamp w/7/8" (22.2 mm) Rod

PAN-1033 Rod Clamp [7/8" (22.2 mm) Rod]

BUG-3320-_H.D. Tube Rack (Specify Length)

At the heart of the Heavy Duty System is the BUG-3320-_H.D. Tube Rack. This rack consists of a 1-3/8" (35 mm) diameter steel tube that has a steel 32 pitch r ack keyed into a machined groove that runs along its side. Choose the length that best suits your application.

The BGV-1165 Clamp Block is made from extruded aluminum with a steel pinion that allows for manually operated positioning of the BUG-3320-_ Heavy Duty Tube Rack. The clamp block also features a ratcheting lock-down lever for quick, easy tightening of the tube rack. It can be bolted to a fixture, or any BUG-O SYSTEMS carriage.

Standard Lengths Available(Specify Length) 8" (203 mm) 12" (305 mm) 15" (381 mm) 24" (609 mm) 30" (760 mm) 44" (1120 mm)

BGV-1165Clamp BlockAssembly3.5" (89 mm)

Litho in U.S.A. LIT-HDTPS-BRO-0608A QUALITY PRODUCT FROM BUG-O SYSTEMS • 280 TECHNOLOGY DRIVE • CANONSBURG, PA 15317-9564 USA

© Weld Tooling Corp. A DIVISION OF WELD TOOLING CORPORATION ROM 1:16

The DC HOB-O lightweight hole borer is easily carried to the work, and is quickly centered on theworkpiece - all you need is a single center- punch mark. Set the hole radius on the built-in scale,light the torch, start your cut and hit the switch to make smooth accurate holes in any position;virtually eliminating the need for grinding and touchup. This flame-cutting machine will cut holesfrom 1" to 8" (25 mm to 200 mm) inside diameter and from 141/2" to 48" (368 mm to 1220 mm)outside diameter. When mounted with magnets, each magnet foot is covered with a shield toprotect it from direct flame and heat.

PATENTS WORLDWIDE


��

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DC HOB-O HOLE BORER

�� !��

�� !��"��#$%� ��&'�(��)!*!�!��+��)��!�#�� !��

PowerRequirements: HOB-2303 120 VAC/50-60/1

HOB-2323 240 VAC/50-60/1HOB-2313 42 VAC/50-60/1

Dimensions: 15.06"L x 28.50"W x 10.50"H(383 mm x 724 mm x 267 mm)

Net Weight: 30 lbs. (13.6 kg)Shipping Weight: 35 lbs. (15.9 kg)

Speed: See Chart

Capacity: See Chart

Drives: The HOB-O Drive Unit is a solid-stateDC drive.

/,"01,23��2#2 �1-/041+04

�##2,"-/0#4

Capacities and Speed Ranges(HOB-5100-F 150:1 Ratio)

1 .4-8 25 10-2004 1.6-33 100 40-8008 3.3-66 200 80-1600

15 6-125 380 150-300020 8-160 500 200-400025 10-200 600 250-500030 12-250 750 300-600035 14-290 900 370-750040 16-330 1000 400-800045 18-375 1100 450-900048 20-400 1200 500-10000

Speed range can also be found from formula:Minimum speed per minute = (0.4 x diameter).Maximum speed per minute = (8 x diameter).

The slug in No. 1, clean scrap, easily handled and readilysold.

NOTE: Individual machines may operate at speeds lowerthan minimum shown in chart.

HOB-1140 Vacuum Base canalso be mounted on allHOB-O units for use on non-ferrous materials. Thevacuum feet adjust to thework surface. Use with ARV-1020 Vacuum Pump Kit.

INCH METRICDIA. SPEED DIA. SPEEDINCH IPM mm mm/min.

The HOB-2080 Blind Area Kitallows you to make smooth ac-curate cuts while eliminating blindarea interference when using theDC HOB-O Hole Borer. It will cutholes from 8" up to 141/2" (203mm to 368 mm). It is lightweightand attaches easily onto themachine.

28.50"(724 mm)

14.00"(356 mm)

15.06"(383 mm)

10.50"(267 mm)

1.68"(43 mm)

.18"(5 mm)1.15"

(30 mm)



HOB-O BLIND AREA KIT

The HOB-2080 BLIND AREA KIT allows you to cut holes from 8" up to 14 1/2" (203 to 368 mm)when using the DC HOB-O PRECISION HOLE BORER, BEVELER AND WELDER. It is lightweightand attaches easily on the machine. Set the hole radius, light the torch, start your cut and hit theswitch to make smooth accurate holes in any position, virtually eliminating the need for grindingand touchup. PATENTS WORLDWIDE

Make smooth accurate cuts while eliminatingblind are interference.

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BLIND AREA KITTo install a Blind Area Kit on a HOB-O:

1. Remove 3 Ring Bolts (A). Caution – besure to keep Ring Spacers (B) in thecorrect position – over the holes in the RingGear.

2. Install new Magnet Ring (C) with 4 CON-1005Legs (D) facing away from Ring Gear. Reinstallthe 3 Ring Bolts (A) through Spacers (B) andtighten securely.

3. Install the 4 Offset Leg and Magnet FootAssemblies (E).NOTE: These may be rotated to any positionand locked using the screw provided (F).

4. Replace original 6" Center Pin with the newHOB-2081 Center Pin (G).

5. Install an adjustable Tip Adaptor BUG-1259 (notsupplied) on torch and insert tip.NOTE: This Adaport is required to reachunder the HOB-O.

6. Rotate Offset Legs & Magnet Feet (E) tooutside of machine and lock.

7. Push Centering Assembly (H) into center ofmachine and lock.

8. Loosen Knob Screw (J) (which locks pin) torelease Center Pin (G).

9. Allow Center Pin (G) to project beneath base ofmachine and place in center-punch mark."Ride" machine down to the work on the centerpin and be sure it seats firmly on the magnets.The entire machine is now centered.Do not hammer or you will knock out thealignment.

10. Set torch on angle and rotate Adjustable TipAdaptor so that cutting tip is perpendicular tothe work surface – adjust to diameter required.

11. Set Rack Stop for diameter required – backtorch away and ignite. When cut is started,switch on Travel Motor, then move rack slowlyagainst stop. Lock rack.

A FAS-0957 Flt Hd Soc Scr 1/4-20 x 3/4B HOB-1042 Ring SpacerC HOB-1044 Magnet Ring 1D CON-1005 Leg 4E CIR-9002 Offset Leg & Magnet Foot 4F FAS-2553 Soc Hd Cap Scr 1/4-20 x 1-1/2 4G HOB-2081 Center Pin 1K ARM-2218 Sleeve-Magnet Cover 4

On OriginalMachine

QuantitySupplied in KitParts List

H

F

D

C

B

GJ

AE

K

Light'n BugAffordable automation that increases production and improves quality.

The Light'n Bug is a versatile travel carriage that can produce machined quality cuts and bevels as well as high quality, uniform welds. It is a compact friction drive machine that will ride on most standard 6" (152 mm) V-grooved track. A solid-state variable speed control allows the Light'n Bug to travel and carry a torch at precise speeds. Plate cutting and welding can be done quickly with a high degree of precision.

Multi-Purpose Burning & Welding Travel Carriage



Light'n Bug

Accessories

.313"(8 mm)

7.00"(178 mm)

6.00"(152 mm)

72.00"(1828 mm)

TRB-1250 72" (183 cm) Rail.

BUG-5485 Contactor/Cable Anchor:Provides built-in contactor switch to control plasma or welding process. The Cable Anchor provides strain relief for all cables.

LBG-1015Fillet Attachment

LBG-1010Radius Attachment

LBG-1020Freehand Steering Attachment

Dimensions:

13.25"337 mm

10.25"260 mm

7.25"184 mm

The addition of these 4 items provides a vertical racking motion for hand held guns.


BUG-9180-4 Rod 7/8 x 4"



A QUALITY PRODUCT FROM BUG-O SYSTEMS • 280 TECHNOLOGY DRIVE • CANONSBURG, PA 15317-9564 USALitho in U.S.A. LIT-LB-BRO-0908A DIVISION OF WELD TOOLING CORPORATION © Weld Tooling Corp. ROM 1:16

6"152 mm

2

Light'n Bug

LBG-1000 Oxy-Fuel Cutting Kit

LBG-1500 Plasma Cutting Kit

Used for straight line cuts and beveling. The Bug-O Torch Holder will accept any standard 1"-3/8" (35 mm) diameter machine torch with a 32 pitch gear rack. Each LBG-1000 kit includes the following: 1 CIR-1010-3 Hose Assembly 1 LBG-1100 Light'n Bug Basic 120 VAC 1 TRB-1126 Manifold LBG-1000 120V Light’n Bug Oxy-FuelLBG-1002 240V Light’n Bug Oxy-FuelLBG-1004 42V Light’n Bug Oxy-Fuel

Dimensions: 13.3" L x 7.3" W x 10.5" H (338 mm L x 185 mm W x 267 mm H)


Net Weight: 28.5 lbs (13 kg)

Shipping Weight: 32.0 lbs (14.5 kg)

Torch and rail not included.

Is specifically designed to work in conjunction with a plasma machine. It's travel speed of 4-85 ipm (100-2160 mm/min) make it ideal as a portable cutting machine for a plasma torch. The torch holder will accept any standard 1-3/8" (35 mm) diameter machine torch with a 32 pitch gear rack. A built-in trigger contactor for initiating the cut makes the Light'n Bug a convenient self contained package.

Each LBG-1500 kit includes the following: 1 BUG-5485 Contactor / Cable Anchor 1 LBG-1100 Light'n Bug Basic 120 VAC LBG-1500 120V Light’n Bug PlasmaLBG-1502 240V Light’n Bug PlasmaLBG-1504 42V Light’n Bug Plasma






NOTE: A shielded gun and cable assembly must be used to reduce hi-frequency interference.

3

Light'n BugLBG-1200 Welding KitA travel carriage that will ride on any standard 6" V-grooved track or by installing guide arms, can be converted into a trackless self-guiding automatic fillet welder. A trigger con-tactor is built into the machine for initiating the arc.Each LBG-1000-OX kit includes the following: 1 BUG-2708 Clamp 1 BUG-5166-8 H.D. Rack Assembly 8" 1 BUG-5485 Contactor / Cable Anchor 1 BUG-9180-4 Rod 4" 1 CON-1020 Swivel Clamp Assembly 1 LBG-1015 Fillet Attachment 1 LBG-1100 Light'n Bug Basic 120 VAC LBG-1200 120V Light’n Bug WeldingLBG-1202 240V Light’n Bug WeldingLBG-1204 42V Light’n Bug Welding






Light'n BugAffordable automation that increases production and improves quality.

The Light'n Bug is a versatile travel carriage that can produce machined quality cuts and bevels as well as high quality, uniform welds. It is a compact friction drive machine that will ride on most standard 6" (152 mm) V-grooved track. A solid-state variable speed control allows the Light'n Bug to travel and carry a torch at precise speeds. Plate cutting and welding can be done quickly with a high degree of precision.

Multi-Purpose Burning & Welding Travel Carriage



Light'n Bug

Accessories

.313"(8 mm)

7.00"(178 mm)

6.00"(152 mm)

72.00"(1828 mm)

TRB-1250 72" (183 cm) Rail.

BUG-5485 Contactor/Cable Anchor:Provides built-in contactor switch to control plasma or welding process. The Cable Anchor provides strain relief for all cables.

LBG-1015Fillet Attachment

LBG-1010Radius Attachment

LBG-1020Freehand Steering Attachment

Dimensions:

13.25"337 mm

10.25"260 mm

7.25"184 mm

The addition of these 4 items provides a vertical racking motion for hand held guns.


BUG-9180-4 Rod 7/8 x 4"



A QUALITY PRODUCT FROM BUG-O SYSTEMS • 280 TECHNOLOGY DRIVE • CANONSBURG, PA 15317-9564 USALitho in U.S.A. LIT-LB-BRO-0908A DIVISION OF WELD TOOLING CORPORATION © Weld Tooling Corp. ROM 1:16

6"152 mm

Powerful Solutions for Welding and Cutting Automation with Precision and Versatility!

The modular design allows the user to quickly reconfigure the unit for straight line cutting or welding, stitch welding or weave welding, all with the same machine!

The Modular Drive System is a powerful machine that allows the operator to custom configure one machine for various applications and runs on standard BUG-O SYSTEMS Rail.

BUG-O SYSTEMS280 Technology DriveCanonsburg, PA 15317Phone: 412-331-1776www.bugo.com

Litho in U.S.A. LIT-MDS-BRO-1208A DIVISION OF WELD TOOLING CORPORATION © Weld Tooling Corp. ROM 1:16

Racking GroupsThere are two machined rack torch mounting groups in the Modular Drive System, one for plasma or oxy-fuel cutting and the other for welding.

Accessories

Remote Control CableInstalls between the Master Drive Unit and the Control Module, allowing the operator to perform work in confined areas where it would be difficult to reach the controls. Two sizes are available as shown below.Order reference: MDS-1060-10 10 Ft (3 m) MDS-1060-25 25 Ft (7.6 m)

Universal Limit KitInstalls between the Master Drive Unit and any of the control modules. This limit kit adds the ability to cycle between limits, stop at limit, or rapid return. All existing functions of the control modules are maintained.Order reference: MDS-1055 For Rigid Rail ApplicationsFMD-1045 For Hi-Flex Rail Applications (not shown)

Spacer w/ScrewsProvides height required to position racking group for plasma cutting applications.Order reference: PAN-1001

Weld Contact CableOrder reference: MDS-1085 10'MDS-1085-25 25'MDS-1085-50 50'

Quick Action ManifoldAllows quick ON/OFF of preset torch and eliminates hose strain.Order reference: MDS-3025 2-Hose MDS-9898 3-HoseHose Assemblies:CIR-1010-3 2-Hose MUG-1119-32 3-Hose

Handle with Cable AnchorKeeps welding cables and contact wires away from the work surface, eliminating drag.Order reference: MPD-1035

Extended Mounting PlateMounts to front of the carriage for use with dual cutting or welding groups, heavy duty racking, etc.Order reference: MDS-1045

Machined Rack Welding GroupOrder reference: MDS-1040

Machined Rack Cutting GroupOrder reference: MDS-1050

A QUALITY PRODUCT FROM BUG-O SYSTEMS • 280 TECHNOLOGY DRIVE • CANONSBURG, PA 15317-9564 USA

2

The Modular Drive System is the only product in the industry that allows the user to configure one machine for various automated applications, now and in the future!Futu re deve lopment has been engineered into the system allowing its modular components to be easily upgraded. As tomorrow’s technologies are introduced, the Modular Drive System can be enhanced to take advantage of new features and capabilities as they are perfected. Other systems will be obsolete as the Modular Drive System will remain “state of the art” in portable motion control!

The Modular Drive System produces precise, accurate cuts and welds.The Master Drive Unit has a high torque, low inertia motor for precise stops and starts and a dedicated fail-safe brake with three times the stopping and holding power of the motor. The unit is equipped with motor overload protection which turns the motor off and engages the brake whenever an excessive load is placed on the machine. In addition, the Master Drive features closed loop speed control for adjustable, repeatable control of critical welding or cutting parameters, and closed loop position control to prevent creep.

Shown Above - Vertical Weld with Linear Weaver

Shown Above - Vertical Weld Shown Above - Overhead Weld with Pendulum Oscillator

7

WPD-1100 Linear WeaverThe Linear Weaver and the Weaver Control Module give the Modular Drive System linear weave motion, producing welds from 1/8" to 2" (3-50 mm) wide. The Linear Weaver bolts onto the front of the Carriage and the Weaver Control Module plugs onto the top of the Master Drive Unit, as shown in the figure below. The Linear Weaver also has motor overload protection which turns off the motor when too much load is placed on the Linear Weaver.

Linear WeaverOrder reference: WPD-1100

WPD-2100 Pendulum WeaverThe Pendulum Weaver and the Weaver Control Module add a pendulum weaving motion to the Modular Drive System. The Pendulum Weaver is particularly useful for weaving fillet welds in a corner joint. The Pendulum Weaver bolts onto the front of the carriage and the Weaver Control Module plugs onto the top of the Master Drive Unit, as shown in the figure below. The Pendulum Weaver has a heavy duty planetary gear box with powerful output for rotating welding gun and attachments.

Pendulum WeaverOrder reference: WPD-2100

The Linear/Pendulum Weaver and Weaver Control Module incorporate the following standard features:

• High torque, low inertia motor for precise starts and stops.• High speed Linear/Pendulum Weaver for weaving, with independent control

of right and left dwell times.• High motor gearing which prevents the crossarm from moving when the

unit is turned off.• Closed loop speed control for adjustable and repeatable control of critical

welding parameters.• Closed loop position control to prevent drift from the weld center

position.• Clutch, to enable rapid installation or replacement of the weaver

cross arm.

Features:

GUN MOUNTING GROUP

LINEAR WEAVERCROSS ARM LINEAR WEAVER

MASTER DRIVE UNIT

CARRIAGE

WEAVER CLUTCH(KNOB ADJUSTMENT)

WEAVER CONTROLMODULE PENDULUM WEAVER

ELECTRONICS BOx

PENDULUM MOUNTING

GROUP

MASTER DRIVEUNIT

CARRIAGE

WEAVER CONTROLMODULE

PENDULUM GEAR BOx

3

Assembling a Modular Drive System is Easy!Choose from the options below to fit your application.

MDS-1002Straight Line Module

MDS-1005Weaver Control

Module

MDS-1004Programmable Stitch

Module

Control Modules 1

MPD-106512" Releasable

CarriageBUG-5910

Tube Carriage

Carriages 3

FMD-1105Hi-Flex

Carriage

2MPD-1000 120 VACMPD-1002 240 VAC

Master Drive Units

For more information on vacuum cups, magnets and rails, please see the corresponding rail page in the “Rails and Attachments” brochure in order to match the correct attachments with your rails.

WPD-2100Pendulum Weaver II

Attachments 5

ARM-Magnets

ARV- Vacuum Cups

FMD-1050Hi-Flex Rail

BRR-1180Bent Rigid Rail

ARR-1080Aluminum Rigid Rail 8'


AFR-3000Semi-Flex Rail

Rails4

CuttingMDS-1050

Machined Rack Cutting Group

WeldingMDS-1040

Machined Rack Welding Group

Weave Welding (Use MDS-1005 Weaver Control Module)

Choose from the following options:

FMD- Vacuum Cups

FMD- Magnets

WPD-1100Linear Weaver

or

6

Weaver Control ModuleThe Weaver Control Module operates the Pendulum or Linear Weaver, and the Master Drive Unit. The Control Module features include: a digital readout and control knob for longitudinal travel speed; a switch for Forward/Stop/Reverse tractor control; an amplitude knob to set weave width from 1/8"-2" (3-50 mm); weave speed control up to 100 in/min (254 cm/min); controls for left and right dwell; a knob to control steering up to 2" (50 mm), either side of center; weld contact; and a power On/Off switch. One of four weld patterns can be chosen using the mode selector switch, as shown in the figure below.

Weaver Control ModuleOrder reference: MDS-1005

Features:

MDS-1005 Weaver Control ModuleDigital display is factory set at cm/min; Field convertible to in/min.

WEAVE SPEED

STEERING CONTROL

DWELL LEFT

SPEED CONTROL

MODE SELECTORSWITCH

POWER OFF-ON SWITCH

DIGITAL READOUT

AMPLITUDE

DWELL RIGHT

DIRECTION SWITCH

WELD CONTACT

1. RUN: In this mode, power to the drive unit is always on and the machine travels continuously both during weave and dwell. Weave speed and dwell time both affect the weld pattern.

2. STEP: The unit travels only during dwell, and stops during the oscillator cross stroke. Changing weave speed does not effect the weld pattern – dwell time does.

3. TRACTOR STOP ON DWELL: The tractor travels during weave stroke; the tractor and weaver stop during dwell.

4. NO WEAVE: In this mode oscillation is stopped. Only the tractor is powered. This mode is used for stringer passes.

1.

2.

3.

4.

Weld Patterns:

4

Control ModulesA Control Module plugs onto the top of the Master Drive Unit and operates various machine functions. Three Control Modules are available; for straight-line cutting and/or welding, programmable stitch welding and one for weave welding capability.

Control Modules

Master Drive UnitAt the heart of the Modular Drive System is the Master Drive Unit which houses the motor, speed control board, power supply, and clutch, that allows rapid manual positioning of the carriage anywhere along the track. The unit runs from 2-120 in/min (51-3048 mm/min) with a vertical load capacity of 60 lbs (27 kg) and a horizontal load capacity of 100 lbs (45 kg).

Order reference: MPD-1000 120 VAC/50-60 HzMPD-1002 240 VAC/50-60 HzMPD-1004 42 VAC/50-60 Hz MPD-1000 Master Drive Unit

MDS-1002 Straight Module

*MDS-1004 Programmable Stitch Module

MDS-1005 Weaver Control Module

The MDS-1002 Straight Control Module provides direction and speed control for continuous cutting or welding.

The MDS-1004 PROGRAM-MABLE MODULE provides stitch controls for welding or cut-ting with the Modular Drive System. All stitching parameters are set and displayed on a graphic screen. This allows each setting to be set exactly the same every time.

The MDS-1005 Weaver Control Module adds a pendulum weaving motion to the Modular Drive System. The Pendulum Weaver is particularly useful for weaving fillet welds in a corner joint.

*MDS-1004: Program Stitch by distance, automatic stop and/or return to start at the end of the cycle, independent timers for puddle-buildup.

5

* Note: see Rails and Attachments brochure for information on BUG-O Systems rails.

CarriagesAluminum Rigid and Semi-Flex Rail CarriagesTwo carriages are available for the Modular Drive System when using BUG-O Aluminum Rigid and Semi-Flex Rails.* One is a releasable 12” carriage equipped with an engagement knob that allows the unit to be placed anywhere along the track. Also available is an 18” carriage which has an extended deck for mounting accessories, wire feeders, etc. (MPD-1055)

MPD-1065 Releasable Carriage 12" on Aluminum Rigid Rail.

Order reference: MPD-1065 Releasable Carriage 12"

Hi-Flex CarriagesHi-Flex carriages are designed for use with

the Modular Drive System when running the equipment on BUG-O Hi-Flex Stainless Steel Rail.* Each carriage has a built-in quick release for mounting or removal at any point along the rail. A cable anchor

is also included to keep welding cables and contact wires away from the work surface.

FMD-1105 Flex Rail Carriage w/Cable Anchor on Hi-Flex Rail.

Order reference: FMD-1105 Drive Carriage

Bent Aluminum Rigid Rail CarriagesFor applications using the Modular Drive System on BUG-O Bent Aluminum Rigid Rail,* a split carriage is available. This releasable carriage can be placed anywhere along the track and easily adjusts to various work diameters. (For outside radii only)

BUG-5910 Tube Carriage on Bent Aluminum Rigid Rail.

Order reference: BUG-5910 Tube Carriage

3

Assembling a Modular Drive System is Easy!Choose from the options below to fit your application.

MDS-1002Straight Line Module

MDS-1005Weaver Control

Module

MDS-1004Programmable Stitch

Module

Control Modules 1

MPD-106512" Releasable

CarriageBUG-5910

Tube Carriage

Carriages 3

FMD-1105Hi-Flex

Carriage

2MPD-1000 120 VACMPD-1002 240 VAC

Master Drive Units

For more information on vacuum cups, magnets and rails, please see the corresponding rail page in the “Rails and Attachments” brochure in order to match the correct attachments with your rails.

WPD-2100Pendulum Weaver II

Attachments 5

ARM-Magnets

ARV- Vacuum Cups

FMD-1050Hi-Flex Rail

BRR-1180Bent Rigid Rail



AFR-3000Semi-Flex Rail

Rails4

CuttingMDS-1050

Machined Rack Cutting Group

WeldingMDS-1040

Machined Rack Welding Group

Weave Welding (Use MDS-1005 Weaver Control Module)

Choose from the following options:

FMD- Vacuum Cups

FMD- Magnets

WPD-1100Linear Weaver

or

6

Weaver Control ModuleThe Weaver Control Module operates the Pendulum or Linear Weaver, and the Master Drive Unit. The Control Module features include: a digital readout and control knob for longitudinal travel speed; a switch for Forward/Stop/Reverse tractor control; an amplitude knob to set weave width from 1/8"-2" (3-50 mm); weave speed control up to 100 in/min (254 cm/min); controls for left and right dwell; a knob to control steering up to 2" (50 mm), either side of center; weld contact; and a power On/Off switch. One of four weld patterns can be chosen using the mode selector switch, as shown in the figure below.

Weaver Control ModuleOrder reference: MDS-1005

Features:

MDS-1005 Weaver Control ModuleDigital display is factory set at cm/min; Field convertible to in/min.

WEAVE SPEED

STEERING CONTROL

DWELL LEFT

SPEED CONTROL

MODE SELECTORSWITCH

POWER OFF-ON SWITCH

DIGITAL READOUT

AMPLITUDE

DWELL RIGHT

DIRECTION SWITCH

WELD CONTACT

1. RUN: In this mode, power to the drive unit is always on and the machine travels continuously both during weave and dwell. Weave speed and dwell time both affect the weld pattern.

2. STEP: The unit travels only during dwell, and stops during the oscillator cross stroke. Changing weave speed does not effect the weld pattern – dwell time does.

3. TRACTOR STOP ON DWELL: The tractor travels during weave stroke; the tractor and weaver stop during dwell.

4. NO WEAVE: In this mode oscillation is stopped. Only the tractor is powered. This mode is used for stringer passes.

1.

2.

3.

4.

Weld Patterns:

2

The Modular Drive System is the only product in the industry that allows the user to configure one machine for various automated applications, now and in the future!Futu re deve lopment has been engineered into the system allowing its modular components to be easily upgraded. As tomorrow’s technologies are introduced, the Modular Drive System can be enhanced to take advantage of new features and capabilities as they are perfected. Other systems will be obsolete as the Modular Drive System will remain “state of the art” in portable motion control!

The Modular Drive System produces precise, accurate cuts and welds.The Master Drive Unit has a high torque, low inertia motor for precise stops and starts and a dedicated fail-safe brake with three times the stopping and holding power of the motor. The unit is equipped with motor overload protection which turns the motor off and engages the brake whenever an excessive load is placed on the machine. In addition, the Master Drive features closed loop speed control for adjustable, repeatable control of critical welding or cutting parameters, and closed loop position control to prevent creep.

Shown Above - Vertical Weld with Linear Weaver

Shown Above - Vertical Weld Shown Above - Overhead Weld with Pendulum Oscillator

7

WPD-1100 Linear WeaverThe Linear Weaver and the Weaver Control Module give the Modular Drive System linear weave motion, producing welds from 1/8" to 2" (3-50 mm) wide. The Linear Weaver bolts onto the front of the Carriage and the Weaver Control Module plugs onto the top of the Master Drive Unit, as shown in the figure below. The Linear Weaver also has motor overload protection which turns off the motor when too much load is placed on the Linear Weaver.

Linear WeaverOrder reference: WPD-1100

WPD-2100 Pendulum WeaverThe Pendulum Weaver and the Weaver Control Module add a pendulum weaving motion to the Modular Drive System. The Pendulum Weaver is particularly useful for weaving fillet welds in a corner joint. The Pendulum Weaver bolts onto the front of the carriage and the Weaver Control Module plugs onto the top of the Master Drive Unit, as shown in the figure below. The Pendulum Weaver has a heavy duty planetary gear box with powerful output for rotating welding gun and attachments.

Pendulum WeaverOrder reference: WPD-2100

The Linear/Pendulum Weaver and Weaver Control Module incorporate the following standard features:

• High torque, low inertia motor for precise starts and stops.• High speed Linear/Pendulum Weaver for weaving, with independent control

of right and left dwell times.• High motor gearing which prevents the crossarm from moving when the

unit is turned off.• Closed loop speed control for adjustable and repeatable control of critical

welding parameters.• Closed loop position control to prevent drift from the weld center

position.• Clutch, to enable rapid installation or replacement of the weaver

cross arm.

Features:

GUN MOUNTING GROUP

LINEAR WEAVERCROSS ARM LINEAR WEAVER

MASTER DRIVE UNIT

CARRIAGE

WEAVER CLUTCH(KNOB ADJUSTMENT)

WEAVER CONTROLMODULE PENDULUM WEAVER

ELECTRONICS BOx

PENDULUM MOUNTING

GROUP

MASTER DRIVEUNIT

CARRIAGE

WEAVER CONTROLMODULE

PENDULUM GEAR BOx

Powerful Solutions for Welding and Cutting Automation with Precision and Versatility!

The modular design allows the user to quickly reconfigure the unit for straight line cutting or welding, stitch welding or weave welding, all with the same machine!

The Modular Drive System is a powerful machine that allows the operator to custom configure one machine for various applications and runs on standard BUG-O SYSTEMS Rail.

BUG-O SYSTEMS280 Technology DriveCanonsburg, PA 15317Phone: 412-331-1776www.bugo.com

Litho in U.S.A. LIT-MDS-BRO-1208A DIVISION OF WELD TOOLING CORPORATION © Weld Tooling Corp. ROM 1:16

Racking GroupsThere are two machined rack torch mounting groups in the Modular Drive System, one for plasma or oxy-fuel cutting and the other for welding.

Accessories

Remote Control CableInstalls between the Master Drive Unit and the Control Module, allowing the operator to perform work in confined areas where it would be difficult to reach the controls. Two sizes are available as shown below.Order reference: MDS-1060-10 10 Ft (3 m) MDS-1060-25 25 Ft (7.6 m)

Universal Limit KitInstalls between the Master Drive Unit and any of the control modules. This limit kit adds the ability to cycle between limits, stop at limit, or rapid return. All existing functions of the control modules are maintained.Order reference: MDS-1055 For Rigid Rail ApplicationsFMD-1045 For Hi-Flex Rail Applications (not shown)

Spacer w/ScrewsProvides height required to position racking group for plasma cutting applications.Order reference: PAN-1001

Weld Contact CableOrder reference: MDS-1085 10'MDS-1085-25 25'MDS-1085-50 50'

Quick Action ManifoldAllows quick ON/OFF of preset torch and eliminates hose strain.Order reference: MDS-3025 2-Hose MDS-9898 3-HoseHose Assemblies:CIR-1010-3 2-Hose MUG-1119-32 3-Hose

Handle with Cable AnchorKeeps welding cables and contact wires away from the work surface, eliminating drag.Order reference: MPD-1035

Extended Mounting PlateMounts to front of the carriage for use with dual cutting or welding groups, heavy duty racking, etc.Order reference: MDS-1045

Machined Rack Welding GroupOrder reference: MDS-1040

Machined Rack Cutting GroupOrder reference: MDS-1050

A QUALITY PRODUCT FROM BUG-O SYSTEMS • 280 TECHNOLOGY DRIVE • CANONSBURG, PA 15317-9564 USA

The Modular Drive Programmable Shape Machine is an easy to use 2-axis machine which you can program to runany contour or pattern for both welding or cutting applications. A handheld terminal supplied with the machine is usedto program the required shape and operation sequence. Other functions besides moves can be programmed, such asrepeats, starts, stops, delays, and rapid traverse. Twenty programs can be stored in machine memory at any one time.

An optional computer software program is available. With this program you can select pre-programmed shapes or createyour own custom shapes, and store and edit any number of them on disk. Selected shapes can then be downloadedto the machine as needed.

The Modular Drive Programmable Shape Machine is compact and portable and can be easily carried throughout yourfacility or job site. The system can be configured to run on all types of Bug-O rail. It is held in position with either powerfulpermanent magnets or vacuum cups, depending on the work material. This enables you to take the machine to the work,which will help reduce your material handling.

Portable Two Axis Shape Machine Cuts In All Positions!


MODULAR DRIVE SYSTEM

PROGRAMMABLE SHAPE MACHINE PACKAGE


3001 WEST CARSON STREET PITTSBURGH, PENNSYLVANIA USA 15204-1899 PHONE: 1- 412-331-1776 http://www.bugo.com FAX: 1- 412-331- 0383

PATENTS WORLDWIDE

Operation:

The machine is in the reference start position,when first plugged in.

There are 3 options (the handheld terminal is notneeded for the first two):

1. MOVE: To change the home position, push theSTOP/PAUSE button, move the machinemanually to the required position using the joystick, and push the reset button.

2. RUN: Push the START/RUN button to cut/weld a shape.

3. PROGRAM: The programming operationrequires the use of the handheld terminal.

Travel Speed: 5-100 ipm (127-2540 mm/min)

Cross Travel: 24" (610 mm)

Max. SegmentDimension: 72" (1800 mm)


Min. IncrementDimension: .01" (0.1 mm)

Delay Increment: .01 seconds

Technical Data: This Windows based software package providesComputer-Aided Programming for ShapeMachines and other BUG-O programmablemachines. The software will run on any PC with theWindows Operating System. A cable is provided tointerface the BUG-O to the PC's serial port. (A USBto RS-232 serial adaptor can be used if a serial portis not available).

The program enables easy creation and editing ofa shape while viewing it on screen. When a shapeis loaded into the program the segment list is shownon the left, and the shape diagram on the right.Selecting (mouse-click) a segment in the listhighlights the corresponding segment in thediagram. Buttons are provided to select Add, Edit,Insert or Delete a segment.

A print function lets you print out the Segment Listand/or Shape Diagram.

Any number of shapes can be saved and stored ondisk. Saved shapes can be loaded from disk intomemory slots corresponding to the 20 shapenumbers in the BUG-O machine.

The software is distributed as a single SETUP file,which when run will install the program on your PC.

Bug-6140 PC Option

SpeedControl

Start/ Run

Manual JogY Axis

Reset

Manual JogX Axis

Stop/Pause

A QUALITY PRODUCT FROM BUG-O SYSTEMS • 3001 WEST CARSON STREET • PITTSBURGH, PA USA 15204-1899Litho in U.S.A. LIT-MDSPSM-BRO-0407A DIVISION OF WELD TOOLING CORPORATION © Weld Tooling Corp. ROM 1:16

MDS - PROGRAMMABLE SHAPE MACHINE

2

The MDS Programmable Shape Machine is a two-axismachine that runs on a track and carries a torch on amotorized cross-arm. It can be used for flame orplasma cutting, or welding, of a variety of shapeswhich are programmed and stored in memory.

The machine has storage capacity in memory for 20different programmed shapes. All programming isdone with the provided handheld terminal. The termi-nal can be plugged into the connector on the rear of the

machine or unplugged at any time. The terminal is notneeded to run the machine once programmed.

Shapes and patterns are built up using segments. Todo this, select the type of segment you want anddetermine what quadrant it is in – type it into theterminal. Any given shape can have up to 50 seg-ments. Other functions such as weld/oxygen, on/off,time delay, or repeat a shape a number of times, alsocount as one segment each, if used.


The programming operation is selected by pressing keys A, B, C, D, or E.

A: ALL SEGMENTS; data entry for new shape consists of total number ofsegments and data for each segment.

B: PROGRAM SEGMENT; press B on terminal to re-program a singlesegment. This is useful if there is an error in data for just one segment, sothat the whole shape does not have to be re-entered.

C: CHANGE SHAPE NUMBER; press C on terminal to change thecurrent shape number. 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 currentshape. The terminal display shows a total number of segments, and data foreach segment one by one each time you press enter.

E: END OF SEGMENT SLOWDOWN; press E to set value of decelera-tion 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 ismaximum slowdown, 0 is no slowdown.

Other functions besides the moves shown above are:Weld Contact/Solenoid On/Off, Pause, Delay, Repeat another shape, Full ellipse, and Rapid Traverse.


Clockwise 90

CounterClockwise 90

X or Y Axis


CounterClockwisePartial Arcs

InclinedLines


3

MPD-1065 4-wheel carriage.Releasable, can be installed or releasedin any position anywhere on the rail.

BUG-5910 Ring Rail Carriage.4 wheels can be adjusted to the requiredring diameter. Releasable.

FMD-1105 Hi-Flex Carriage.Runs on high flex rail as shown below.Releasable.

Carriages

FMD-1050 Hi-Flex RailLength = 5' (1.5 m)

R - Minimum Radius30" (1,000 mm)

The above shown carriages can be used on the rails shown below:

Magnet Bars and Vacuum Bars

Ring Rails DiameterBRR-1210-20 (20" 500 mm)BRR-1210-27 (27" 680 mm)BRR-1210-34 (34" 860 mm)BRR-1210-41 (41" 1040 mm)BRR-1210-48 (48" 1220 mm)

Custom sizes are available.

ARR-1080 L = 8' (2.4 m)HD-Rigid Aluminum RailARR-1085 L = 4' (1.2 m)HD-Rigid Aluminum RailAFR-3000 L = 8' (2.4 m)Semi-Flex Aluminum Rail

ARM-2325Magnet w/Release


ARV-1080/1085Vacuum System

ARM-2380Support Bar withScrew Feet

ARM-2480Support Bar withScrew Magnet Feet

ARM-2120RE-Magnetw/Release

FMD-2325Magnetw/Release

FMD-1220/1230Vacuum System

R

For Rigid and Semi-Flex rail For Ring Rail For Hi-Flex Rails


ITEM QTY PART NUMBER DESCRIPTION1 1 MPD-1000 Master Drive Unit 120 VAC1 1 MPD-1002 Master Drive Unit 240 VAC1 1 MPD-1004 Master Drive Unit 42 VAC2 1 MDS-1165 Shape Control Module3 1 WPD-1100-40 Linear Weaver W/ 40'' ( 1m) Cross Arm4 1 BUG-6050 Hand Held Terminal5 1 MDS-1170 Gas Solenoid 120 VAC6 1 MDS-1172 Gas Solenoid 240 VAC7 1 MPD-1035 Handle w/ Cable Anchor8 1 BUG-5188 Torch Holder Assembly

PARTS LIST

4

8 3

1

5 6

2

7

The Modular Drive Programmable Shape Machine is an easy to use 2-axis machine which you can program to runany contour or pattern for both welding or cutting applications. A handheld terminal supplied with the machine is usedto program the required shape and operation sequence. Other functions besides moves can be programmed, such asrepeats, starts, stops, delays, and rapid traverse. Twenty programs can be stored in machine memory at any one time.

An optional computer software program is available. With this program you can select pre-programmed shapes or createyour own custom shapes, and store and edit any number of them on disk. Selected shapes can then be downloadedto the machine as needed.

The Modular Drive Programmable Shape Machine is compact and portable and can be easily carried throughout yourfacility or job site. The system can be configured to run on all types of Bug-O rail. It is held in position with either powerfulpermanent magnets or vacuum cups, depending on the work material. This enables you to take the machine to the work,which will help reduce your material handling.

Portable Two Axis Shape Machine Cuts In All Positions!


MODULAR DRIVE SYSTEM

PROGRAMMABLE SHAPE MACHINE PACKAGE



PATENTS WORLDWIDE

Operation:

The machine is in the reference start position,when first plugged in.

There are 3 options (the handheld terminal is notneeded for the first two):

1. MOVE: To change the home position, push theSTOP/PAUSE button, move the machinemanually to the required position using the joystick, and push the reset button.

2. RUN: Push the START/RUN button to cut/weld a shape.

3. PROGRAM: The programming operationrequires the use of the handheld terminal.

Travel Speed: 5-100 ipm (127-2540 mm/min)


Max. SegmentDimension: 72" (1800 mm)




Technical Data: This Windows based software package providesComputer-Aided Programming for ShapeMachines and other BUG-O programmablemachines. The software will run on any PC with theWindows Operating System. A cable is provided tointerface the BUG-O to the PC's serial port. (A USBto RS-232 serial adaptor can be used if a serial portis not available).

The program enables easy creation and editing ofa shape while viewing it on screen. When a shapeis loaded into the program the segment list is shownon the left, and the shape diagram on the right.Selecting (mouse-click) a segment in the listhighlights the corresponding segment in thediagram. Buttons are provided to select Add, Edit,Insert or Delete a segment.

A print function lets you print out the Segment Listand/or Shape Diagram.

Any number of shapes can be saved and stored ondisk. Saved shapes can be loaded from disk intomemory slots corresponding to the 20 shapenumbers in the BUG-O machine.

The software is distributed as a single SETUP file,which when run will install the program on your PC.

Bug-6140 PC Option

SpeedControl

Start/ Run

Manual JogY Axis

Reset

Manual JogX Axis

Stop/Pause

A QUALITY PRODUCT FROM BUG-O SYSTEMS • 3001 WEST CARSON STREET • PITTSBURGH, PA USA 15204-1899Litho in U.S.A. LIT-MDSPSM-BRO-1008A DIVISION OF WELD TOOLING CORPORATION © Weld Tooling Corp. ROM 1:16


Mini-Vert III…The Power Tool For Welding.Compact Battery Powered Welding Travel Carriage.

2

MINI-VERT III

The Bug-O Systems Mini-Vert IIIis held on the workpiece withstrong permanent magnets. It willtravel and carry a welding gun inflat or vertical positions producingcontinuous uniform fillet welds.The Mini-Vert III features a quicktorch mount which allows thewelding gun to be rapidly movedfrom one side of the machine tothe other, enabling the operator toweld the entire work piece fromend to end. The Mini-Vert III isshipped with one (1) battery andone (1) battery charger.

• Lightweight, easy to carry design.• Permanent magnet for powerful traction.• Equipped with a four-wheel drive carriage.• Dynamic braking for crisp starts and stops.• Closed loop speed control.• 4 to 39 ipm (100-990 mm/min)

welding speed range.• 14.4-volt rechargeable battery

with battery charger.• Spatter guard on work side wheels.• Versatile quick disconnect gun clamp

will fit most MIG guns.• Precision micro-adjustable slides for gun

positioning.• Available in two charging voltages: 110 &

220 VAC.• Current sensing cable anchor provides auto-

travel Start/Stop.

FEATURES:

2

3

MINI-VERT III

Power Supply: 14.4V, 3Ah batteryDrive: 4 wheel driveClearance: 3/32" (2.4mm)Manual TorchAdjustment: Horizontal/Vertical 3/4"-3/4" (20-20mm)CarryingCapacity: Wall - Vertical 15 lbs. (7kg)

Wall - Horizontal 15 lbs. (7kg)Downhand/flat position 50 lbs. (22.7kg)

Travel: Bi-directionalSpeed: 3.9-39 ipm (100-990mm/min)Dimensions: 13.5" x 8.4" x 10.6"

(345 x 210 x 270mm)Weight: 16 lbs. (7.2kg) without battery

TECHNICAL DATA:

BMV-3000 MINI-VERT III 120 VACBMV-3002 MINI-VERT III 220 VAC

DIMENSIONS:

13.5"(345mm)

10.6"(270mm)

8.4"(21mm)

3

A QUALITY PRODUCT FROM BUG-O SYSTEMS • 3001 WEST CARSON STREET • PITTSBURGH, PA USA 15204-1899Litho in U.S.A. LIT-MINI-VERT-BRO-0806A DIVISION OF WELD TOOLING CORPORATION © Weld Tooling Corp. ROM 1:16

MINI-VERT III

Accessories:

BMV-1510 110 VoltBMV-1512 220 VoltAn adaptor is available for the Mini-Vert III that plugs into thebattery pack adaptor so the machine can run directly from a 110,240 VAC line power.

Battery

QuickDisconnectClamp

Cross Slide

SpeedControlDirection

Power Switch

CableAnchor

Auto-TravelStart Switch

Mini-Vert III Controls:

Economical, Automated Pipe Cutter Saves Layout and Fit-Up Time.

The MM1 is a computer-controlled machine that automates the cutting of profiles, holes, nozzles and shapes on pipe with diameters from 4" to 16" (10-40 cm). It rotates the pipe on it’s roller bed with a three jaw chuck while simultaneously moving a cutting torch back and forth along the pipe’s axis. Pre-programmed shapes such as saddle, hillside, lateral and miter cuts can be made by simply selecting the type of cut from the menu, then entering the diameters of the pipe being processed and pressing the run button to cut your pipe. No need for templates. No time consuming layout or calculations to do. In addition irregular or uncommon shapes can be plotted, programmed and saved for future use.

The machine’s pipe bed is designed for handling lengths of pipe up to 6' (1.83 m) long. Additional pipe bed extensions of 8' (2.44 m) can be added to make up to a 38' (11.6 m) bed. The method of cutting can be oxy-fuel or plasma. If oxy-fuel is used, the machine will be equipped with solenoids and a three-hose cutting torch. When plasma is used, a rotary ground is installed on the machine. The machine can be delivered with plasma torch leads and power source or the customer may provide his own plasma equipment.


280 Technology Drive • Canonsburg, PA 15317-9564 USATelephone: 1-412-331-1776 • 1-800-245-3186 • Fax: 1-412-331-0383


Programmable Pipe CutterMM1

Oxy-Propane, Natural Gas Cutting Tips

Part No. Tip Size Plate Thickness Oxygen PSIG Fuel Gas PSIG Orifice Drill SizeBUG-4070-000 000 Light Gauge to 3/16 15-30 5-15 #68BUG-4070-00 00 3/16-3/8 20-30 5-15 #64BUG-4070-0 0 3/8-5/8 30-40 5-15 #60BUG-4070-1 1 5/8-1 35-50 5-15 #56BUG-4070-2 2 1-2 40-55 5-15 #52BUG-4070-3 3 2-3 45-60 5-15 #42BUG-4070-4 4 3-6 50-75 5-15 #42BUG-4070-5 5 6-8 65-80 5-15 #35BUG-4070-6 6 8-12 70-90 5-15 #30

Oxy-Acetylene Tips

Part No. Tip Size Plate Thickness Oxygen PSIG Fuel Gas PSIG Orifice Drill SizeBUG-1270-000 000 Light Gauge to 3/16 15-20 5-15 #68BUG-1270-00 00 3/16-3/8 20-25 5-15 #64BUG-1270-0 0 3/8-5/8 35-40 5-15 #60BUG-1270-1 1 5/8-1 35-40 5-15 #56BUG-1270-2 2 1-2 40-45 5-15 #52BUG-1270-3 3 2-3 45-50 5-15 #48BUG-1270-4 4 3-6 50-75 10-15 #42

* For tips to cut 6" to 15", please consult factory.

CWO-7635 Powermax 1250Includes the following:• Interface cable to the Cypress Pipe Cutter • 50' (15.24 m) Machine Barrel Torch

Power Requirements:Auto voltage runs on 200-600 Volts, 1 or 3-phase, without the need of rewiring.

Adjustable Output Current: 25-80 Amps

Cutting Capacity: (Recommended) 7/8" (22 mm)

CWO-7636 Consumable Kit for CWO-7635

BUG-1274 3-Hose Machine Torch 10"(254 mm) Cutting Torch is the same for Acetylene-Propane-Natural Gas. Only the tip changes.

MM1 Programmable Pipe Cutter - Accessories

5 LIT-BRO-MM1-0908




137" (3480mm)

MM1 Programmable Pipe Cutter - Dimensions

Dimensions:

MM-1 Application Photos

55" (1397mm)

36" (914mm)

Types of Cuts: A. Pipe Program 1. Saddle Cuts 2. Offset from Center-Line (Hillside) 3. Lateral Cuts 4. Miter Cuts 5. Hole Cuts B. Shape Program 1. Custom Irregular Shapes

Programming Custom Shapes.

Linear Drivewith Torch Holder

Cable Carrier

3-Jaw Chuck

Pipe RollersSEO-3590

Adjustable TableSEO-5480

Bed ExtensionSEO-3390

Rail AssemblyARR-1080

PART NUMBER DESCRIPTIONSEO-3500 MM1 120VSEO-3502 MM1 240V

(See detail below.)

Part No. Description Pipe Bed Pipe Cut LengthSEO-3500 120VAC 6' (1.83 m) 7' (2.13 m)SEO-3500-1 120VAC 14' (4.27 m) 13' (3.96 m)SEO-3500-2 120VAC 22' (6.71 m) 21' (6.40 m)SEO-3500-3 120VAC 30' (9.14 m) 29' (8.84 m)SEO-3500-4 120VAC 38' (11.58 m) 37' (11.28 m)

*Oxy-fuel versions are available.*Machine cutting capacity can be increased to 24" (610 mm) diameter at factory.

When inquiring about 24" (610 mm) diameter models, the machine part number will be followed by -24.

Cutting Diameter: 4"-16" O.D. (10-40 cm)Load Capacity: 1600 lb. (725 kg)Dimensions: 137"L x 36"W x 55"H (348 cm L x 91 cm W x 140cm H) Input Power: 115 VAC / 240 VACNet Weight: 550 lbs (250 kg)Shipping Weight: 800 lbs. (363 kg)

Technical Data:

MM1 Programmable Pipe Cutter - Technical Data MM1 Programmable Pipe Cutter - Programming

Programming With The Handheld Terminal

Main Control Panel

To cut a nozzle or hole, the sequence of actions would be to take the handheld terminal connected to the Control Panel and:

1. Press the reset button on the machine. The handheld terminal will display “READY”.

2. Press “A” on the terminal. The terminal will ask you what type of cut you want. (See Types 1-5, Page 4).

3. Press the number desired and then press “ENTER”.

4. The terminal will ask for the diameter of the small pipe. Press the appropriate dimensions and press “ENTER”.

5. The terminal will ask for the diameter of the large pipe. Press the appropriate dimensions and press “ENTER”.

6. Enter the offset dimension if cutting a hillside nozzle.

7. Enter the “ANGLE” in degrees if cutting a lateral.

8. Press “START” on the machine to begin to cut.

When using Plasma, press “B” and enter the time delay required (which is stored until changed again.)

Mirror Image Switch

Power “On / Off”Circuit Breaker

Speed Control

Stop/PauseResetManual Jog

Start / Resume

CBO-4160 MM1 Panel with Remote

Remote Pendant Connection

CBO-4170MM1 Remote Pendant

Power Indicator

Light

Power Cord

Contact Output

Pendant Control Connection

OFFSET SADDLE


MM1 Programmable Pipe Cutter - Programming

Capabilities

MITER CUT

TYPE 4

HOLE CUTTING AT VARIOUS ANGLES

TYPE 5

SHAPE PROGRAMCUSTOM IRREGULAR SHAPES

TYPE 3

LATERAL NOZZLE CUTS

TYPE 1

SADDLE NOZZLE CUTS

TYPE 2

Programming Arbitrary ShapesFor custom shapes select the “shape” software. Programming is simple but will require a few more steps due to all the variations possible.First, the developed pattern should be laid out as if the pipe is unrolled flat. The cut is then split into a sequence of straight lines or circular arcs that make up the desired pattern.Next, these should be listed in a table on paper, with the type, quadrant and required dimensions (referring to the chart in the Instruction Manual).To program the shape, press “A” , then enter the total segments at the prompt.Next, the data for each segment – type, quadrant and dimensions – are entered in turn, at the prompt.

TIME DELAY

PERCENT SPEED

WELD/OXY ON

WELD/OXY OFF

WAIT FOR START

BUTTON

REPEAT ANOTHER

STEP

AUXILIARY MODES

PIPE CUT NUMBER

2 3 4










Oxy-Acetylene Tips










5 LIT-BRO-MM1-0908




137" (3480mm)


Dimensions:


55" (1397mm)

36" (914mm)










Oxy-Acetylene Tips










5 LIT-MM1-BRO-0908




137" (3480mm)


Dimensions:


55" (1397mm)

36" (914mm)

All Position Overlay System



The All Position Overlay System is designed for pulp digesters, boiler tube walls or any vessel or surface that requires over-lay repair. The system will travel at a regulated, precise travel speed producing consistent uniform overlay patterns. A welding current sensor monitors and controls the torch arc length on pitted or irregular surfaces. The system can be customized for job specific applications on circumferences or flat walls and can be configured to handle a variety of operating windows. The whole system is portable and can be broken down into small pieces for moving thru small manholes or openings.

Custom configured systems for your specific application to increase arc-on time and weld quality.

Overlay Brochure 8_08.indd 1 9/5/2008 2:59:43 PM

All Position Overlay System

Utilizing BUG-O MODULAR DRIVE SYSTEM components, the unit provides precise, repeatable travel patterns with a coverage area of 11’ (3.35 m) vertically by 8’ (2.4 m) horizontally. The vertical height can be customized and the horizontal length can be expanded indefinitely by adding standard BUG-O rails and magnets.

Two Horizontal travel carriages, with full function pendant control, run on parallel rails supporting the vertical rail and tractor and provide adjustable horizontal stepping position . These rails and carriages can be provided for either straight (rigid rail) or curved (flexible rail) work.

The vertical tractor carries the welding gun. Travel speed range is 2-120 ipm (50-3000 mm). The vertical tractor, with full pendant control, includes pendulum weaving, automatic gun work height control and a cycle select module. This module can be preset for one of three cycles; continuous cycle, bi-directional stop at limit or rapid return at limit to start position. Systems can be adapted for horizontal/step-up welding.

All systems are custom configured for your application. Contact BUG-O SYSTEMS to discuss your requirements.

Custom configured systems for your specific application to increase arc-on time and weld quality.

Master Drive Anchor Bolt Hi-Flex Rail

Height Control

Box

Gun

PendulumWeaver

Auto-HeightPower Slide

Vertical RailWith Support

Vertical DriveAnd Weaver

Control

Master Drive(stepper) Control

Slave DriveSensor

TargetHi-Flex RailMagnets

13 FeetC/L to C/L

A QUALITY PRODUCT FROM BUG-O SYSTEMS • 280 TECHNOLOGY DRIVE • CANONSBURG, PA 15317-9564A DIVISION OF WELD TOOLING CORPORATION © Weld Tooling Corp. ROM 1:16 Litho in U.S.A. LIT-BRO-APO-0808

Overlay Brochure 8_08.indd 2 9/5/2008 2:59:43 PM

Pipe-BugMotorized & Manual ChainDriven Pipe Cutting MachinesFrom Bug-O Systems.

2

THE PIPE-BUGBUG-O Systems Pipe-Bug provides a quick, economical way to cut and bevel pipe. One machine canbe fitted to cut any size pipe beginning at a 3" (7.6mm) diameter. Triple link chain and precise controlof chain tension on the traveling wheels give the Pipe-Bug the straightest cutting capability of anytype of chain machine available. For pipe diameters above 18" (457mm) or cuts that must be madewith the machine in the horizontal position, use of a guide strip is recommended. (see page 4)

Manual Pipe-Bug. Part # 05-0520-000Weight: 34 lbs. (16kg) Shipping Weight: 39 lbs. (18kg)

Motorized Pipe-Bug 110V. Part # 05-0520-M00Weight: 42lbs (19kg) Shipping Weight: 47 lbs. (22kg)

Motorized Pipe-Bug 230V. Part # 05-0520-ME2Weight: 56 lbs. (26kg) Shipping Weight: 61 lbs. (28kg)

A motorized Pipe-Bug sets a constant travel speed of the torch making cleaner cuts that reduce grinding andclean-up time.

Torch and chain sold separately.

3

THE PIPE-BUG - Chain KitsPipe-Bug Chain Kits come with the length of chain required for the particular pipe or tube diameter,connecting link, screw and nuts. Purchasing individual Chain Kits help reduce costly set up time. Chainlengths can be shortened or lengthened to fit different diameters.

Chain Kit For 8" (219mm) pipe 01-0520-008 4 lbs. (1.8kg)10" (273mm) pipe 01-0520-010 4 lbs. (1.8kg)12" (330mm) pipe 01-0520-012 5 lbs. (2kg)16" (408mm) pipe 01-0520-016 6 lbs. (2.7kg)20" (508mm) pipe 01-0520-020 7 lbs. (3kg)24" (609mm) pipe 01-0520-024 8 lbs. (3.6kg)30" (762mm) pipe 01-0520-030 9 lbs. (4kg)36" (914mm) pipe 01-0520-036 11 lbs. (5kg)42" (1066mm) pipe 01-0520-042 13 lbs. (5.9kg)48" (1219mm) pipe 01-0520-048 14 lbs. (6.4kg)

Description Part Number Net Weight

Individual chain lengths used for extending pre-existing chain - 18" (457mm) long - 05-0520-007

Length of chain required for various pipe diameters.

Pipe Diameter 3" 4" 6" 8" 10" 12"76mm 114mm 168mm 219mm 273mm 330mm

Chain Length 24.44" 28" 33.875" 39.75" 46" 52.375"621mm 710mm 860mm 1010mm 1170mm 1330mm


Chain Length 55.125" 62.25" 68.375" 72.875" 79.25" 85.4375"1400mm 1580mm 1735mm 1850mm 2013mm 2170mm


Chain Length 91.375" 98" 103.125" 111" 117.67" 123.54"2320mm 2490mm 2620mm 2820mm 2989mm 3138mm

For pipe diameters and chain lengths not listed consult factory.

A DIVISION OF WELD TOOLING CORPORATIONA QUALITY PRODUCT FROM BUG-O SYSTEMS • 3001 WEST CARSON STREET • PITTSBURGH, PA 15204

Litho in U.S.A.LIT-PIPEBUG-BRO-0804© Weld Tooling Corp. ROM 1:16

BUG-O SYSTEMSWelding & Cutting Automation Since 1948.

www.bugo.com

THE PIPE-BUGGuide Strips for extra precision on larger pipe.For larger pipe sizes [above 18" (457mm)] the use of a Guide Strip is recommended. Guide Stripsreduce set up times as the Pipe-Bug does not have to be rotated around the pipe to align the chain onthe pipe.

Selecting the right Guide Strip.Pipe-Bug Guide Strips are sold in sections. There are four basic sections - the head, tail, short centerand long center sections.

To choose the right Guide Strip find your pipe size in the left column then order the type and quantity ofhead, tail and short and long sections as indicated in the column.

Pipe Range Quantity Quantity Quantity Quantity(in/mm) Required Required Required Required

18-32/610-813 1 1 1

18-36/864-914 1 1 1

18-48/1118-1219 1 1 1 1

18-52/1270-1321 1 1 2

18-58/1372-1473 1 1 2 1

18-64/1524-1625 1 1 1 2

18-72/1674-1829 1 1 2 2

18"-32" (457-813mm)Guide Strip Kit 05-0520-012 12 lbs. (5.4kg)

18"-48" (457-1219mm)Guide Strip Kit 05-0520-013 15 lbs. (6.8kg)

Head Section 05-0520-013B 4.7 lbs. (2kg)

Tail Section 05-0520-013D 3.6lbs. (1.6kg)

Short Center Section 05-0520-013C 3.2lbs. (1/5kg)

Long Center Section 05-0520-013A 4.3 lbs (2kg)

Long CenterSectionHead Tail

Short CenterSection

Pipe-Bug Guide StripDescription Part Number Net Weight

Flexible, Modular Motion Control.

Rails and Attachments

Bug-O Systems offers rail for a variety of applications. Each type of rail requires a corresponding carriage and magnets or vacuum cups. Bug-O rail is lightweight and portable. When attached to the work with magnets or vacuum cups the rail can be used in any plane or position. The rail is pre-drilled for easy installation on a fixture. Choose the appropriate rail and attachments for your application.



Aluminum Rigid Rail (ARR) for all position straight line applications. (Page 2)

Bent Rigid Rail (BRR) & Ring Rails for circumferential applications. (Page 3)

Aluminum Semi-Flex Rail (AFR) for large diameter applications down to a minimum radius of 15' (5 m). (Page 4)

Hi-Flex Rail (FMD) for various circumferential and irregular surface applications down to 30" (760 mm) radius. (Page 5)

Custom Configurations From Standard Components.

Carriages & Fixture Building

BUG-2790 Carriage 24" (609 mm)Net Weight: 11 lbs. (5 kg)Shipping Weight: 15 lbs. (6.80 kg)


• Longer deck to mount accessories, wire feeder, etc.

BUG-2785 Carriage 36" (914 mm)Net Weight: 16.5 lbs. (7.50 kg)Shipping Weight: 23.0 lbs. (10.44 kg)



Specialty Carriages For ARR Rail.

8.00"(203 mm)

18.00"(457 mm)

2.00"(50 mm)

BUG-5260 Carriage 18" (457 mm)Net Weight: 6 lbs. (2.72 kg)Shipping Weight: 8 lbs. (3.62 kg)



24.00"(609 mm)

8.00"(203 mm)

Optional Carriages for ARR.

BUG-2205 Carriage Trailer w/Hitch Net Weight: 6 lbs. (2.72 kg)Shipping Weight: 8 lbs. (3.62 kg)

• Used to carry accessories, wire feeder, etc.

8.00"(203 mm)

12.00"(305 mm)

2.00"(50 mm)


• Knob is used manually to move the carriage along the track.

• Bottom knob locks carriage to a fixed rail position.

12.00"(305 mm)

6.18"(157 mm)

2.00"(50 mm)

8.00"(203 mm)

36.00"(914 mm)

2.00"(50 mm)

8.00"(203 mm)

BUG-1096 Yoke Carriage

Fixture BuildingCross Beam AssembliesLongitudinal rail sections are fabricated from rectangular steel tubing with ARR-1080 or ARR-1085 HD Rigid Rail mounted on each side. Two (2) standard lengths are available and these sections can be joined together to provide the length required.

Splicing PlatesBUG-1053 Splicing Plates are used with the BUG-1040-1 and BUG-1040-2 longitudinal rail sections. Order one splice plate per joint.

BUG-1040-1 4' (1.18 m) longBUG-1040-2 8' (2.37 m) long

Special lengths are available on request, contact sales office.

BUG-1045-1 Vertical Column 20" (500 mm) BUG-1045-2 Vertical Column 40" (1000 mm)BUG-1045-3 Vertical Column 60" (1500 mm)

Vertical columns for BUG-1040-1 or BUG-1040-2 longitudinal rail sections are available in three lengths.

BUG-1040-1Rail

BUG-1053Splice Plate

BUG-1045-1Column

20"(500 mm)

For use on BUG-1040_ Cross Beams.

A QUALITY PRODUCT FROM BUG-O SYSTEMS • 280 TECHNOLOGY DRIVE • CANONSBURG, PA 15317-9564 USALitho in U.S.A. LIT-R&A-BRO-0608A DIVISION OF WELD TOOLING CORPORATION © Weld Tooling Corp. ROM 1:16

5

The FMD Flex Rail can flex from a straight to a 30" (760 mm) radius inside or outside. The rail is made from a tempered, wear resistant, stainless steel with a steel rack. It is designed for use with the FMD Hi-Flex Carriage and MDS Drive System. The rail comes in 57.7" (1.47 m) lengths and can be held in place with magnets or vacuum cups. An optional stiffener can be installed behind the rail for heavy duty, straight line applications.

FMD-1050 Hi-Flex RailWithout Magnet Assemblies

Carriages For Hi-Flex Rail

FMD-1105 Drive Carriagewith cable anchor for MDS Master Drive or Universal Bug-O-Matic on High-Flex Rail.

FMD-1150 Hi-Flex Carriage for DC-III Drive.

FMD-1056 Hi-Flex Rail StiffenerConverts Hi-Flex Rail To Rigid Rail.

FMD-2155 Hi-Flex Rail with 8 magnets.

FMD-1220 Vacuum Support for (1) FMD-1050*FMD-1230 Vacuum Support for additional FMD-1050*

*FMD-1050 railsold separately.

ARV-2020 120 Volt/50-60 HzARV-2030 220 Volt/50-60 Hz

R 30"(760 mm)

R 30"(760 mm)

FMD Hi-Flex Rail can flex inside or outside to a minimum radius of 30" (760 mm).3.995"

(102 mm) .080"(2 mm)

.250"(6.4 mm)

Hi-Flex Rail (FMD) & Corresponding Attachments

Note: Only for Universal Bug-O-Matic and Modular Drive.

57.722" (1.47 m) Actual Length

FMD-2150 Hi-Flex Rail with 8 R. E. magnets.

Holding Power 150 lbs. (68 kg)

ARM-2120 Channel Magnet with release.

ARV-1060 Leap Frog KitFor ARV-1080 & ARV-1085. Used to reposition rail without losing vacuum.

FMD-1020 Rail Alignment Tool

FMD-1036VAC Support Bar For Hi-Flex Rail.

Gauging device for rapid alignment of rails to joint.

FMD-2325 Flex Magnet Assembly with release.


Magnets, Vacuum Accessories and Rail Alignment Tool For Hi-Flex Rail

2.00"(50 mm)

Aluminum Rigid Rails (ARR) & Corresponding Attachments

Drive Carriages For Aluminum Rigid Rail.

Magnets, Spacer and Rail Alignment Tool For Aluminum Rigid Rail.A Minimum of 4 Magnets Are Required Per Rail For All Out Of Position Applications.

Heavy Duty Rigid RailARR-1080 & ARR-1085

Extra Heavy Duty Rigid RailARR-1250 & ARR-1200

ARR rail is used for straight line applications and is made from extruded aluminum to machine tool tolerances. A steel machined gear rack is mounted on the rail. Carriage wheels run on recessed ways that are protected from dirt and spatter. The rail can be mounted with magnets, vacuum cups or bolted to a permanent fixture.

2

Vacuum Systems For Non-Ferrous Metals Where Magnets Will Not Hold.Standard Vacuum Support Kits: ARV-1080 Vacuum Kit For ARR-1080 & AFR-3000 Rails. ARV-1085 Vacuum Kit For ARR-1085 Rails.Custom systems are required for Bent Rail.

A C

D

BA. 2.75" (70 mm)B. 4.0" (102 mm)

C. .375" (9.5 mm)D. .875" (22 mm)

A. 2.75" (70 mm)B. 4.0" (102 mm)

C. .375" (9.5 mm)D. .875" (22 mm)


8.00"(203 mm)

2.00"(50 mm)

12.00" (305 mm)

• Releasable (can be installed anywhere along the track).

MPD-1065 Releasable Carriage Net Weight: 7.75 lbs. (3.52 kg)Shipping Weight: 9 lbs. (4.09 kg)

8.00"(203 mm)

12.00"(305 mm)

2.00"(50 mm)

The ARV-2020 (ARV-2030) Vacuum Pump Kit is recommended for use with a maximum of four (4) pieces of rail, or sixteen (16) vacuum bars.

For Modular Drive And Universal Bug-O-Matic. For DC IV Drives.

A

B

D

C

ARR-1080 8' (2.37 m) 93-7/16" Actual LengthARR-1085 4' (1.18 m) 46-9/16" Actual Length

ARR-1250 8' (2.37 m) 93-7/16" Actual LengthARR-1200 4' (1.18 m) 46-9/16" Actual Length

ARV-1085 Vacuum Kit for ARR-1085 4' (1.18 mm) Rigid Rail.

Keep flame or arc at least 4" (100 mm) away from vacuum cups. Vacuum systems can be used on material to 6000 F (3180 C).

Vacuum kits require a source of vacuum which is provided by a Vacuum Pump Kit.

ARV-1036 Vacuum Bar Assemblies are available separately.


Swivel MagnetARM-2325Holding Power 250 lbs. (113 kg)

Fixed MagnetARM-2265Holding Power 200 lbs. (91 kg)

On/Off MagnetARM-2500Holding Power 100 lb. (45 kg)

Spacer ARM-2505Use with ARM-2500 only.

Short MagnetARM-2248Holding Power 200 lbs. (91 kg)

Rail Alignment ToolARR-1090Gauging device for rapid alignment of rails to joint.

3

Bent Rigid Rail (BRR), Ring Rails & Corresponding Attachments

Complete Ring Rail Assemblies

(1) BRR-1210-20 9-16 230-400 20 500(2) BRR-1210-27 16-23 410-580 27 680(3) BRR-1210-34 23-30 590-760 34 860(4) BRR-1210-41 30-37 770-940 41 1040(5) BRR-1210-48 37-44 950-1120 48 1220

* Ring Rails do not include attachments.

Part Number Inches MM Inches MMWork Diameters

RingInside Diameter

Ring Rails and Tube Size Ranges

BRR-1210-_

Magnet AttachmentsA minimum of three (3) magnet plate or screw feet assemblies are required for each ring rail. Either provides 8" (203 mm) of range adjustment.

Vacuum SupportsVacuum Supports may be used instead of mag-nets to mount the Ring Rail on non-magnetic work pieces. Each Vacuum Support System requires a Vacuum Pump Kit for operation.ARV-1240-20 20" Dia. Vacuum Support SystemARV-1240-27 27" Dia. Vacuum Support SystemARV-1240-34 34" Dia. Vacuum Support SystemARV-1240-41 41" Dia. Vacuum Support SystemARV-1240-48 48" Dia. Vacuum Support System

Bent Rigid Rail BRR-1180

Screw Feet AssembliesARM-2380

Magnet Plate AssembliesARM-2480

ARV-2020 120VAC Vacuum Pump KitARV-2030 220VAC Vacuum Pump Kit

BRR rail is used for circumferential applications. The rail can be ordered either as a complete ring or as individual sections.

When ordering specify inside or outside work diameter, method of mounting (magnets, vacuum cups or bolts) and if a complete circle is required.

We will take into consideration the use of magnets or vacuum cups when bending the rail. If you don’t want to order a complete ring, on larger ID’s or OD’s you can “Leapfrog” the rail around the vessel. Use at least four (4) magnets or vacuum cups on each piece of BRR-1180.

Individual sections of Bent Rigid Rail - BRR-1180.

2 3'-11" (1.20 m) 4'-5" (1.35 m) 3 6'-1" (1.85 m) 6'-7" (2.00 m) 4 8'-2" (2.49 m) 8'-8" (2.64 m) 5 10'-2" (3.10 m) 10'-8" (3.25 m) 6 12'-5" (3.79 m) 12'-11" (3.94 m) 8 16'-8" (5.08 m) 17'-2" (5.23 m) 10 20'-11" (6.08 m) 21'-5" (6.23 m)

Pieces ofRail Needed

To Form Complete

Ring

Maximum Outside

Diameter ofWorkpiece

Maximum Inside

Diameter ofWorkpiece

A. 2.75" (70 mm) C. 375" (9.5 mm)B. 4.0" (102 mm) D. 875" (22 mm)

C

A

B

D

WorkDiameter

Ring ID

Carriage For Bent Rigid Rail.

BUG-5910 Split CarriageNet Weight: 7 lbs. (3.17 kg)Shipping Weight: 8 lbs. (3.62 kg)

12.00"(305 mm) 2.56"

(65 mm)

8.12"(206 mm)

• Mounts a DC IV Drive Unit, Modular Drive Unit and Universal Bug-O-Matic.


• Runs on straight or BRR Ring Rail.

A splice plate is mounted at one end of each AFR-3000 Semi-Flex Rail, for joining to additional rail sections. A rack-adjusting tool is supplied with every two (2) rails, for moving the rack on the rail.

NOTE:Use at least four (4) attachments (magnets or vacuum cups) on each SEMI-FLEX RAIL.

Rack Adjusting Tool

Carriages For AFR-3000 Rail.

MPD-1065 Releasable CarriageNet Weight: 7.75 lbs. (3.52 kg)Shipping Weight: 9 lbs. (4.09 kg)


For Modular Drive And Universal Bug-O-Matic.

8.00"(203 mm)

12.00"(305 mm)

2.00"(50 mm)



Magnets and Rail Alignment Tool For AFR-3000 Rail.

4

Vacuum Attachments For AFR-3000 Rail.

Swivel Magnet250 lbs. Holding Power

Fixed Magnet200 lbs. Holding Power

ARM-2425

ARM-2465


ARV-2020 [120 VAC], ARV-2030 [220VAC].

Vacuum Cups are used for mounting the rail to the workpiece when magnet bars will not hold.

Each vacuum bar is fitted with two (2) cups and will exert a maximum pull of 100 lbs. (45 kg).

The ARV-2020 (ARV-2030) Vacuum Pump Kit is recommended for use with a maximum of four (4) pieces of rail, or sixteen (16) vacuum bars.

For DC IV Drives

Minimum Radius15' (5 m)

8' (2.37 m)

8' (2.37 m)

Semi-Flex Rail AFR-3000 & Corresponding AttachmentsSEMI-FLEX RAIL can be bent inside or outside to a minimum radius of 15' (5.0 m) or 30' (10.0 m) diameter without permanent deformation.

CD

A

B

A 2.75" (70 mm)B 4.0" (102 mm)C .33" (8.5 mm)D .500" (12.7 mm)

CAUTION: Bending beyond the recommended 15'-0" (5.0 m) radius may put a permanent bend in the rail and break off some of the rack screws.

8.00"(203 mm)

12.00"(305 mm)

2.00"(50 mm)

ARV-1080 Vacuum Kit on AFR-3000 8' (203 mm) Semi-Flex Rail

Standard Vacuum Support Kit: ARV-1080 Vacuum Kit For AFR-3000 Semi-Flex Rail.

Keep flame or arc at least 4" (100 mm) away from vacuum cups. Vacuum system can be used on material to 6000 F (3180 C).

Vacuum Kits require a source of vacuum which is provided by the Vacuum Pump Kit.


AFR-1090Rail Alignment ToolGauging device for rapid alignment of rails to joint.

ARV-1080 Vacuum Kit for ARR-1080 8' (2.37 mm) Rigid Rail.

ARV-1036 Vacuum BarAssembly


Flexible, Modular Motion Control

Rails and Attachments

Bug-O Systems offers rail for a variety of applications. Each type of rail requires a corresponding carriage and magnets or vacuum cups. Bug-O rail is lightweight and portable. When attached to the work with magnets or vacuum cups the rail can be used in any plane or position. The rail is pre-drilled for easy installation on a fixture. Choose the appropriate rail and attachments for your application.



Aluminum Rigid Rail (ARR) for all position straight line applications. (Page 2)

Bent Rigid Rail (BRR) & Ring Rails for circumferential applications. (Page 3)

Aluminum Semi-Flex Rail (AFR) for large diameter applications down to a minimum radius of 15' (5 m). (Page 4)

Hi-Flex Rail (FMD) for various circumferential and irregular surface applications down to 30" (760 mm) radius. (Page 5)

Custom Configurations From Standard Components.

Carriages & Fixture Building

BUG-2790 Carriage 24" (609 mm)Net Weight: 11 lbs. (5 kg)Shipping Weight: 15 lbs. (6.80 kg)



BUG-2785 Carriage 36" (914 mm)Net Weight: 16.5 lbs. (7.50 kg)Shipping Weight: 23.0 lbs. (10.44 kg)



Specialty Carriages For ARR Rail.

8.00"(203 mm)

18.00"(457 mm)

2.00"(50 mm)




24.00"(609 mm)

8.00"(203 mm)

Optional Carriages for ARR.

BUG-2205 Carriage Trailer w/Hitch Net Weight: 6 lbs. (2.72 kg)Shipping Weight: 8 lbs. (3.62 kg)

• Used to carry accessories, wire feeder, etc.

8.00"(203 mm)

12.00"(305 mm)

2.00"(50 mm)


• Knob is used manually to move the carriage along the track.

• Bottom knob locks carriage to a fixed rail position.

12.00"(305 mm)

6.18"(157 mm)

2.00"(50 mm)

8.00"(203 mm)

36.00"(914 mm)

2.00"(50 mm)

8.00"(203 mm)

BUG-1096 Yoke Carriage

Fixture BuildingCross Beam AssembliesLongitudinal rail sections are fabricated from rectangular steel tubing with ARR-1080 or ARR-1085 HD Rigid Rail mounted on each side. Two (2) standard lengths are available and these sections can be joined together to provide the length required.

Splicing PlatesBUG-1053 Splicing Plates are used with the BUG-1040-1 and BUG-1040-2 longitudinal rail sections. Order one splice plate per joint.

BUG-1040-1 4' (1.18 m) longBUG-1040-2 8' (2.37 m) long

Special lengths are available on request, contact sales office.

BUG-1045-1 Vertical Column 20" (500 mm) BUG-1045-2 Vertical Column 40" (1000 mm)BUG-1045-3 Vertical Column 60" (1500 mm)

Vertical columns for BUG-1040-1 or BUG-1040-2 longitudinal rail sections are available in three lengths.

BUG-1040-1Rail

BUG-1053Splice Plate

BUG-1045-1Column

20"(500 mm)

For use on BUG-1040_ Cross Beams.

A QUALITY PRODUCT FROM BUG-O SYSTEMS • 280 TECHNOLOGY DRIVE • CANONSBURG, PA 15317-9564 USALitho in U.S.A. LIT-R&A-BRO-0608A DIVISION OF WELD TOOLING CORPORATION © Weld Tooling Corp. ROM 1:16

5

The FMD Flex Rail can flex from a straight to a 30" (760 mm) radius inside or outside. The rail is made from a tempered, wear resistant, stainless steel with a steel rack. It is designed for use with the FMD Hi-Flex Carriage and MDS Drive System. The rail comes in 57.7" (1.47 m) lengths and can be held in place with magnets or vacuum cups. An optional stiffener can be installed behind the rail for heavy duty, straight line applications.

FMD-1050 Hi-Flex RailWithout Magnet Assemblies

Carriages For Hi-Flex Rail

FMD-1105 Drive Carriagewith cable anchor for MDS Master Drive or Universal Bug-O-Matic on High-Flex Rail.

FMD-1150 Hi-Flex Carriage for DC-III Drive.

FMD-1056 Hi-Flex Rail StiffenerConverts Hi-Flex Rail To Rigid Rail.

FMD-2155 Hi-Flex Rail with 8 magnets.

FMD-1220 Vacuum Support for (1) FMD-1050*FMD-1230 Vacuum Support for additional FMD-1050*

*FMD-1050 railsold separately.


R 30"(760 mm)

R 30"(760 mm)

FMD Hi-Flex Rail can flex inside or outside to a minimum radius of 30" (760 mm).3.995"

(102 mm) .080"(2 mm)

.250"(6.4 mm)

Hi-Flex Rail (FMD) & Corresponding Attachments

Note: Only for Universal Bug-O-Matic and Modular Drive.

57.722" (1.47 m) Actual Length

FMD-2150 Hi-Flex Rail with 8 R. E. magnets.


ARM-2120 Channel Magnet with release.


FMD-1020 Rail Alignment Tool

FMD-1036VAC Support Bar For Hi-Flex Rail.

Gauging device for rapid alignment of rails to joint.

FMD-2325 Flex Magnet Assembly with release.


Magnets, Vacuum Accessories and Rail Alignment Tool For Hi-Flex Rail

2.00"(50 mm)

Now you can make Saddle Cuts, Offset Cuts, Laterals, Miters, Holes and Shapes quickly, easily, and economically.




Programmable Saddle, Elbowand Shape Cutter for Pipes.

SE-4PD, SE-2PTD& SE-4PTD

The Programmable SE-4PD, SE-2PTD and SE-4PTD Machines provide dual programming capabilities. A “Pipe” program for making Saddle Cuts, Offset Cuts, Laterals and Miters. A second (selectable) program is used for cutting customized shapes in pipes. These machines are available for plasma or oxy-fuel cutting and eliminate the need to make templates or layout complex cuts.



SE-2-4PTD-BRO-1208

© Weld Tooling Corp. ROM 1:16http://www.cypressweld.com


Part No. Tip Size Plate Thickness Oxygen PSIG Fuel Gas PSIG Orifice Drill SizeBUG-4070-000 000 Light Gauge to 3/16" (4.8mm) 15-30 5-15 #68BUG-4070-00 00 3/16"-3/8" (4.8-9.5mm) 20-30 5-15 #64BUG-4070-0 0 3/8"-5/8" (9.5-15.9mm) 30-40 5-15 #60BUG-4070-1 1 5/8"-1" (15.9-25.4mm) 35-50 5-15 #56BUG-4070-2 2 1"-2" (25.4-50.8mm) 40-55 5-15 #52BUG-4070-3 3 2"-3" (50.8-76.2mm) 45-60 5-15 #42BUG-4070-4 4 3"-6" (76.2-152.4mm) 50-75 5-15 #42BUG-4070-5 5 6"-8" (152.4-203.2mm) 65-80 5-15 #35BUG-4070-6 6 8"-12" (203.2-304.8mm) 70-90 5-15 #30

Oxy-Acetylene Tips

Part No. Tip Size Plate Thickness Oxygen PSIG Fuel Gas PSIG Orifice Drill SizeBUG-1270-000 000 Light Gauge to 3/16" (4.8mm) 15-20 5-15 #68BUG-1270-00 00 3/16"-3/8" (4.8-9.5mm) 20-25 5-15 #64BUG-1270-0 0 3/8"-5/8" (9.5-15.9mm) 35-40 5-15 #60BUG-1270-1 1 5/8"-1" (15.9-25.4mm) 35-40 5-15 #56BUG-1270-2 2 1"-2" (25.4-50.8mm) 40-45 5-15 #52BUG-1270-3 3 2"-3" (50.8-76.2mm) 45-50 5-15 #48BUG-1270-4 4 3"-6" (76.2-152.4mm) 50-75 10-15 #42

* For tips to cut 6" to 15" (152.4-381 mm), please consult factory.





CWO-7636 Consumable Kit for CWO-7635BUG-1274

3-Hose Oxy-Acetylene Machine Torch 10" (254 mm)

ACCESSORIES

BUG-4072 3-Hose Propane/Natural Gas Machine Torch 10" (254 mm)

2

MODEL SE-2PTD

Technical Data:Cutting Diameter: Pass through 1" to 4 3/4" (25 mm to 120 mm) O.D.

Rotation Speed: Min: 0.3 rpm Max: 3.7 rpm

Dimensions: 40"L x 19"W x 35"H (1016 x 483 x 889 mm)

Input Power: 120/50-60/1 or 220/50-60/1



Types of Cuts: Pipe Program: 1. Saddle Cuts 2. Offset (Hillside) 3. Laterals 4. Miter Cuts, Single Cut 3. Piece Elbow 5. Hole Cuts

Shape Program: Standard Any Arbitrary Shape

PLASMA VERSION:

PART NUMBER DESCRIPTIONSEO-4250-PL SE-2PTD 120V PlasmaSEO-4252-PL SE-2PTD 240V Plasma

Cable Support Post

Programming Pendant

Linear Drive has 18" (457 mm) of Work Area Travel

Adjustable Pipe Support

5" (127 mm) I.D Hole Through

Ground Brushes

Ground Ring

Mirror Image Switch

When using the pass through feature the max weight of the pipe should not exceed 375 lbs. (170 kg). It is very important to have your pipe supports in alignment with the machine to support the pipe in the back of the machine.

The machine is designed to sit on a work table. Method of cutting can be oxy-fuel or plasma. If oxyfuel is used, the machine will be equipped with solenoids and a three hose cutting torch. When plasma is used, a rotary ground is installed on the machine and an external contactor relay. The machine can be delivered with plasma torch leads and power source, or the customer may provide their own plasma equipment.

3 Jaw Chuck

Contact Relay:Turns Plasma Cutting Torch On and Off Automatically!

Capacity: Max Weight: 375 lbs. (170 kg) (pass through, when supported).

Short sections of pipe up to 14" (355 mm) dia.can be mounted off the chuck face.

Max Overhung Length: 15" (383 mm) Max Overhung Weight: 150 lbs. (68 kg)

OXY-FUEL VERSION:

PART NUMBER DESCRIPTIONSEO-4250-OX SE-2PTD 120V Oxy-fuelSEO-4252-OX SE-2PTD 240V Oxy-fuel

Oxy-Fuel Manifold with Solenoid Kit:Turns Cutting Oxy On and Off Automatically!

7

PROGRAMMING CONT’D.

Capabilities

MITER CUT

TYPE 4


TYPE 5


TYPE 3

LATERAL NOZZLE CUTS

TYPE 1

SADDLE NOZZLE CUTS

TYPE 2OFFSET SADDLE


TIMEDELAY

PERCENTSPEED

WELD/OXYON

WELD/OXYOFF

WAIT FOR START

BUTTON

REPEATANOTHER

STEP

AUXILIARYMODES

PIPE CUTNUMBER

Programming Arbitrary ShapesFor custom shapes select the “shape” software. Programming is simple but will require a few more steps due to all the variations possible.First, the developed pattern should be laid out as if the pipe is unrolled flat. The cut is then split into a sequence of straight lines or circular arcs that make up the desired pattern.Next, these should be listed in a table on paper, with the type, quadrant and required dimensions (referring to the chart in the Instruction Manual).For example, to cut a slot like the one in the diagram, the shape would consist of the six segments shown. The first segment is a clockwise 900 arc, which is Type 1, in quadrant 3 and the required dimension is the radius.To program the shape, press “A”, then enter the total segments at the prompt.Next, the data for each segment – type, quadrant and dimensions – are entered in turn, at the prompt.

3

MODEL SE-4PTDPLASMA VERSION:


OXY-FUEL VERSION:


Cable Support Post

Programming Pendant



12 3/4" (324 mm) Pipe will Pass Through Machine

Ground Brushes

Ground Ring

Mirror Image Switch

3 Jaw Chuck



Technical Data:Cutting Diameter: Pass through 4"-12 3/4" O.D. (100 mm to 325 mm).

Internal chucking of pipe (for short lengths) up to 20" (500 mm) diameter.

Rotation Speed: Min: 0.2 rpm Max: 3 rpm

Dimensions: 52 1/2"L x 24 1/4"W x 33"H (1334 x 616 x 838 mm)

Input Power: 120/50-60/1 or 220/50-60/1

Net Weight: 705 lbs. (320kg)




Additional Capacity: Short sections of pipe up to 20" (500 mm) can be chucked internally.

Max Length: 18" (460 mm)

Max Weight: 375 lbs. (170 kg)


The machine is designed to sit on a work table. Method of cutting can be oxy-fuel or plasma. If oxyfuel is used, the machine will be equipped with solenoids and a three hose cutting torch. When plasma is used, a rotary ground is installed on the machine and an external contactor relay. The machine can be delivered with plasma torch leads and power source, or the customer may provide his own plasma equipment.


6

MAIN CONTROL PANEL & PROGRAMMING


Main Control Panel

ContactOutput

Reset

Power“On / Off”

Stop / PauseStart / Resume

SpeedControl

PowerCord

ManualJog

PendantControlConnection

CircuitBreaker

Power Indicator Light











6

4

MODEL SE-4PD

PLASMA VERSION:

PART NUMBER DESCRIPTIONSEO-4520-PL SE-4PD 120V PlasmaSEO-4522-PL SE-4PD 240V Plasma

OXY-FUEL VERSION:

PART NUMBER DESCRIPTIONSEO-4520-OX SE-4PD 20V Oxy-fuelSEO-4520-OX SE-4PD 240V Oxy-fuel

Cable Support Post

Programming Pendant


Rotary Ground

Rotary Ground Bracket

Mirror Image Switch

3 Jaw Chuck



Technical Data:Cutting Diameter: 1"-12" O.D. (25 mm to 304 mm).


Dimensions: 38"L x 15.25"W x 22.25"H (965 x 387 x 565 mm)

Input Power: 115 VAC





Capacity: 100 lbs. (45.36 kg)

The SE-4PD is a computer-controlled machine that automates the cutting of profiles, holes, nozzles and shapes on pipe with diameters from 1" to 12" (2.54-30.48 cm). It rotates the pipe on it’s roller bed with a three jaw chuck while simultaneously moving a cutting torch back and forth along the pipe’s axis. Pre-programmed shapes such as saddle, hillside, lateral and miter cuts can be made by simply selecting the type of cut from the menu, then entering the diameters of the pipe being processed and pressing the run button to cut your pipe. No need for templates. No time consuming layout or calculations to do. In addition irregular or uncommon shapes can be plotted, programmed and saved for future use.

The machine is designed to sit on a work table. Method of cutting can be oxy-fuel or plasma. If oxy-fuel is used, the machine will be equipped with solenoids and a three hose cutting torch. When plasma is used, a rotary ground is installed on the machine and an external contactor relay. The machine can be delivered with plasma torch leads and power source, or the customer may provide his own plasma equipment.

Hose Nut Oxygen,Hose Nut NippleHose Nut Fuel GasHose Clamp

3-Hose Assembly 5' (1.5 m)

5

ACCESSORY KITS

PLASMA KITThe Plasma Kit enables you to convert the machine to use a plasma cutting process. The kit includes a grounding brush and support, rotary grounding ring and a voltage specific contact relay.

Plasma Kits for SE-2PTDSEO-4560 Plasma Kit 120 VACSEO-4562 Plasma Kit 240 VAC

Plasma Kits for SE-4PTDSEO-4470 Plasma Kit 120 VACSEO-4472 Plasma Kit 240 VAC

Plasma Kits for SE-4PDSEO-4570 Plasma Kit 120 VACSEO-4572 Plasma Kit 240 VAC

OXY-FUEL KIT:The Oxy-Fuel Kit enables you to convert the machine to use an oxy-fuel cutting process. The kit includes (2) oxygen hose nuts, (1) fuel gas hose nut, (3) 1/4" hose nipples, (3) hose clamps, 3-hose assembly 5', manifold mounting plate & hardware as well as voltage specific quick acting manifold with solenoid.

SEO-4480 Oxy-Fuel Kit 120 VACSEO-4482 Oxy-Fuel Kit 240 VAC

MECHANICAL ELEVATING TABLE:The Mechanical Elevating Table provides an adjustable mobile surface for the machine to be mounted to. The Mechanical Elevating Table is equipped with (2) fixed and (2) swivel 5" diameter base-wheels and can be raised from a lowered height of 24" to a raised height of 42". A floor lock is provided for holding the table securely in position when in use.

SEO-5486 Mechanical Elevating Table.

3

MODEL SE-4PTDPLASMA VERSION:


OXY-FUEL VERSION:


Cable Support Post

Programming Pendant



12 3/4" (324 mm) Pipe will Pass Through Machine

Ground Brushes

Ground Ring

Mirror Image Switch

3 Jaw Chuck



Technical Data:Cutting Diameter: Pass through 4"-12 3/4" O.D. (100 mm to 325 mm).

Internal chucking of pipe (for short lengths) up to 20" (500 mm) diameter.

Rotation Speed: Min: 0.2 rpm Max: 3 rpm

Dimensions: 52 1/2"L x 24 1/4"W x 33"H (1334 x 616 x 838 mm)

Input Power: 120/50-60/1 or 220/50-60/1





Additional Capacity: Short sections of pipe up to 20" (500 mm) can be chucked internally.

Max Length: 18" (460 mm)

Max Weight: 375 lbs. (170 kg)


The machine is designed to sit on a work table. Method of cutting can be oxy-fuel or plasma. If oxyfuel is used, the machine will be equipped with solenoids and a three hose cutting torch. When plasma is used, a rotary ground is installed on the machine and an external contactor relay. The machine can be delivered with plasma torch leads and power source, or the customer may provide his own plasma equipment.


6

MAIN CONTROL PANEL & PROGRAMMING


Main Control Panel

ContactOutput

Reset

Power“On / Off”

Stop / PauseStart / Resume

SpeedControl

PowerCord

ManualJog

PendantControlConnection

CircuitBreaker

Power Indicator Light











6

2

MODEL SE-2PTD

Technical Data:Cutting Diameter: Pass through 1" to 4 3/4" (25 mm to 120 mm) O.D.


Dimensions: 40"L x 19"W x 35"H (1016 x 483 x 889 mm)

Input Power: 120/50-60/1 or 220/50-60/1





PLASMA VERSION:


Cable Support Post

Programming Pendant



5" (127 mm) I.D Hole Through

Ground Brushes

Ground Ring

Mirror Image Switch


The machine is designed to sit on a work table. Method of cutting can be oxy-fuel or plasma. If oxyfuel is used, the machine will be equipped with solenoids and a three hose cutting torch. When plasma is used, a rotary ground is installed on the machine and an external contactor relay. The machine can be delivered with plasma torch leads and power source, or the customer may provide their own plasma equipment.

3 Jaw Chuck


Capacity: Max Weight: 375 lbs. (170 kg) (pass through, when supported).


Max Overhung Length: 15" (383 mm) Max Overhung Weight: 150 lbs. (68 kg)

OXY-FUEL VERSION:



7

PROGRAMMING CONT’D.

Capabilities

MITER CUT

TYPE 4


TYPE 5


TYPE 3

LATERAL NOZZLE CUTS

TYPE 1

SADDLE NOZZLE CUTS

TYPE 2OFFSET SADDLE


TIMEDELAY

PERCENTSPEED

WELD/OXYON

WELD/OXYOFF

WAIT FOR START

BUTTON

REPEATANOTHER

STEP

AUXILIARYMODES

PIPE CUTNUMBER

Programming Arbitrary ShapesFor custom shapes select the “shape” software. Programming is simple but will require a few more steps due to all the variations possible.First, the developed pattern should be laid out as if the pipe is unrolled flat. The cut is then split into a sequence of straight lines or circular arcs that make up the desired pattern.Next, these should be listed in a table on paper, with the type, quadrant and required dimensions (referring to the chart in the Instruction Manual).For example, to cut a slot like the one in the diagram, the shape would consist of the six segments shown. The first segment is a clockwise 900 arc, which is Type 1, in quadrant 3 and the required dimension is the radius.To program the shape, press “A”, then enter the total segments at the prompt.Next, the data for each segment – type, quadrant and dimensions – are entered in turn, at the prompt.

Now you can make Saddle Cuts, Offset Cuts, Laterals, Miters, Holes and Shapes quickly, easily, and economically.




Programmable Saddle, Elbowand Shape Cutter for Pipes.

SE-4PD, SE-2PTD& SE-4PTD

The Programmable SE-4PD, SE-2PTD and SE-4PTD Machines provide dual programming capabilities. A “Pipe” program for making Saddle Cuts, Offset Cuts, Laterals and Miters. A second (selectable) program is used for cutting customized shapes in pipes. These machines are available for plasma or oxy-fuel cutting and eliminate the need to make templates or layout complex cuts.



SE-2-4PTD-BRO-1208

© Weld Tooling Corp. ROM 1:16http://www.cypressweld.com


Part No. Tip Size Plate Thickness Oxygen PSIG Fuel Gas PSIG Orifice Drill SizeBUG-4070-000 000 Light Gauge to 3/16" (4.8mm) 15-30 5-15 #68BUG-4070-00 00 3/16"-3/8" (4.8-9.5mm) 20-30 5-15 #64BUG-4070-0 0 3/8"-5/8" (9.5-15.9mm) 30-40 5-15 #60BUG-4070-1 1 5/8"-1" (15.9-25.4mm) 35-50 5-15 #56BUG-4070-2 2 1"-2" (25.4-50.8mm) 40-55 5-15 #52BUG-4070-3 3 2"-3" (50.8-76.2mm) 45-60 5-15 #42BUG-4070-4 4 3"-6" (76.2-152.4mm) 50-75 5-15 #42BUG-4070-5 5 6"-8" (152.4-203.2mm) 65-80 5-15 #35BUG-4070-6 6 8"-12" (203.2-304.8mm) 70-90 5-15 #30

Oxy-Acetylene Tips

Part No. Tip Size Plate Thickness Oxygen PSIG Fuel Gas PSIG Orifice Drill SizeBUG-1270-000 000 Light Gauge to 3/16" (4.8mm) 15-20 5-15 #68BUG-1270-00 00 3/16"-3/8" (4.8-9.5mm) 20-25 5-15 #64BUG-1270-0 0 3/8"-5/8" (9.5-15.9mm) 35-40 5-15 #60BUG-1270-1 1 5/8"-1" (15.9-25.4mm) 35-40 5-15 #56BUG-1270-2 2 1"-2" (25.4-50.8mm) 40-45 5-15 #52BUG-1270-3 3 2"-3" (50.8-76.2mm) 45-50 5-15 #48BUG-1270-4 4 3"-6" (76.2-152.4mm) 50-75 10-15 #42

* For tips to cut 6" to 15" (152.4-381 mm), please consult factory.





CWO-7636 Consumable Kit for CWO-7635BUG-1274

3-Hose Oxy-Acetylene Machine Torch 10" (254 mm)

ACCESSORIES

BUG-4072 3-Hose Propane/Natural Gas Machine Torch 10" (254 mm)

Now You Can Make Saddle Cuts, Offset Cuts, LateralMiters and Elbows Quickly, Easily and Economically.

The Programmable Saddle and Elbow Cutter is a computer controlled machine that auto-mates the end preparation of pipes for fabrication. It rotates a pipe in a three jaw chuckwhile driving a cutting torch back and forth along the pipe’s axis. The cutting torch tracesthe path of intersection of the pipe with another pipe of the same or larger diameter.

CYPRESS WELDING EQUIPMENT INC.A SUBSIDIARY OF WELD TOOLING CORPORATION

P.O. BOX 690168, HOUSTON, TEXAS 77269 Telephone: 1-281-469-0746 Fax: 1-281-469-9354http://www.cypressweld.com

Programmable Saddle and Elbow CutterSE-4P

Programmable Saddle and Elbow CutterSE-4PTECHNICAL DATA:

Cutting Diameter: 1"-12" O.D. (25-304 mm)Rotation Speed: 0.2-3.7 rpmDimensions: 38"L x 15.25"W x 22.25"H

(965 x 387 x 565 mm)

Input Power: 115 VACNet Weight: 200 lbs (91 kg)Shipping Weight: 300 lbs. (136 kg)

Types of Cuts:1. Saddle Cuts2. Offset (Hillside)3. Laterals4. Miter Cuts; single cut or 3 piece elbow5. Hole Cuts

The machine is designed to sit on a work table.Method of cutting can be oxy-fuel or plasma. Ifoxy-fuel is used, the machine will be equippedwith solenoids and a three-hose cutting torch.When plasma is used, a rotary ground is installedon the machine. The machine can be deliveredwith plasma torch leads and power source. Thecustomer may provide his own plasma equipment.

2

TYPE 1 TYPE 2

TYPE 3 TYPE 4

SADDLE CUTS OFFSET SADDLE CUTS(Hillside)

LATERAL MITER CUT


3

JOYSTICK - To Position Torch

To HANDHELD TERMINAL

ROTATION GROUNDfor Plasma Cutting

SPEED CONTROL

CIRCUIT BREAKER

STOP

START

RESETPOWER CORD

PILOT LIGHTPOWER ON/OFF

HANDHELD TERMINAL:

1. Press the reset button on the machine. The handheldterminal will display “READY”.

2. Press “A” on the terminal. The terminal will ask youwhat type of cut you want. (See Types 1-4, Page 2).


4. The terminal will ask for the diameter of the small pipe.Press the appropriate dimensions and press “ENTER”.

5. The terminal will ask for the diameter of the large pipe.Press the appropriate dimensions and press “ENTER”.

6. Enter the offset dimension.

7. Enter the “ANGLE” in degrees.

8. Press “START” on the machine to begin to cut. Itcouldn’t be easier!

When using Plasma, press “B” and enterthe time delay required (which is storeduntil changed again.)


SE-4P-499

CYPRESS WELDING EQUIPMENT, INC.A SUBSIDIARY OF WELD TOOLING CORPORATION

P.O. BOX 690168, HOUSTON, TEXAS 77269 Telephone: 1-281-469-0746 Fax: 1-281-469-9354http://www.cypressweld.com

PATENTS WORLDWIDE

The BUG-6150 Programmable Shape Machine is an easy to use 2-axis machine which you can program to run any contour or pattern for both welding or cutting applications. A handheld terminal supplied with the machine is used to program the required shape and operation sequence. Other functions besides moves can be programmed, such as repeats, starts, stops, delays, and rapid traverse. 10 programs can be stored in machine memory at any one time.

An optional computer software program is available, for any IBM compatible computer. With this program you can select pre-programmed shapes or create your own custom shapes, and store any number of them on disk. Selected shapes can then be downloaded to the machine as needed.

The Programmable Shape Machine is compact and lightweight and can be easily carried throughout your facility. It is held in position with either powerful permanent magnets or vacuum cups, depending on the work material. This enables you to take the machine to the work, which will help reduce your material handling.

Burn Virtually Any Shape, Weld Any Pattern, Quickly And Easily, In Any Position…


PROGRAMMABLE SHAPE MACHINE



BUG-6200 PROGRAMMABLE SHAPE OXY-FUEL CUTTING KIT 120VAC/50-60/1Includes:1 BUG-6150 Programmable Shape Machine and Handheld Terminal 2.5-50 ipm (63-1250 mm/min)1 BUG-6090 Q.A. Manifold w/Solenoid 120 VAC1 BUG-6155 Cutting Group

BUG-6202 PROGRAMMABLE SHAPE CUTTING KIT 240VAC/50-60/1


BUG-6201 PROGRAMMABLE SHAPE WELDING KIT 120VAC/50-60/1Includes:1 BUG-6150 Programmable Shape Machine and Handheld Terminal 2.5-50 ipm (63-1250 mm/min)1 BUG-6080 Relay Box w/Cable Anchor [To Control Arc On/Off]1 BUG-6145 Welding Group

BUG-6203 PROGRAMMABLE SHAPE WELDING KIT 240VAC/50-60/1


BUG-6210 PROGRAMMABLE SHAPE PLASMA CUTTING KIT 120VAC/50-60/1Includes:1 BUG-6150-E Programmable Shape Machine and Handheld Terminal. 4-80 ipm (100-2000 mm/min)1 BUG-6080 Relay Box w/Cable Anchor (To control arc on/off)1 BUG-6155 Cutting Group

BUG-6212 PROGRAMMABLE SHAPE MACHINE 240VAC/50-60/1



BUG-6155 Cutting Group BUG-6145 Welding GroupBUG-6080 Relay Boxw/Cable Anchor

BUG-6090 Cutting SolenoidAccessory 120VAC

*Rail is not included with kits.

A QUALITY PRODUCT FROM BUG-O SYSTEMS • 280 TECHNOLOGY DRIVE • CANONSBURG, PA USA 15317-9564A DIVISION OF WELD TOOLING CORPORATION © Weld Tooling Corp. ROM 1:16 Litho. in U.S.A. LIT-PSM-BRO-1208

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PROGRAMMABLE SHAPE MACHINEThe Programmable Shape Machine is a two-axis machine that runs on a track and carries a torch on a motorized cross-arm. It can be used for flame or plasma cutting, or welding, of a variety of shapes which are programmed and stored in memory.

The machine has storage capacity in memory for 10 different programmed shapes. At any time, one of these shape numbers is selected to be active, and will stay selected even when the power is shut off, and turned back on, until the shape number is changed by the machine operator.

All programming is done with the handheld terminal provided. The terminal can 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 and patterns are built up using segments. To do this, select the type of segment you want and determine what quadrant it is in – type it into the terminal. Any given shape can have up to 50 segments. Other functions such as weld/oxygen, on/off, time delay, or repeat a shape a number of times, also count as one segment each, if used.


The programming operation is selected by pressing keys A, B, C, D, or E.A: ALL SEGMENTS; data entry for new shape consists of total number of segments and data for each segment.B: PROGRAM SEGMENT; press B on terminal to re-program a single segment. This is useful if there is an error in data for just one segment, so that the whole shape does not have to be re-entered.C: CHANGE SHAPE NUMBER; press C on terminal to change the cur-rent shape number. 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 a 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 value of deceleration 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.

Other functions besides the moves shown above are:Weld Contact/Solenoid On/Off, Pause, Delay, Repeat another shape, Full ellipse, and Rapid Traverse.


Clockwise 90

CounterClockwise 90

X or Y Axis


Counter Clockwise Par-tial Arcs

Inclined Lines

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Operation:

The machine is in the reference start position, when first plugged in.

There are 3 options (the handheld terminal is not needed for the first two):

1. MOVE: To change the home position, push the STOP/PAUSE button, move the machine manually to the required position using the joy stick, and push the reset button.

2. RUN: Push the START/RUN button to cut/ weld a shape.

3. PROGRAM: The programming operation requires the use of the handheld terminal.

PowerRequirements: BUG-6150 120VAC/50-60/1 BUG-6152 240VAC/50-60/1 BUG-6154 42VAC/50-60/1

Travel Speed: 2.5-50 ipm (63-1250 mm/min)


Max. SegmentDimension: 72" (1800 mm) Within Limits of Travel



Net Weight OfDrive Unit: 37 lbs. (17 kg)

Dimensions OfDrive Unit: 15.0"L x 8.25"W x 10.0"H (381 mm x 210 mm x 255 mm)

Technical Data:COMPUTER SOFTWARE

SPEED

MANUAL/JOG/MOVE

START/RUN

RESET

STOP/PAUSE

The Programmable Shape Machine can be programmed from a PC, using either of two software packages described below. Shapes can be created off-line, and downloaded to the machine when required. Each program is supplied with a cable to connect to the serial port of the PC.

1. PC Option. This runs under Windows, and allows you to: • Create shapes on the PC. • Save any number of shapes to disk, and retrieve them as necessary. • View a programmed shape on screen - which helps program verification. • Download programmed shapes from the PC to the Gantry.

2. BESTNEST Program.These are full fledged CAD interface programs, available in three different levels, each adding further capabilities to those listed above. A. Basic: enables you to • Read and convert standard DXF files generated by CAD programs. • Draw and edit shapes graphically on screen. • Specify parameters like kerf, lead in, lead out, or use defaults. • Specify different materials to save shapes. B: Manual Nesting: allows interactive nesting of parts. C: Auto-nesting: full auto-nesting and multiple torch nesting.

BUG-O

Ready

PATENTS WORLDWIDE

The BUG-6150 Programmable Shape Machine is an easy to use 2-axis machine which you can program to run any contour or pattern for both welding or cutting applications. A handheld terminal supplied with the machine is used to program the required shape and operation sequence. Other functions besides moves can be programmed, such as repeats, starts, stops, delays, and rapid traverse. 10 programs can be stored in machine memory at any one time.

An optional computer software program is available, for any IBM compatible computer. With this program you can select pre-programmed shapes or create your own custom shapes, and store any number of them on disk. Selected shapes can then be downloaded to the machine as needed.

The Programmable Shape Machine is compact and lightweight and can be easily carried throughout your facility. It is held in position with either powerful permanent magnets or vacuum cups, depending on the work material. This enables you to take the machine to the work, which will help reduce your material handling.

Burn Virtually Any Shape, Weld Any Pattern, Quickly And Easily, In Any Position…





BUG-6200 PROGRAMMABLE SHAPE OXY-FUEL CUTTING KIT 120VAC/50-60/1Includes:1 BUG-6150 Programmable Shape Machine and Handheld Terminal 2.5-50 ipm (63-1250 mm/min)1 BUG-6090 Q.A. Manifold w/Solenoid 120 VAC1 BUG-6155 Cutting Group



BUG-6201 PROGRAMMABLE SHAPE WELDING KIT 120VAC/50-60/1Includes:1 BUG-6150 Programmable Shape Machine and Handheld Terminal 2.5-50 ipm (63-1250 mm/min)1 BUG-6080 Relay Box w/Cable Anchor [To Control Arc On/Off]1 BUG-6145 Welding Group



BUG-6210 PROGRAMMABLE SHAPE PLASMA CUTTING KIT 120VAC/50-60/1Includes:1 BUG-6150-E Programmable Shape Machine and Handheld Terminal. 4-80 ipm (100-2000 mm/min)1 BUG-6080 Relay Box w/Cable Anchor (To control arc on/off)1 BUG-6155 Cutting Group




BUG-6155 Cutting Group BUG-6145 Welding GroupBUG-6080 Relay Boxw/Cable Anchor

BUG-6090 Cutting SolenoidAccessory 120VAC

*Rail is not included with kits.

A QUALITY PRODUCT FROM BUG-O SYSTEMS • 280 TECHNOLOGY DRIVE • CANONSBURG, PA 15317-9564 USAA DIVISION OF WELD TOOLING CORPORATION © Weld Tooling Corp. ROM 1:16 Litho. in U.S.A. LIT-PSM-BRO-1208

Shipyard Fit-Up Tools



Designed to facilitate the work of a plate fitter in shipbuilding and steel construction.


PUL-TON pulling device for hull section joining.

PUL-JAK/MAX-JAK tools for pushing and pulling.

BULB-MOV-R grippers for hollandprofiles.

BULB-LIFT-R lifting clamps forholland profiles.

MINI-BULB-ALIGN a tool for aligningstiffeners.

BULB-ALIGN a tool for aligning stiffenerswhen joining sections.

Shipyard Fit-Up Tools

Litho in U.S.A.© Weld Tooling Corp.A DIVISION OF WELD TOOLING CORPORATIONA QUALITY PRODUCT FROM BUG-O SYSTEMS • 3001 WEST CARSON STREET • PITTSBURGH, PA USA 15204-1899

Tools for pushing andpulling.

PUL-JAK-7, PUL-JAK-12The PUL-JAK is a versatile tooldesigned to suit the needs of a platefitter. Due to it’s design, light weight andsimple construction the PUL-JAK is veryhandy when working in restrictedspaces or when working alone. Themain application of the PUL-JAK isfitting bulkheads and frames in hullconstruction. Two models are availablewith capacities of 10 or 12 ton.Weight: 13.5 lbs. (6kg)

Pulling device for hullsection joining.

PUL-TONThe PUL-TON is a tool for convertingthe pushing force of a standard jack intoa pulling force. All standard jacks suchas Enerpak, Simplex, OTC and PowerTeam can be used. The recommendedmaximum capacity is 25 tons.Weight: 55 lbs. (24.9kg)

A tool for aligningstiffeners when joiningsections.

BULB-ALIGNThe application of the BULB-ALIGN willresult in remarkable time saving whenaligning holland profile stiffeners.Welding and removing of fastening lugsfor the jack as well as grinding the spotare not needed any more. BULB-ALIGNis fastened just by inserting a wedge.The adjusting screw makes it possibleto use the same tool on holland profilesof different sizes.Weight: 22 lbs. (10kg)

A tool for aligningstiffeners.

MINI-BULB-ALIGNA tool for aligning stiffeners at thesection joints. The MINI-BULB-ALIGNworks on 100 to 120 mm hollandprofiles. It can be used in right handand left hand modes.Weight: 25 lbs. (11kg)

Grippers for hollandprofiles.

BULB-MOV-R-1.5, BULB-MOV-R-3.0, BULB-MOV-R-5.0The BULB-MOV-R is a light and handytool for attaching a chain block quicklyto a holland profile in steel fabricationwithout need to weld an eye piece.Gripping is based on the wedging effect,which causes MOV-R to clamp firmlyon the holland profile under pull fromthe eye. The MOV-R is not designedfor lifting applications. The innovativedesign and the special material providea high safety factor against breakage.The MOV-R comes in three sizes withcapacities of 1.5, 3 and 5 tons.Weight: Tara 1.5 - 6.10 lbs. (2.8kg), Tara3.0- 10.5 lbs. (4.7kg), Tara 5.0- 13.25lbs. (6.0kg)

Lifting clamps forholland profiles.

BULB-LIFT-R-1,BULB-LIFT-R-2The LIFT-R is a lifting appliance designedexclusively for holland profiles. It shallnot be used for lifting other sections orplates. The BULB-LIFT-R-1 fits hollandprofiles of size 80-220 mm.Weight: 17 lbs. (7.7kg)

MAX-JAK-20The MAX-JAK-20 is the name for theheavy duty tool for producing pullingforces up to 20 ton in installation work.Typical application in ship building isthe joining of hull sections. Maximumallowed pushing force is 5 ton.Weight: 29 lbs. (13kg)

A 20 ton pulling tool.

ROM 1:16

Automating Your Welding and Cutting Can Save You Money!Automating Your Welding and Cutting Can Save You Money!

SIX WAYS

BUG-O SYSTEMSWelding & Cutting Automation Since 1948.www.bugo.com 1-412-331-1776

SIX WAYS

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AdvantagesAdvantagesofAutomating

YourWELDING & CUTTING

The machine replaces the operator’s hand to control the process.

INCREASEProduction1

IMPROVEQuality2Precise speed and path control improve appearance and quality.

2

3

REDUCEMaterial Handling3Take the small light-weight machine to the work. Work in all positions.

REDUCEDistortion4Provides uniform heat input, puts the right amount of weld in the right place.

3

IMPROVEWorker’s Environment5Keeps the worker further away from the arc and reduces operator fatigue.

© Weld Tooling Corp. Litho in U.S.A. LIT-SIXWAY-BRO-0508A DIVISION OF WELD TOOLING CORPORATION ROM 1:16 A QUALITY PRODUCT FROM BUG-O SYSTEMS • 280 TECHNOLOGY DRIVE • CANONSBURG, PA USA 15317-9564

ADAPTABLEFlexible Modular Construction6Adapts to your job.



DC SPEED WEAVING KIT

The DC SPEED WEAVING KIT combines a DC-IV drive unit and a Speed Weaver II for thosestraight line welding applications that require oscillation. Rack and pinion drive along with heavyduty rigid rail and magnets make all-position operation possible. The weaver is normally mountedto the carriage. A swivel mount is also provided for mounting the weaver so that it can swivel around2 axis (see photo). This enables the kit to perform fillet welds.

PATENTS WORLDWIDE

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DC SPEED WEAVING KIT

PowerRequirements: BUG-1916 120 VAC/50-60/1

BUG-1917 240 VAC/50-60/1BUG-1918 42 VAC/50-60/1

Travel Speed: 1.5-30 ipm (38-780 mm/min)

Load Capacity: 30 lbs. (14 kg) VERTICAL100 lbs. (45 kg) HORIZONTAL

Net WeightOf Kit: 91 lbs. (41.5 kg)

Shipping WeightOf Kit: 101 lbs. (46 kg)

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Specifications

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1. RUN: In this mode, power to the drive unit isalways on, and the machine travels continuouslyboth during weave and dwell. Weave speed anddwell time affect the weld pattern.

2. STEP: The unit travels only during dwell, andstops during the oscillator cross stroke. Changingweave speed does not affect the weld pattern–dwell time does.

3. TRACTOR STOP ON DWELL: The tractortravels during weave stroke; tractor and oscillatorstop during dwell.

4. NO WEAVE: In this mode oscillation is stoppedand powers the tractor only for stringer passes.

1.

2.

3.4.

BUG-1916 DC SPEED WEAVING KIT(120/50-60/1)

Includes:1 BUG-0343 BUG-O DC-IV

1.5-30 ipm (38-750 mm.min)

Includes:1 BUG-9444 Tool Kit

1 BUG-5300 SPEED WEAVER II1 BUG-5195 Weaver Swivel Mount1 BUG-2975 Cable Mounting Assembly1 ARR-1080 H.D. Rigid Rail 931/2" (2.37 m)1 ARR-1085 H.D. Rigid Rail 461/2" (1.18 m)5 ARM-2325 Magnet Bar, Swivel w/Release

BUG-1917 Same as above except with:240 VAC BUG-O DC IV240 VAC SPEED WEAVER II

BUG-1918 Same as above except with:42 VAC BUG-O DC IV42 VAC SPEED WEAVER II

Factory Installed Options:BUG-1760Digital readout. Displays speed of machine ininches/minutes (cm/m for 42 VAC and 240 VAC).

The Speed Weaver II is a compact, precision, all-position machine, designed for maximum versatility in oscillation. Its solid-state controls with graduated dials provide adjustable and readily repeatable control of critical weld parameters.


Make Precision Weave Welds Quickly, Easily, And Economically!

The Speed Weaver II is designed to mount on any BUG-O carriage, the DCD ROL-O carriage, or, with a special weaver mount, in front of the Super-Flex drive carriage on Super-Flex rail. Its lightweight permits easy movement of the machine from one welding location to another.

PATENTS WORLDWIDE



SPEED WEAVER II

Includes: 1 BUG-2990-F DCD ROL-O CARRIAGE 2-30 IPM (38-750 mm/min) Includes: 1 BUG-9444 Tool Kit 1 BUG-5300 SPEED WEAVER II 1 BUG-5195 Weaver Swivel Mount 1 BUG-1540 Cable Anchor Assembly

BUG-1910 ROL-O WEAVING KIT (120/50-60/1)

BUG-1912 ROL-O WEAVING KIT (240/50-60/1)BUG-1914 ROL-O WEAVING KIT (42/50-60/1)

Net Weight of Kit: 40 lbs. (18.2 kg kg)Shipping Weight of Kit: 50 lbs. (22.7 kg)

Includes: 1 BUG-0343 BUG-O DC-IV 1.5-30 ipm (38-750 mm/min) Includes: 1 BUG-9444 Tool Kit 1 BUG-5300 SPEED WEAVER II 1 BUG-5195 Weaver Swivel Mount 1 BUG-2975 Cable Mounting Assembly 1 ARR-1080 H.D. Rigid Rail 93-1/2" (2.37 m) 1 ARR-1085 H.D. Rigid Rail 46-1/2" (1.18 m) 5 ARM-2325 Magnet Bar, Swivel w/Release

BUG-1916 DC SPEED WEAVING KIT (120/50-60/1)

BUG-1917 DC SPEED WEAVING KIT (240/50-60/1)BUG-1918 DC SPEED WEAVING KIT (42/50-60/1)

Net Weight of Kit: 91 lbs. (41.5 kg)Shipping Weight of Kit: 101 lbs. (46 kg)

SFX-1020 SUPER-FLEX WELD WEAVING KIT (120/50-60/1)SFX-1022 SUPER-FLEX WELD WEAVING KIT (240/50-60/1)SFX-1024 SUPER-FLEX WELD WEAVING KIT (42/50-60/1)

Includes: 1 SFX-1200-F SUPER-FLEX CARRIAGEIncludes: 1 BUG-9444 Tool Kit 1 BUG-5300 SPEED WEAVER II 1 SFX-1255 Super-Flex Weaver Mount 2 SFX-1160 Super-Flex Laminated Rail 5' (1.5 m) 8 SFX-1140 Swivel Magnet Bar w/Release 8 SFX-1130 Spacer Bar 1 BUG-1540 Cable Anchor Assembly

*SFX-1020-1 SUPER-FLEX WELD WEAVING KIT (120/50-60/1)*SFX-1022-1 SUPER-FLEX WELD WEAVING KIT (240/50-60/1)*SFX-1024-1 SUPER-FLEX WELD WEAVING KIT (42/50-60/1)

Net Weight of Kit: 74 lbs. (33.7 kg)Shipping Weight of Kit: 86 lbs. (39.2 kg)

* Uses SFX-1120 Fixed Magnet Bar w/Release

A QUALITY PRODUCT FROM BUG-O SYSTEMS • 280 TECHNOLOGY DRIVE • CANONSBURG, PA 15317-9564 USALitho in U.S.A. LIT-SPWV-BRO-1108A DIVISION OF WELD TOOLING CORPORATION © Weld Tooling Corp. ROM 1:16

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SPEED WEAVER II

The SPEED WEAVER II with solid-state design eliminates relays and limit switches. Integrated circuits control all functions, and the SPEED WEAVER II extends the usefulness

of weld weaving by ensuring accurate control of amplitude and constant speed, up to 150 ipm (3800 mm/min).

Controls: 1. Stroke Width 2. Adjustable Rack 3. Circuit Breaker 4. Power Switch

5. Weld Contactor Switch 6. AC Outlet 7. Mode Selector Switch 8. All-Position Torch Support Group

9. Crossrail10. Dwell Right11. Dwell Left12. Weave Speed Control

The unit provides infinitely variable speed control 6 to 150 ipm (150 to 3800 mm/min), weld contactor, power on-off, a circuit breaker and adjustable/lockable amplitude 0.125 to 2.0" (3 to 50 mm).The speed control , dwell selectors and

amplitude control are calibrated for quick and easy set up. The SPEED WEAVER II housing is anodized black to reduce arc reflection.

The BUG-5300 SPEED WEAVER II mounts directly onto the various BUG-O carriages. It can also be supplied with the SFX-1255 Super-Flex weaver mount accessory, which is used to mount the SPEED WEAVER II directly onto Super-Flex rail when attached to the Super-Flex carriage.

9 8

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12 11 10

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SPEED WEAVER II

Technical Data: Weld Patterns:

Power Requirement: BUG-5300 120VAC/50-60/1 BUG-5302 240VAC/50-60/1 BUG-5304 42VAC/50-60/1

Linear Speed: 6 to 150 ipm (150 to 3800 mm/min)

Dwell: 0 to 3 Seconds Each Side; Calibrated

CyclesPer Minute: Maximum; (Zero Dwell Left and Right)

Stroke: .125" .25" .5" 1.0" 2.0" (3 mm) (6 mm) (12 mm) (25 mm) (50 mm) Cycles: 160 120 85 60 37

CubeDimensions: 8.5"L x 8.75"W x 6.5"H (216 mm x 222 mm x 160 mm)

Net Weight: 19 lbs. (8.6 kg) (Not including rail and torch mounting.)

ShippingWeight: 22 lbs (10 kg) (Not including rail and torch mounting.)

A rotary mode selector switch allows you to choose the following patterns:

1. RUN: In this mode, power to the drive unit is always on, and the machine travels continuously both during weave and dwell. Weave speed and dwell time both affect the weld pattern.2. STEP: The unit travels only during dwell, and stops during the oscillator cross stroke. Changing weave speed does not affect the weld pattern, changing dwell time or tractor speed does.3. TRACTOR STOP ON DWELL: The tractor travels during weave stroke. Tractor and oscillator stop during dwell.4. NO WEAVE: In this mode oscillation is stopped and powers the tractor only for stringer passes.

BUG-5300 SPEED WEAVER IIMOUNTED ON A BUG-O DC DRIVE

BUG-5195 WEAVER SWIVEL MOUNTFOR FILLET WELDS

MountsTo Weaver

MountsTo Carriage

SAMPLE WELD

BUG-5195Weaver Swivel Mount

1.

2.

3.

4.

SPEED WEAVER II

Includes:1 BUG-2990-F DCD ROL-O CARRIAGE

2-30 IPM (38-750 mm/min)Includes:

1 BUG-9444 Tool Kit1 BUG-5300 SPEED WEAVER II1 BUG-5195 Weaver Swivel Mount1 BUG-1540 Cable Anchor Assembly

BUG-1910 ROL-O WEAVING KIT (120/50-60/1)

BUG-1912 ROL-O WEAVING KIT (240/50-60/1)BUG-1914 ROL-O WEAVING KIT (42/50-60/1)

Net Weight of Kit: 40 lbs. (18.2 kg kg)Shipping Weight of Kit: 50 lbs. (22.7 kg)

Includes:1 BUG-0343 BUG-O DC-IV

1.5-30 ipm (38-750 mm/min)Includes:

1 BUG-9444 Tool Kit1 BUG-5300 SPEED WEAVER II1 BUG-5195 Weaver Swivel Mount1 BUG-2975 Cable Mounting Assembly1 ARR-1080 H.D. Rigid Rail 93-1/2" (2.37 m)1 ARR-1085 H.D. Rigid Rail 46-1/2" (1.18 m)5 ARM-2325 Magnet Bar, Swivel w/Release

BUG-1916 DC SPEED WEAVING KIT (120/50-60/1)

BUG-1917 DC SPEED WEAVING KIT (240/50-60/1)BUG-1918 DC SPEED WEAVING KIT (42/50-60/1)

Net Weight of Kit: 91 lbs. (41.5 kg)Shipping Weight of Kit: 101 lbs. (46 kg)

SFX-1020 SUPER-FLEX WELD WEAVING KIT (120/50-60/1)SFX-1022 SUPER-FLEX WELD WEAVING KIT (240/50-60/1)SFX-1024 SUPER-FLEX WELD WEAVING KIT (42/50-60/1)

Includes:1 SFX-1200-F SUPER-FLEX CARRIAGE

Includes:1 BUG-9444 Tool Kit

1 BUG-5300 SPEED WEAVER II1 SFX-1255 Super-Flex Weaver Mount2 SFX-1160 Super-Flex Laminated Rail 5' (1.5 m)8 SFX-1140 Swivel Magnet Bar w/Release8 SFX-1130 Spacer Bar1 BUG-1540 Cable Anchor Assembly

*SFX-1020-1 SUPER-FLEX WELD WEAVING KIT (120/50-60/1)*SFX-1022-1 SUPER-FLEX WELD WEAVING KIT (240/50-60/1)*SFX-1024-1 SUPER-FLEX WELD WEAVING KIT (42/50-60/1)

Net Weight of Kit: 74 lbs. (33.7 kg)Shipping Weight of Kit: 86 lbs. (39.2 kg)

* Uses SFX-1120 Fixed Magnet Bar w/Release

A QUALITY PRODUCT FROM BUG-O SYSTEMS � 280 TECHNOLOGY DRIVE � CANONSBURG, PA 15317-9564 USALitho in U.S.A. LIT-SPWV-BRO-1108A DIVISION OF WELD TOOLING CORPORATION © Weld Tooling Corp. ROM 1:16

FABRICATE SPRINKLER PIPE quickly andeasily with Cypress Welding Equipment’scomplete line of SPRINKLER FABRICATIONMACHINES. This easy to use equipmentincreases production and quality withreduced costs.

SPRINKLER FABRICATION EQUIPMENT

CYPRESS WELDING EQUIPMENT, INC.A Subsidiary of Weld Tooling Corporation

P.O BOX 690168, HOUSTON, TEXAS 77269 Telephone: 1-281-469-0746 Fax: 1-281-469-9354http://wwwcypressweld.com


CB-1P (CBO-1020)AIR PLASMA MACHINE

Cut from 3/4" to 12" (19 mm to 300 mm) diameterholes in pipe up to 3/8" (9.5 mm) wall thickness,utilizing the Air Plasma process.

The CB-1P (CBO-1020) AIR PLASMA MACHINEallows you to cut precise, clean holes in 5 to 15 sec-onds with no distortion of the pipe.

The machine may be operated continuously ineither direction without hose or power cablewrap-up.

The machine is equipped with machine torch, powersource control cables, PM drive motor and variablespeed control for rotation, horizontal and verticaladjustment.

It has switches for manual rotation without cutting aswell as automatic rotation with cutting.

TECHNICAL DATA

Rating: 60% Duty Cycle Rise and Fall Cam: 5" (125 mm)

Input Voltage: 220 VAC Single Phase Piercing Capability: 3/8" (9.5 mm)

Cutting 3/4" - 12" O.D. Cutting Capability: 1/2" (12 mm)Diameter: (19 - 300 mm)

Rotation 20 - 400 ipmSpeed: (500 - 10,000 mm/min)

Height: 29" (737 mm)


NOTE: Alternate power sources are available for wall thicknesses up to 1" (25 mm).Saddle cut diameters should not exceed 2/3 the diameter of the pipe.

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CWO-4530 MODEL 151 CARRIAGE

May be used only with CW-5 CIRCLE WELDERS.The carriage, which is mounted on a standard mono-rail, is used to move the welder along a length ofpipe.

Carriage Net Weight: 72 lbs. (32.7 kg)

CWO-4540 MODEL 151P CARRIAGE

This carriage, which is mounted on a standard mono-rail, is used with the CB-1P AIR PLASMA MACHINE.A winch holds the machine and prevents the ma-chine from falling into the hole when the slug drops.This carriage may also be used with CW-5 CIRCLEWELDERS.


CWO-4550 MODEL 151M CARRIAGE

May be used with either the CW-5 CIRCLE WELDERor the CB-1P AIR PLASMA MACHINE. The primaryuse is with machines on “bridge crane” type setups,to allow the operator to raise or lower the machinewhild reaching over a number of pieces of pipe. Thecarriage may also be used on standard monorails.


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SE-4P (SEO-4520)PROGRAMMABLE SADDLE & ELBOW CUTTER

The SE-4P programmable machinewill cut saddles, laterals, miters,offsets (hillsides) and elbows usinga micro-processor and handheldterminal. Oxyfuel or Plasma may beused. Cutting diameter 1" - 12" (25-300 mm). (Maximum length of pipeto be cut, 18" [450 mm]). Maximumrotation speed is 3.7 rpm, which is47 ipm (1160 mm/min) on 4" (100mm) O.D.’s.

TECHNICAL DATACutting 1-12" O.D.Diameter: (25 - 300 mm)

Rotation 0.2-3.7 rpm (47 ipm)Speed: (1160 mm/min)


Dimensions: 38"L x 15.25"W x 22.25"H

Input Power: 115 VAC

OSCILLATION FOR CW-5• The CWO-3943 PENDULUM TYPE OSCILLATOR is used to weld out-of-position with MIG.• Wire sizes used with oscillation are: .035" and .045" (.8 mm and 1.1 mm)• The width of oscillation is determined by a mechanical cam. Maximum width of oscillation is 3/4" (19 mm)• Oscillators may be added to existing machines in operation or as an option on new machines.• Please consult the factory for oscillator applications.

CW0-3671 STEP ADAPTORUsed to center the welder in the coupling. The adaptor holds the couplingin place, eliminating the need for tacking. The adaptor is for couplingsizes: 1/2", 3/4", 1", 1-1/4", 1-1/2", 2", 2-1/2", 3", 3-1/2", 4".


CW-5 (CWO-1500 FOR MIGAND FLUX CORED WELDING

The CW-5 (CWO-1500) CIRCLE WELDER isdesigned for single pass or multipass welding ofcouplings on sprinkler pipe, utilizing MIG or the FluxCored process, with gas shielding.

The machine is equipped with its own wire feeder,welding control, drive motor, speed control for rota-tion, horizontal and vertical adjusting racks, rise andfall cam, gun and cable assembly, burnback control,50 feet (15 m) of control cable, and wire reel adaptorfor 30 lb. (14 kg) spools.

Welding control has wire feed speed (amperagecontrol), cold wire inch, wire direction and weldswitches.

TECHNICAL DATA

Amperage: 0-300 AMPS

Input Voltage: 115 VAC

Voltage: 0-50 VAC

Wire Sizes: .035-.062" (.8-1.6 mm)

Rotation 3-130 ipmSpeed: (75-3300 mm/min.

Cam Range: 5" (125 mm)

Welding Diameter: 1-12" (25-300 mm)

Shielding Gas: Solenoid Control

Height: 29" (737 mm)


5


TYPICAL SETUP FORSPRINKLER FABRICATION

6



Dual Sided Fillet WelderDoubles Production.The Programmable Stiffener Welder will weld bothsides of a stiffener at the same time.


The Programmable Stiffener Welder is a self-contained, dual head welding travel carriage withintegrated wire feeders and spool mounts. It will produce continuous or programmable intermittent filletwelds on stiffeners with heights of 4" to 18" (102-457mm) and widths of 4" to 12" (102-305mm). The unitis self propelled and runs directly on the stiffener. Spring loaded floating torch holders compensate andmaintain torch standoff with variations of work piece fit-up. The machine can be used with solid or coredwelding wire.

2 ROM 1:16 Litho in U.S.A.© Weld Tooling Corp. LIT-SW-BRO-0404A DIVISION OF WELD TOOLING CORPORATIONA QUALITY PRODUCT FROM BUG-O SYSTEMS • 3001 WEST CARSON STREET • PITTSBURGH, PA USA 15204-1899

STIFFENER WELDER

Technical Data:

Programmable Weld/SkipTravel Speed: 0"-36" ipm

(0-900mm/min)

Programmable ReverseDrive Crater Fill: 0"-1"

(0-25mm)

Programmable Pre-Weld/Post Weld Gas Purge: 0-10 seconds

Stiffener Size Range: 4"-18" High(102-457mm)

4"-12" Wide(102-305mm)

VoltageControl

WireSpeed

Control

WireJog

FeederOn/Off

Solenoid Purge

Main Weld Cycle Start

Travel Jog

Soft Touch Programming CenterWith Digital Readout

VoltageControl

WireSpeedControl

WireJog

Solenoid Purge

FeederOn/Off

Main Weld Cycle Stop

18.00"(457mm)

47.00"(1194mm)

24.00"(610mm)

14.00"(356mm)

35.00"(889mm)

(A)

(A)

(A)

(A) (B)

(B)

(B)

(B)

The Programmable Stiffener Welder can accommodate 10, 30 or 60 pound wire reel spools andfeatures independent wire feeder controls for voltage, wire feed speed, cold wire jog and gas purge.When intermittent stitch welding is required the Stiffener Welder features programmable control ofweld length and travel speed, skip length, reverse drive crater fill, pre-weld and post-weld gas purgetimes.


The Stiffener Welder will weld "I", "T", and "L" stiffeners onone or both sides at the same time.

Automate two heavy duty wirefeeders at the same time!

PATENTS WORLDWIDE

The STIFFENER WELDER from BUG-O SYSTEMS is a self-contained, dual head welder. It willproduce continuous or intermittent fillet welds on stiffeners with flange widths up to 12" (0-300 mm) andheights of 3"-16" (75-400 mm). The unit is self-propelled and tracks on the stiffener. The floating gunholders are spring loaded and have dual wheels to ride over tacks. Three ready to use models areavailable: MIG, Flux-Core or Sub-Arc. A bare machine is also available for those who wish to mount theirown feeders.



2

STIFFENER WELDER

Operation:

The Stiffener Welder is rolled into position on one end of the beam or stiffener to be welded. The guide wheelsare set on each side of the beam to insure that the machine will follow the web of the beam/stiffener as it is beingwelded. The spring loaded gunholder assemblies are racked into position and the welding guns are centeredin the joint to be welded.

The Stiffener Welder has two Spring LoadedGunholder Assemblies which keep the weldingtorches aligned while the unit is running. Two "V"wheels ride over tack welds and keep the weldingguns centered.

Gunholder Assembly:

POWER CORDTO RIGHT

WIRE FEEDERTO LEFT

WIRE FEEDER TO DRIVEUNIT

H

F

E

A

B

C

K

D

G

J

A. Power Switch

B. Wire Feed Switches

C. Skip/Continuous Switch

D. Carriage Travel Switch

E. Puddle Buildup and Crater Fill

F. Skip Length(The amount of time the machine

travels without welding)

Control Box:

H. Digital Readout(Of Travel Speed)

G. Weld Length(The amount of time the machinewelds; skip mode only)

J. Carriage Travel Speed Knob

For continuous welding, turn the Skip/Continuous switch to the Continuous position. Then start the machineby turning on the Carriage Travel switch and set the speed of the machine as it welds. A timer is provided forPuddle Buildup and Crater Fill. (See below)

All controls for the machine are located on the control panel on the front of the machine. To skip weld, turn theSkip/Continuous switch to the Skip Mode. Set the Skip Length dial to determine how long the machine will travelwithout welding. Next, set the weld length dial to determine how long the machine will travel while welding. (Todo this, make a chalk mark on the work piece and time the machine as it travels). Travel distance is determinedby the length of time the dials are set for and the speed the machine is traveling while it welds or skips.

3

STIFFENER WELDER

Power [Supplied from welding power source]Requirement: 80 watts 120/50-60/1

Net Weight: 264 lbs. (120 kg) with feeders and reels,but without wire

Travel Speed: 3-44 ipm (75-1100 mm/min)[Digital speed readout of carriagespeed - inches or cms]

Controls: Wire feed: manual or automatic [coldwire feed for set up]. Independentcontrol for left and right. Crater travelforward/off/reverse.Continuous or intermittent welds:Weld length timer: 1-30 secondsSkip length timer: 1-30 seconds

BUG-3190Stiffener Welder Without Feeder 120VACIncludes:

1 BUG-3219 Chain Assembly1 BUG-3220 Carriage Assembly1 BUG-3230 Drive Assembly1 BUG-3240 Drive Support1 BUG-3250 Cable Anchor Assembly1 BUG-3335-L H.D. Corner Follower LH1 BUG-3335-R H.D. Corner Follower RH1 BUG-3270 Spool Bracket1 BUG-3275 Motor/Control Mounting1 BUG-3280 Control Box 120 VAC

Net Weight: 131 lbs. (60 kg)Shipping Weight: 226 lbs. (103 kg)

BUG-3192Same as above except 240 VAC.

A

BC

A

B

C

Technical Data:

Direction of Travel

38.625(981 mm)

17.500(445 mm)

19.000(483 mm)

39.625(1006 mm)

16.625(422 mm)

19.250(489 mm)

STIFFENER WELDERBUG-3200-_____*Stiffener Welder Flux Core 120 VAC/50-60/1Includes:

1 Stiffener Welder with Feeders2 Gun and Cable Assemblies1 Spare Parts Kit2 Reel Assemblies

BUG-3202-___* Same as above except 240 VAC

Net Weight of Kit: 264 lbs. (120 kg) [without wire]Shipping Weight of Kit: 360 lbs. (163 kg) [without wire]* Wire sizes available: .068, 5/64, 3/32, 7/64, and .120"

BUG-3180-_____*Stiffener Welder MIG 120 VAC/50-60/1Includes:

1 Stiffener Welder with Feeders2 Gun and Cable Assemblies1 Spare Parts Kit2 Reel Assemblies


Net Weight of Kit: 270 lbs. (123 kg) [without wire]Shipping Weight of Kit: 365 lbs. (166 kg) [without wire]* Wire sizes available: .035, .045, .052, and 1/16"

BUG-3170-_____*Stiffener Welder Sub Arc 120 VAC/50-60/1Includes:

1 Stiffener Welder with Feeders2 Gun and Cable Assemblies2 Flux Hoppers2 Nozzle Assemblies1 Spare Parts Kit2 Clamps2 Adaptor Bracket Assemblies2 Reel Assemblies


Net Weight of Kit: 270 lbs. (123 kg) [without wire]Shipping Weight of Kit: 365 lbs. (166 kg) [without wire]* Wire sizes available: .035, .045, .052, and 1/16"

A QUALITY PRODUCT FROM BUG-O SYSTEMS • 3001 WEST CARSON STREET • PITTSBURGH, PA USA 15204-1899Litho in U.S.A. LIT-SWL-BRO-0305A DIVISION OF WELD TOOLING CORPORATION © Weld Tooling Corp. ROM 1:16

Bug-O Sub-Arc Tractor

Affordable automation that increases production and improves quality.

Heavy Duty for Welding Fillet and Butt Joints.

The Bug-O System’s Submerged-Arc Tractor is outfitted with all of the necessary equipment for performing sub-merged-arc welding for fillet and butt joints. The integrated wire-feeder and torch provide racking for cross-seam andvertical position fine-tuning. The heavy duty tractor is capable of travel speeds ranging from 5-100 ipm (127-2540 mm/min). It can carry a maximum payload of 350 lb (159 kg). All of the tractor controls are integrated into the wire-feedcontrol unit, providing a seamless interface to the complete welding process. Heavy duty wire feed equipment isincluded on the machine with wire feed speed capabilities of 25 to 600 inches per minute for wire diameters of 1/16” -7/32” (1.59 - 5.56 mm). An optional flux recovery unit provides recycling of the submerged-arc flux.



Dimensions:

Bug-o Sub-Arc Tractor

HDT-1000


14.02"(356.12 mm)

23.53"(597.75 mm)

47.42"(1204.42 mm)

42.22"(1072.4 mm)

13.54"(343.92 mm)

40.47"(1027.94 mm)

24.89"(632.10 mm)

HDT-1300

34.41"(874.01 mm)

42.82" max.(1087.63 mm)

27.44"(696.98 mm)

Controls:HDT-1086 Control Box

Weld CurrentAnalog Read-Out

Weld VoltageAnalog Read-Out

Cycle Start

Control Power/Emergency Stop

VoltageControlKnob

CurrentControlKnob

SpeedControlKnob

Cycle Stop

WireFeedInchUp & Down

Digital SpeedRead-Out

TravelSelectionSwitch

Travel Direction Switch

A QUALITY PRODUCT FROM BUG-O SYSTEMS • 3001 WEST CARSON STREET • PITTSBURGH, PA USA 15204-1899A DIVISION OF WELD TOOLING CORPORATION © Weld Tooling Corp. ROM 1:16 Litho. in U.S.A. LIT-SAT-BRO-1107



Supports & Accessories



The TOOL POSITIONINGSYSTEM is a compact andrigid system which can beused to hold a wide variety ofcutting torches, welding gunsand other handheld tools.

It consists of black anodized7/8" (22.2mm) square aluminumbars with 16-pitch machinedracks and ways, right angleclamps, machined rackholdersand torchholders.

A. BUG-1796 Machined Rack 14" (355.6mm)B. BUG-1853 Machined Rack 7-1/2" (190.5mm)C. MDS-1031 3.5" (88.9mm) RackholderD. BUG-5455 Gun Mounting GroupE. BUG-5462 Right Angle Clamp

MDS-1040Machined Rack Welding Group

C

A

E

B

D

MDS-1075Dual Torch Welding Group

Includes:(2) H. MDS-1040 Machine Rack Group(1) I. MDS-1045 Double Rackholder Mount

IH

H

MDS-1090Dual Torch Cutting Group

Includes:(2) G. MDS-1050 Machined Rack Cutting Group(1) I. MDS-1045 Double Rackholder Mount

EC

A

F

MDS-1050Machined Rack Cutting GroupA. BUG-1796 Machined Rack 14" (355.6mm)C. MDS-1031 3.5" (88.9mm) RackholderE. BUG-5462 Right Angle ClampF. BUG-5188 Torchholder Assembly

I

G G

BUG-2708Clamp with7/8" (22.2mm)Rod

BUG-2915TorchholderAssembly

BUG-5462Right Angle ClampAssembly [for7/8" (22.2mm)Rods]

7/8" (22.2mm)

7/8"(22.2mm)

BUG-3232Dropping Bar

7/8"(22.2mm)

7/8"(22.2mm)

Litho in U.S.A. LIT-SA-BRO-0208A DIVISION OF WELD TOOLING CORPORATION

A QUALITY PRODUCT FROM BUG-O SYSTEMS • 280 TECHNOLOGY DRIVE • CANONSBURG, PA USA 15317-9564© Weld Tooling Corp. ROM 1:16

BUG-9865SteppingModule120VAC

BUG-94852-Pin Connector

BUG-9180_7/8" (22.2mm) DiameterRod (Specify Length)



BUG-2597(Specify Length)Machined Rackwith rounded 7/8"(22.2mm) end

BUG-2597-8 8" (203.2mm)BUG-2597-15 15" (381mm)BUG-2597-22 22" (558.8mm)BUG-2597-27 27" (685.8mm)BUG-2597-30 30" (762mm)BUG-2597-36 36" (914.4mm)BUG-2597-39 39" (990.6mm)BUG-2597-42 42" (1066.8mm)BUG-2597-48 48" (1219.2mm)BUG-2597-54 54" (1371.6mm)BUG-2597-60 60" (1524mm)BUG-2597-72 72" (1828.8mm)

Supports & Accessories - Accessories

BUG-5295Rod MountAssembly

BUG-2594-10Taper GlidesPackage of 10

MDS-10313.5" (88.90mm)Rackholder

UNI-1036Rackriderwith Post

BUG-2407Post Assembly-Vertical

BUG-54513.5" (88.90mm)Rackholder

CIR-1010-_Twin Hose Assembly

MUG-1119-36Triple Hose Assembly18. 18" (457.2mm)32. 32" (812.8mm)

BUG-5930Low Profile CableAnchor Assembly

BUG-5485Contactor/CableAnchor

BUG-2975Cable MountingAssembly

BUG-2660Fits-All Clamp

BUG-5188Torchholder Assemblyw/7/8" (22.2mm) Rod

UNI-1035Outrigger Arm

CON-1020Swivel ClampAssembly

MDS-10854-pin WeldContact Cable15' (457.2cm)

Supports & Accessories - Panograph

PAN-1000Panograph Torch Floater

J. PAN-1071 Panograph RackholderK. PAN-1015 Rack 22 5/8" (574.68mm)L. PAN-1010 Panograph with

Torchholder

K

JL

PAN-1072Double Torch Panograph

N. PAN-1070 Panograph MountingDouble Torch

O. PAN-1000 Panograph TorchFloater

N

O

MJ

K

BUG-O SYSTEM'S CUTTING AND WELDING PANOGRAPHS arespring loaded torch holders that automatically compensate for surfacevariations. They are designed to carry a cutting torch or welding gunalong an irregular or wavy surface to maintain torch to work distance.

2


J. PAN-1071 Panograph RackholderK. PAN-1015 Rack 22 5/8" (574.68mm)M. PAN-1007 Panograph with fits-all

clamp

Supports & Accessories - Seam Tracking

3

PAN-2145-L, RMechanical Corner Follower

F

B

A

C

DE

Used for tracking a fillet weld, the CORNERFOLLOWER using a spring loaded V-wheel keeps awelding torch centered in the corner of the joint andmaintains correct torch to work distance. The CornerFollower is available in Right hand or Left handconfigurations.

A. BUG-1796 Machined Rack 14'' (355.60mm)B. BUG-5451 3.5'' (88.90mm) RackholderC. BUG-5462 Right Angle ClampsD. BUG-9180-10 Rod 10'' (254mm)E. PAN-2100 Seam Tracker

PAN-2160Mechanical Seam Follower

A. BUG-1796 Machined Rack 14'' (355.60mm)B. BUG-1853 Machined Rack 7.5'' (190.5mm)C. MDS-1031 3.5'' (88.90mm) RackholderD. UNI-1036 RackriderE. BUG-5462 Right Angle ClampF. PAN-2140-L or -R Adjustable Corner Follower

Used for tracking a V grooved butt joint, the SEAMFOLLOWER features 2 axis of adjustment determinedby a follower wheel which rides in the joint. It willprovide up to 2'' (50.8mm) of compensation up anddown as well as left and right for fit up variations.

E

DB

AC



Supports & Accessories



The TOOL POSITIONINGSYSTEM is a compact andrigid system which can beused to hold a wide variety ofcutting torches, welding gunsand other handheld tools.

It consists of black anodized7/8" (22.2mm) square aluminumbars with 16-pitch machinedracks and ways, right angleclamps, machined rackholdersand torchholders.

A. BUG-1796 Machined Rack 14" (355.6mm)B. BUG-1853 Machined Rack 7-1/2" (190.5mm)C. MDS-1031 3.5" (88.9mm) RackholderD. BUG-5455 Gun Mounting GroupE. BUG-5462 Right Angle Clamp

MDS-1040Machined Rack Welding Group

C

A

E

B

D

MDS-1075Dual Torch Welding Group

Includes:(2) H. MDS-1040 Machine Rack Group(1) I. MDS-1045 Double Rackholder Mount

IH

H

MDS-1090Dual Torch Cutting Group

Includes:(2) G. MDS-1050 Machined Rack Cutting Group(1) I. MDS-1045 Double Rackholder Mount

EC

A

F

MDS-1050Machined Rack Cutting GroupA. BUG-1796 Machined Rack 14" (355.6mm)C. MDS-1031 3.5" (88.9mm) RackholderE. BUG-5462 Right Angle ClampF. BUG-5188 Torchholder Assembly

I

G G

BUG-2708Clamp with7/8" (22.2mm)Rod

BUG-2915TorchholderAssembly

BUG-5462Right Angle ClampAssembly [for7/8" (22.2mm)Rods]

7/8" (22.2mm)

7/8"(22.2mm)

BUG-3232Dropping Bar

7/8"(22.2mm)

7/8"(22.2mm)

Litho in U.S.A. LIT-SA-BRO-0208A DIVISION OF WELD TOOLING CORPORATION

A QUALITY PRODUCT FROM BUG-O SYSTEMS • 280 TECHNOLOGY DRIVE • CANONSBURG, PA USA 15317-9564© Weld Tooling Corp. ROM 1:16

BUG-9865SteppingModule120VAC

BUG-94852-Pin Connector

BUG-9180_7/8" (22.2mm) DiameterRod (Specify Length)



BUG-2597(Specify Length)Machined Rackwith rounded 7/8"(22.2mm) end

BUG-2597-8 8" (203.2mm)BUG-2597-15 15" (381mm)BUG-2597-22 22" (558.8mm)BUG-2597-27 27" (685.8mm)BUG-2597-30 30" (762mm)BUG-2597-36 36" (914.4mm)BUG-2597-39 39" (990.6mm)BUG-2597-42 42" (1066.8mm)BUG-2597-48 48" (1219.2mm)BUG-2597-54 54" (1371.6mm)BUG-2597-60 60" (1524mm)BUG-2597-72 72" (1828.8mm)

Supports & Accessories - Accessories

BUG-5295Rod MountAssembly

BUG-2594-10Taper GlidesPackage of 10

MDS-10313.5" (88.90mm)Rackholder

UNI-1036Rackriderwith Post

BUG-2407Post Assembly-Vertical

BUG-54513.5" (88.90mm)Rackholder

CIR-1010-_Twin Hose Assembly

MUG-1119-36Triple Hose Assembly18. 18" (457.2mm)32. 32" (812.8mm)

BUG-5930Low Profile CableAnchor Assembly

BUG-5485Contactor/CableAnchor

BUG-2975Cable MountingAssembly

BUG-2660Fits-All Clamp

BUG-5188Torchholder Assemblyw/7/8" (22.2mm) Rod

UNI-1035Outrigger Arm

CON-1020Swivel ClampAssembly

MDS-10854-pin WeldContact Cable15' (457.2cm)



SUPER-FLEX

The SUPER-FLEX RAIL AND CARRIAGESYSTEM consists of an all position positiverack and pinion drive unit mounted on aSUPER-FLEX rail. The rail conforms to anyshape with a radius of 24" (600 mm) or largerand is easily mounted directly on theworkpiece. The SUPER-FLEX rail can beused on compound curvatures and can betwisted 10 degrees per 24" (600 mm) oflength. Powerful permanent magnets orvacuum cups clamp the rail onto the worksurface, fixture or jig. SUPER-FLEX railscan be bolted together for unlimited lengths.SUPER-FLEX rails are made of stainlesssteel for long life and rugged durability.Several sections of rail, bolted together canbe used for a wide range of diameters,shapes and sizes. Standard BUG-Oaccessories may be used for torchmounting, positioning, and weld weavingapplications.

PATENTS WORLDWIDE


3001 WEST CARSON STREET PITTSBURGH, PENNSYLVANIA USA 15204-1899 PHONE: 1- 800-245-3186 http://www.bugo.com TELEFAX: 1- 412-331-0383

WELD OR CUT DIFFERENT DIAMETERSWITH ONE PIECE OF EQUIPMENT!

2

SUPER-FLEX

ACCESSORIES:BUG-5451 Rackholder 3.5" (89 mm)BUG-1540 Cable Anchor AssemblyBUG-5455 Gun Mounting GroupBUG-2915 Torchholder AssemblyBUG-5025 Angle MountBUG-5300 Speed Weaver II 120 VACBUG-9198 Right Angle RackBUG-9898 Quick Acting Manifold (for 3-hose torch)

GOF-3025 Quick Acting Manifold (for 2-hose torch)PAN-1000 Panograph Torch Floater (flame cutting)PAN-1008 Panograph Torch Floater, with Fits-All

Clamp (welding)PAN-1015 22 5/8" (574 mm) RackPAN-1033 Rod ClampSFX-1255 Weaver Mount for Super-Flex

COMPONENTS:Carriages: SFX-1200-F Super-Flex Drive Carriage

SFX-1255 Super-Flex Weaver Mount

Rail: SFX-1160 Super-Flex Rail 5' (1.5 m)

Magnets: SFX-1120 Magnet Bar With ReleaseSFX-1140 Magnet Bar - Swivel With Release

Spacer Bar: SFX-1130 Spacer Bar

GOF-3025 BUG-5451

PAN-1015

BUG-9198

BUG-5455

BUG-2915

PAN-1033

BUG-5025 BUG-5300

SFX-1200-FBUG-5025

BUG-1540

SFX-1120 SFX-1130

SFX-1255

3

SUPER-FLEX

The Super-Flex Rail and Carriage System provides fast easysetup… and can be used almost anywhere!SFX-1160 SUPER-FLEX RAIL: is designed tobe used on inside or outside radii 24" (600 mm)or larger. The rails are 4" (102 mm) wide and 5'(1.5 m) long.

Net Weight: 7.75 lbs. (3.52 kg)Shipping Weight: 8.6 lbs. (3.88 kg)

USE WITHSUPER-FLEX

RAIL ONLY

7.25"(184 mm)

7.25"(184 mm)

9.00"(229 mm)

8.25"(210 mm)

4"(102 mm)

4"(102 mm)

SFX-1160Super-Flex Rail

MAGNETS: Two types of magnetsare available for use with SUPER-FLEX RAILS – the SFX-1120 magnetbar with release, or the SFX-1140magnet bar swivel with release. Bothmagnets have the same holding ca-pacity. We normally suggest using theSFX-1120 but, the choice is yours –specify the magnet bars you want. Aminimun of four magnets and fourspacer bars (SFX-1130), should beused on each SFX-1160 Super-Flexrail. FOR HORIZONTAL APPLICA-TIONS, use eight magnets and eightspacer bars.

5.5"(140 mm)

5.5"(140 mm)

8"(203 mm)

8"(203 mm)

1.5"(38 mm)

2"(51 mm)

2"(51 mm)

SFX-1120Magnet Bar, Fixed

SFX-1130Spacer Bar

Net Weight: SFX-1120/1140 2.25 lbs (1.02 kg)Shipping Weight: SFX-1120/1140 4 lbs (1.81 kg)

Net Weight: SFX-1130 0.25 lbs (0.11 kg)Shipping Weight: SFX-1130 1 lb (0.45 kg)

Models:SFX-1200-F Super-Flex DriveCarriage 120/50-60/1SFX-1202-F Super-Flex DriveCarriage 240/50-60/1SFX-1204-F Super-Flex DriveCarriage 42/50-60/1

Travel Speed:1.5-30 ipm (38-760 mm/min)Infinitely Variable Speed Control

Load Capacity:15 lbs (7 kg) On Drive Carriage,or 30 lbs (15 kg) on trailer.

Overall Dimensions:7.25"L x 8.25"W x 9.00"H(184 mm x 207 mm x 228 mm)

Net Weight of SFX-1200-F14 lbs (6.4 kg)

Trailer Carriage:

Model: SFX-1250Super-Flex Trailer

Load:Capacity: 30 lbs (15 kg)

MountingSurface: 6"L x 7"W

(152 mm x 178 mm)

TECHNICAL DATA:

ROM 1:16 Litho in U.S.A.© Weld Tooling Corp. LIT-SFX-BRO-1098

A DIVISION OF WELD TOOLING CORPORATIONA QUALITY PRODUCT FROM BUG-O SYSTEMS • 3001 WEST CARSON STREET • PITTSBURGH, PA USA 15204-1899

SUPER-FLEX

Super-Flex Flame Cutting Kits SFX-1000Includes:1 SFX-1200-F Super-Flex Carriage

Includes: 1 BUG-9444 Tool Kit

2 SFX-1160 Super-Flex LaminatedRail 5' (1.5 m)

8 SFX-1140 Magnet Bar, Swivel8 SFX-1130 Spacer Bar1 BUG-5451 Rackholder 3.5" (89 mm)1 PAN-1015 Rack 22-5/8" (574 mm)1 PAN-1033 Rod Clamp1 BUG-2915 Torchholder Assembly1 GOF-3025 2-Hose Q.A. Manifold1 CIR-1010-3 Twin Hose Assembly

32" (812 mm)2 BUG-5025 Angle Mount

SFX-1002Same as above except 240 VAC


SFX-1000-1Includes:1 SFX-1200-F Super-Flex Carriage



8 SFX-1120 Magnet Bar, Fixed8 SFX-1130 Spacer Bar1 BUG-5451 Rackholder 3.5" (89 mm)1 PAN-1015 Rack 22-5/8" (574 mm)1 PAN-1033 Rod Clamp1 BUG-2915 Torchholder Assembly1 GOF-3025 2-Hose Q.A. Manifold1 CIR-1010-3 Twin Hose Assembly

32" (812 mm)2 BUG-5025 Angle Mount

SFX-1002-1Same as above except 240 VAC


Net Weight Of Kit: 60 lbs. (27.3 kg)Shipping Weight Of Kit: 70 lbs. (31.9 kg)

Super-Flex Flame Welding Kits SFX-1010Includes:1 SFX-1200-F Super-Flex Carriage



8 SFX-1140 Magnet Bar, Swivel8 SFX-1130 Spacer Bar1 BUG-5440 Machined Rack Welding Grp.2 BUG-5025 Angle Mount1 BUG-1540 Cable Anchor Assembly






8 SFX-1120 Magnet Bar, Fixed8 SFX-1130 Spacer Bar1 BUG-5440 Machined Rack Welding Grp.2 BUG-5025 Angle Mount1 BUG-1540 Cable Anchor Assembly



Net Weight Of Kit: 59 lbs. (26.9 kg)Shipping Weight Of Kit: 70 lbs. (31.9 kg)

Super-Flex Weld Weaving Kits SFX-1020Includes:1 SFX-1200-F Super-Flex Carriage


1 BUG-5300 Speed Weaver II1 SFX-1255 Super-Flex Weaver Mount2 SFX-1160 Super-Flex Laminated

Rail 5' (1.5 m)8 SFX-1140 Magnet Bar, Swivel8 SFX-1130 Spacer Bar1 BUG-1540 Cable Anchor Assembly





1 BUG-5300 Speed Weaver II1 SFX-1255 Super-Flex Weaver Mount2 SFX-1160 Super-Flex Laminated

Rail 5' (1.5 m)8 SFX-1120 Magnet Bar, Fixed8 SFX-1130 Spacer Bar1 BUG-1540 Cable Anchor Assembly



Net Weight Of Kit: 74 lbs. (33.7 kg)Shipping Weight Of Kit: 86 lbs. (39 kg)

NOTE: SUPER-FLEX KITS ARE AVAILABEL WITH VACUUMCUP SUPPORTS FOR 120 VAC AND 220 VAC – CONSULTFACTORY.

TANK FABRICATIONTANK FABRICATIONAutomated Solutions for YourTank Fabrication Project.Automated Solutions for YourTank Fabrication Project.

Bug-o Systemswww.bugo.com


© Weld Tooling Corp. Litho in U.S.A. LIT-TANK-BRO-0408A DIVISION OF WELD TOOLING CORPORATION ROM 1:16

BUG-O SYSTEMSSix Advantages of Automating Your Welding and Cutting Applications:1) Increase Production2) Increase Quality3) Reduce Material Handling

4) Reduce Distortion5) Improve Workers' Environment6) Adapts to Your Application

Go-fer IIIThe straight line Go-fer III can be used to cut, bevel and weld the floor plates. The Go-fer’s low cost and high reliability make it a great fit for many tank fabrication applications including repair work.

GOF-3250 120 VoltGOF-3252 240 Volt

For more detailed information please see our Go-fer III Brochure.

GO-FER III

BUG-O SYSTEMSAutomated Solutions Since 1948.

A QUALITY PRODUCT FROM BUG-O SYSTEMS • 280 TECHNOLOGY DRIVE • PITTSBURGH, PA USA 15317-9564

2

BUG-O ALL TIME GIRTH WELDER

Bug-o Systems offers the Automatic Girth Welder for tank fabrication applications. Unlike current girth welders on the market, the BGW Series comes standard with a Dual Drive System. This self-propelled submerged arc welding system can reduce field storage tank welding time up to 40%. Weld defects are greatly reduced saving tank erection costs. The Girth Welder is applicable for bottom-up or jack-up constructed single or double wall storage tanks inside and outside welding. There are four standard units, however our design allows us to offer custom built units for non-standard applications.

Dual DriveBug-o All Time exclusive dual AC motor design, allows for constant travel across the entire tank circumference. When fit up is not quite perfect or there is an uneven surface for the machine to travel, the dual motors will power the machine across the imperfection. This design can reduce the amount of time required to repair weld defects, and can decrease the overall tank erection costs. The dual motors are controlled by one easily programmable frequency inverter.

Heavy Duty Flux Recovery System with Flux Lifting WinchThe BGW-Series offers a flux recovery system that can hold 130lbs (60 kg) of flux for use on long plate. The BGW also offers the convenience of a Flux Lifting Winch for easy refilling of the main flux hopper. The winch can lift 350lb (159 kg) of flux up to 100 feet (30.5 m) off the ground.

7

BUG-GY AND BUG-GY-VERT

BuggyThe BUG-GY Fillet Welder is designed for making continuous or intermittent stitch welds on fillet, lap or butt joints. It is a lightweight portable carriage that uses powerful magnets and guide wheels to clamp and track on the work piece.

AFW-3000 120 VoltAFW-3002 240 Volt

For more detailed information please see our Bug-gy Brochure.

Bug-gy-vertThe BUG-GY-VERT is a portable battery powered 4-wheel drive welding carriage with or without torch oscillation. Strong permanent magnets hold the machine on the workpiece allowing it to travel on vertical or oblique work surfaces.

With Oscillation:VFW-3150 110 Volt

(includes battery and charger)VFW-3152 220 Volt

(includes battery and charger)

Without Oscillation:VFW-3000 110 Volt



For more detailed information please see our Bug-gy-vert Brochure.

The Base welds on a tank can easily be made with either the Buggy or Buggy-vert. The Buggy and Buggy-vert fillet welders will self guide off of the bottom course of the tank, providing a uniform weld for the entire circumference. If there is not enough space to run the Buggy on the base plate, the Buggy-vert can be mounted to the tank itself as long as the tank is over 25' (8 m) diameter. An optional submerged arc gun and auxiliary magnets are available if necessary.

Modular Drive SystemThe Modular Drive System helps to make the vertical seam welds with increased precision and repeatability. By incorporating the Linear Weaver, the Bug-o Modular Drive System can help to increase your overall fabrication productivity.

For more detailed information please see our Modular Drive Weaver Brochure.

BMV-1000 Multi Pass Vertical WelderThe BVW-1000 Vertical Welder is designed for welding the vertical seams on field storage tanks in an enclosed environment. The frame of the Vertical Welder is covered by Aluminum panels to provide a weather tight seal. With the motorized drives and permanently mounted rails, setup time and cost is reduced between the vertical weld seams. This unit is designed to run on any wire feeder/welding power supply combination. A powered elevating platform allows the operator to follow the Bug-o drive carriage up the seam. An exhaust fan helps to keep the interior free from welding fumes. A Lincoln Electric fume extractor can be added for additional fume removal. The BVW-1000 Vertical Welder utilizes many of the same features that the Bug-o Girth Welder BGW Series has; dual drive motors, welding power supply storage container and tool box.

3


Rotating Flux Dam and Welding HeadThe adjustable rotating flux dam holds the flux in the weld joint and conveyors the flux to the heavy duty flux recovery vacuum. The flux dam can be adjusted both vertically and horizontally for easy positioning of the flux belt. The welding head has a fine adjustment vertical and horizontal cross slides that gives 4'' x 6'' (102 x 152 mm) of adjustment. A laser pointer mounted on the welding head permits for simple positioning of the welding wire.

Lincoln Welding Equipment and Power Source StorageThe BGW series comes complete with SAW equipment by Lincoln Electric. The DC-600 with NA-3 controls and NA-3 feeders come standard on all models. Optional power sources and feeder

combination are available. The power source is stored in a weather proof container for protection. A single power input supplies electrical power to all the components of the system. The complete BGW series comes complete with 200' (61 m) of control cable and welding leads with a guide on the machine itself to keep the cable away from the plate.

Environmental FeaturesA series of fireproof and weather tight canvas covers provide protection for the operator. All models also include interior lighting and a spot light for the Flux Belt. Under the seat is the convenience of a storage area for wire spools, tools, or whatever the operator may need.

MDS WEAVER AND VERTICAL WELDER

6

4


Power Switch

110 VAC / 220 VAC

Flux Recovery Vacuum On/Off Switch

Interior Lighting Switch

Input Power Indicator

Travel ReadyIndicator

LCD Speed Display

Speed Adjustment Knob

Weld SpeedIndicator

Maximum WeldSpeed Indicator

Left-Stop-RightTravel DirectionSwitch

Girth Welder Control Panel

Min. - Max. Model Application Tank Welding Travel Shell Plate Wire Approx. Diameter Thickness Speed Height Weight

BGW-1000 6'-10' 3/32'' 2,094 lbs. Single Side Weld Conventional (1.8 - 3.0 m) (2.4mm) 950 kg Storage Tanks BGW-2000 Min. 15' 5/16''-1 9/16'' 4-114 ipm 1/8'' 3,968 lbs. Double Side Weld (4.5m) (8-40mm) (100-2900 (3.2mm) 1800 kg mm/min) BGW-1000-LNG Double Shell Single Side Weld Cryogenic 7'-13' 2 x 1/16" 1,984 lbs. Storage Tanks (2-4 m) (2 x 1.6mm) 900 kg

BGW-1000-D Top Down 6'-10' (Tinytwin Arc) 2,425 lbs Single Side Weld Constructed (1.8-3.0m) 1100 kg Storage Tanks

5


Girth Welder Application Photos

Modular Drive SystemThe Modular Drive System helps to make the vertical seam welds with increased precision and repeatability. By incorporating the Linear Weaver, the Bug-o Modular Drive System can help to increase your overall fabrication productivity.

For more detailed information please see our Modular Drive Weaver Brochure.

BMV-1000 Multi Pass Vertical WelderThe BVW-1000 Vertical Welder is designed for welding the vertical seams on field storage tanks in an enclosed environment. The frame of the Vertical Welder is covered by Aluminum panels to provide a weather tight seal. With the motorized drives and permanently mounted rails, setup time and cost is reduced between the vertical weld seams. This unit is designed to run on any wire feeder/welding power supply combination. A powered elevating platform allows the operator to follow the Bug-o drive carriage up the seam. An exhaust fan helps to keep the interior free from welding fumes. A Lincoln Electric fume extractor can be added for additional fume removal. The BVW-1000 Vertical Welder utilizes many of the same features that the Bug-o Girth Welder BGW Series has; dual drive motors, welding power supply storage container and tool box.

3


Rotating Flux Dam and Welding HeadThe adjustable rotating flux dam holds the flux in the weld joint and conveyors the flux to the heavy duty flux recovery vacuum. The flux dam can be adjusted both vertically and horizontally for easy positioning of the flux belt. The welding head has a fine adjustment vertical and horizontal cross slides that gives 4'' x 6'' (102 x 152 mm) of adjustment. A laser pointer mounted on the welding head permits for simple positioning of the welding wire.

Lincoln Welding Equipment and Power Source StorageThe BGW series comes complete with SAW equipment by Lincoln Electric. The DC-600 with NA-3 controls and NA-3 feeders come standard on all models. Optional power sources and feeder

combination are available. The power source is stored in a weather proof container for protection. A single power input supplies electrical power to all the components of the system. The complete BGW series comes complete with 200' (61 m) of control cable and welding leads with a guide on the machine itself to keep the cable away from the plate.

Environmental FeaturesA series of fireproof and weather tight canvas covers provide protection for the operator. All models also include interior lighting and a spot light for the Flux Belt. Under the seat is the convenience of a storage area for wire spools, tools, or whatever the operator may need.

MDS WEAVER AND VERTICAL WELDER

6

2


Bug-o Systems offers the Automatic Girth Welder for tank fabrication applications. Unlike current girth welders on the market, the BGW Series comes standard with a Dual Drive System. This self-propelled submerged arc welding system can reduce field storage tank welding time up to 40%. Weld defects are greatly reduced saving tank erection costs. The Girth Welder is applicable for bottom-up or jack-up constructed single or double wall storage tanks inside and outside welding. There are four standard units, however our design allows us to offer custom built units for non-standard applications.

Dual DriveBug-o All Time exclusive dual AC motor design, allows for constant travel across the entire tank circumference. When fit up is not quite perfect or there is an uneven surface for the machine to travel, the dual motors will power the machine across the imperfection. This design can reduce the amount of time required to repair weld defects, and can decrease the overall tank erection costs. The dual motors are controlled by one easily programmable frequency inverter.

Heavy Duty Flux Recovery System with Flux Lifting WinchThe BGW-Series offers a flux recovery system that can hold 130lbs (60 kg) of flux for use on long plate. The BGW also offers the convenience of a Flux Lifting Winch for easy refilling of the main flux hopper. The winch can lift 350lb (159 kg) of flux up to 100 feet (30.5 m) off the ground.

7

BUG-GY AND BUG-GY-VERT

BuggyThe BUG-GY Fillet Welder is designed for making continuous or intermittent stitch welds on fillet, lap or butt joints. It is a lightweight portable carriage that uses powerful magnets and guide wheels to clamp and track on the work piece.

AFW-3000 120 VoltAFW-3002 240 Volt

For more detailed information please see our Bug-gy Brochure.

Bug-gy-vertThe BUG-GY-VERT is a portable battery powered 4-wheel drive welding carriage with or without torch oscillation. Strong permanent magnets hold the machine on the workpiece allowing it to travel on vertical or oblique work surfaces.

With Oscillation:VFW-3150 110 Volt



Without Oscillation:VFW-3000 110 Volt



For more detailed information please see our Bug-gy-vert Brochure.

The Base welds on a tank can easily be made with either the Buggy or Buggy-vert. The Buggy and Buggy-vert fillet welders will self guide off of the bottom course of the tank, providing a uniform weld for the entire circumference. If there is not enough space to run the Buggy on the base plate, the Buggy-vert can be mounted to the tank itself as long as the tank is over 25' (8 m) diameter. An optional submerged arc gun and auxiliary magnets are available if necessary.

TANK FABRICATIONTANK FABRICATIONAutomated Solutions for YourTank Fabrication Project.Automated Solutions for YourTank Fabrication Project.



© Weld Tooling Corp. Litho in U.S.A. LIT-TANK-BRO-0408A DIVISION OF WELD TOOLING CORPORATION ROM 1:16

BUG-O SYSTEMSSix Advantages of Automating Your Welding and Cutting Applications:1) Increase Production2) Increase Quality3) Reduce Material Handling

4) Reduce Distortion5) Improve Workers' Environment6) Adapts to Your Application

Go-fer IIIThe straight line Go-fer III can be used to cut, bevel and weld the floor plates. The Go-fer’s low cost and high reliability make it a great fit for many tank fabrication applications including repair work.

GOF-3250 120 VoltGOF-3252 240 Volt

For more detailed information please see our Go-fer III Brochure.

GO-FER III

BUG-O SYSTEMSAutomated Solutions Since 1948.

A QUALITY PRODUCT FROM BUG-O SYSTEMS • 280 TECHNOLOGY DRIVE • PITTSBURGH, PA USA 15317-9564





A magnetic based surveying tool that reduces plumbing and alignment time.

Reduce structural erection costs with TAR-GIT. Lightweight, held in position with a powerful permanent magnet and easily seen through a transit. The 24" (610 mm) model is a calibrated aluminum scale. PATENTS WORLDWIDE

TAR-GIT

Litho in U.S.A. LIT-TAR-BRO-0908A DIVISION OF WELD TOOLING CORPORATIONA QUALITY PRODUCT FROM BUG-O SYSTEMS • 280 TECHNOLOGY DRIVE • CANONSBURG, PA 15317-9564 USA


TAR-GIT

TAR-1100 SCALE

Features:

A. TAR-1101 Aluminum Scale 24'' (609 mm)

B. TAR-1102 Angle Mount

C. TAR-1110 Magnet Assembly

D. TAR-1140 TAR-GIT, Plastic

Technical Data:

TAR-1100 24'' (610 mm) ScaleNet Weight: 1 lb. (0.45 kg)


A

C

B

D



Bug-O SystemsMachine Cutting TorchesVersatile torches for your cutting application.


Bug-O's Machine cutting torches are designed to handle all types of machine cutting applications. The torches canprovide up to 15'' (381 mm) cutting capacity. Two hose and three hose torches are available for all fuel gases atpressures as low as 4 oz. All torches are a standard 1 3/8'' (34.93 mm) diameter barrel and come with a 32 pitch rack(10.12 teeth/in.) ready to fit in all Bug-O torch holders and automated cutting systems.

Two Hose Torches:• Cutting capacity to 8'' (203 mm).• Torches supplied with check valves on

preheat oxygen and preheat fuel.

Three Hose Torches:• Quick opening cutting oxygen valve for

immediate full flow.• Separate preheat and cutting oxygen

valves for high and low preheat control.• Cutting capacity to 15'' (381 mm).• Torches supplied with check valves on

preheat oxygen and preheat fuel.

Positive Pressure "F" Type Torchesfor Oxy-Propane and Natural Gas

Part No. Style Barrel Weight

BUG-4071 2 Hose & Rack 10'' (254 mm) 3.3 lbs. (1.50 kg)

Positive Pressure "E" Type Torchesfor Oxy-Acetylene and Alternate Fuels

Part No. Style Barrel Weight

BUG-1271 2 Hose & Rack 10'' (254 mm) 3.3 lbs. (1.50 kg)BUG-1274 3 Hose & Rack 10'' (254 mm) 3.3 lbs. (1.50 kg)BUG-1275 3 Hose & Rack 18'' (457 mm) 4.2 lbs. (1.91 kg)

A QUALITY PRODUCT FROM BUG-O SYSTEMS • 280 TECHNOLOGY DRIVE • CANONSBURG, PA 15317-9564 USALitho in U.S.A. LIT-TORCH-BRO-0708A DIVISION OF WELD TOOLING CORPORATION © Weld Tooling Corp. ROM 1:16

Cutting Tips and Accessories

Oxy-Acetylene Tips

Part No. Tip Plate Oxygen Fuel Gas OrificeSize Thickness PSIG PSIG Drill Size

BUG-1270-000 000 Light Gauge to 3/16 15-20 5-15 #68BUG-1270-00 00 3/16-3/8 20-25 5-15 #64BUG-1270-0 0 3/8-5/8 35-40 5-15 #60BUG-1270-1 1 5/8-1 35-40 5-15 #56BUG-1270-2 2 1-2 40-45 5-15 #52BUG-1270-3 3 2-3 45-50 5-15 #48BUG-1270-4 4 3-6 50-75 10-15 #42


Part No. Tip Plate Oxygen Fuel Gas OrificeSize Thickness PSIG PSIG Drill Size

BUG-4070-000 000 Light Gauge to 3/16 15-30 5-15 #68BUG-4070-00 00 3/16-3/8 20-30 5-15 #64BUG-4070-0 0 3/8-5/8 30-40 5-15 #60BUG-4070-1 1 5/8-1 35-50 5-15 #56BUG-4070-2 2 1-2 40-55 5-15 #52BUG-4070-3 3 2-3 45-60 5-15 #42BUG-4070-4 4 3-6 50-75 5-15 #42BUG-4070-5 5 6-8 65-80 5-15 #35BUG-4070-6 6 8-12 70-90 5-15 #30

Adjustable Tip AdapterBUG-1289

Adjust tip to any angle without moving thetorches. Tips not included.

Beveling HeadBUG-1290

Increases speed of quality bevel cuts. Preheattip swivels for either left or right travel. Equippedwith a heating tip. Use with natural gas or propanetips (not included).

Twin Hose AssemblyCIR-1010

Specify Length When Ordering

Machined Rack Cutting GroupMDS-1050

A. BUG-1796 Machined Rack 14'' (355.6 mm)B. MDS-1031 3.5'' (88.9 mm) RackholderC. BUG-5462 Right Angle ClampD. BUG-5188 Torchholder Assembly

Triple Hose AssemblyMUG-1119

Specify Length When Ordering

2-Hose Quick-ActingManifold

GOF-3025

3-Hose Quick-ActingManifold

BUG-9898

Adjustable Twin Tip HolderBUG-1291

For making two cuts simultaneously with onetorch. Adjusts from 1 1/2'' (38.10 mm) to 12''(304.8 mm) width. Tips not included.

A

B

C

D

* For tips to cut 6'' to 15'', please consult factory.



Produce machined quality cuts and bevels with Oxy-Fuel or Plasma.

Trac-Bug Affordable automation that increases production and improves quality.

The Trac-Bug is a compact friction drive cutting machine that will ride on any standard 6" (152 mm) V-grooved track. A solid-state variable speed control allows the Trac-Bug to travel and carry a torch at precise speeds producing a machined quality cut or bevel. Plate cutting and welding preparation can now be done quickly and with a high degree of precision. Quality bevels produced with the Trac-Bug reduce fit-up and grinding time and lay a foundation for a stronger weld.

Straight Line Track Burning Machine.

Trac-BugThe Trac-Bug is available in two standard configurations, for Oxy-Fuel cutting TRB-1000 and for Plasma Cutting TRB-1500. Each version is equipped with a 22-7/8" (581 mm) geared rack with 1-3/8" (47.6 mm) diameter machine torch holder that will accommodate a 32 pitch rack.

TRB-1000 Trac-Bug Oxy-Fuel*Includes a GOF-3025 quick action manifold and a CIR-1010-3, 32" twin hose assembly.

TRB-1500 Trac-Bug Plasma*Includes Bug-5485 plasma contactor and cable support.

Technical Specifications:

Travel Speed: 4-72 ipm (100-1800 mm/min) Net Weight: 33 lbs. (15 kg) Shipping Weight: 38 lbs. (17 kg) Trac-Bug Oxy-Fuel TRB-1000 110 VAC TRB-1002 240 VAC TRB-1004 42 VAC

.313''(8 mm)

7.00''(178 mm)

6.00''(152 mm)

72.00''(1828 mm)

Trac-Bug PlasmaTRB-1500 110 VACTRB-1502 240 VACTRB-1504 42 VAC

*Does not include track or torch.

7.25''(185 mm)

6.00''(152 mm)

18.00''(470 mm)

18.38''(467 mm)

12.00''(305 mm)

9.00''(229 mm)

7.25''(185 mm)

6.00''(152 mm)

8.00''(204 mm)

17.25''(439 mm)

12.00''(305 mm)

TRB-1250 72" (183 cm) Track.

A QUALITY PRODUCT FROM BUG-O SYSTEMS • 280 TECHNOLOGY DRIVE • CANONSBURG, PA 15317-9564 USALitho in U.S.A. LIT-TRB-BRO-0908A DIVISION OF WELD TOOLING CORPORATION © Weld Tooling Corp. ROM 1:16

•Runsdirectlyonworkpieces upto2"(50mm)thick.•Weighsonly14lbs.(6.5kg).•Cangofromastraighttoa6" (152mm)radiusinsideorout.

ReliableLowCostMotionControl.

TheUNI-BUGII...TheUltimateWeldingAndCuttingSystem!

BUG-OSYSTEMSPowerfulSolutionsForWeldingAndCuttingAutomation.www.bugo.com

PowerRequirement: 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)

SpeedRange: 4 ipm to 75 ipm (102 to 1905 mm/min)

MaximumStiffenerSize: 2" (50.8 mm)

NetWeight: 14 lbs. (6.35 kg)

ShippingWeight: 16 lbs. (7.26 kg)

THEUNIVERSALBUG-OII

Kits:

Dimensions:TechnicalData:

2.00''(51 mm)

NOTE:Minimum work height is 2" (50.8 mm).(4" [101.6 mm] when welding).

Minimum work height with corner followeris 5" (127 mm).

BUG-1780RigidRail is available forstraight line applications, 40" (1 m) long,includes two ON/OFF magnets.

UNI-1100UNI-BUGIIWeldingKit 120VACUNI-1102UNI-BUGIIWeldingKit 240VACUNI-1104UNI-BUGIIWeldingKit 42VAC

NetWeight: 19lbs.(8.62kg)

ShippingWeight: 21lbs.(9.53kg)

Includes: (1)BUG-1855 WeldingGroup (1)UNI-100_ UNI-BUGII

UNI-1200UNI-BUGIICuttingGroup 120VACUNI-1202UNI-BUGIICuttingGroup 240VACUNI-1204UNI-BUGIICuttingGroup 42VAC



Includes: (1)BUG-1875 CuttingGroup (1)UNI-100_ UNI-BUGII

A QUALITY PRODUCT FROM BUG-O SYSTEMS • 280 TECHNOLOGY DRIVE • CANONSBURG, PA 15317-9564 USA © Weld Tooling Corp. Litho in U.S.A. LIT-UBII-BRO-0608A DIVISION OF WELD TOOLING CORPORATION ROM 1:16

7.62''(194 mm)

6.25''(159 mm)

5.75''(146 mm)

8.00''(203 mm)6.25'' - 9.0''

(159-229 mm)

2.00''(51 mm)

6.00''(152 mm)

10.50''(267 mm)

2

THEUNIVERSALBUG-OII

The UNI-BUG II will 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 lines and radii 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) load 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.

3

Features:

The UNI-BUG II can operate without a track. A gear 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 against 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.

UNI-BUGII(Torch holding devices not shown for clarity,see back page).

Typical UNI-BUG II applications.

Straightlineburning.

Beamsplitting. Irregularshapeburningandwelding.

Filletwelding.

Circleburningandwelding.

Coamingwelding.

•Runsdirectlyonworkpieces upto2"(50mm)thick.•Weighsonly14lbs.(6.5kg).•Cangofromastraighttoa6" (152mm)radiusinsideorout.

ReliableLowCostMotionControl.

TheUNI-BUGII...TheUltimateWeldingAndCuttingSystem!

BUG-OSYSTEMSPowerfulSolutionsForWeldingAndCuttingAutomation.www.bugo.com

PowerRequirement: 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)

SpeedRange: 4 ipm to 75 ipm (102 to 1905 mm/min)

MaximumStiffenerSize: 2" (50.8 mm)

NetWeight: 14 lbs. (6.35 kg)

ShippingWeight: 16 lbs. (7.26 kg)

THEUNIVERSALBUG-OII

Kits:

Dimensions:TechnicalData:

2.00''(51 mm)

NOTE:Minimum work height is 2" (50.8 mm).(4" [101.6 mm] when welding).

Minimum work height with corner followeris 5" (127 mm).

BUG-1780RigidRail is available forstraight line applications, 40" (1 m) long,includes two ON/OFF magnets.

UNI-1100UNI-BUGIIWeldingKit 120VACUNI-1102UNI-BUGIIWeldingKit 240VACUNI-1104UNI-BUGIIWeldingKit 42VAC



Includes: (1)BUG-1855 WeldingGroup (1)UNI-100_ UNI-BUGII

UNI-1200UNI-BUGIICuttingGroup 120VACUNI-1202UNI-BUGIICuttingGroup 240VACUNI-1204UNI-BUGIICuttingGroup 42VAC



Includes: (1)BUG-1875 CuttingGroup (1)UNI-100_ UNI-BUGII

A QUALITY PRODUCT FROM BUG-O SYSTEMS • 280 TECHNOLOGY DRIVE • CANONSBURG, PA 15317-9564 USA © Weld Tooling Corp. Litho in U.S.A. LIT-UBII-BRO-0608A DIVISION OF WELD TOOLING CORPORATION ROM 1:16

7.62''(194 mm)

6.25''(159 mm)

5.75''(146 mm)

8.00''(203 mm)6.25'' - 9.0''

(159-229 mm)

2.00''(51 mm)

6.00''(152 mm)

10.50''(267 mm)

Produce uniform high quality welds with the:

PROGRAMMABLE UNI-BUG III StItch WELdER

A QUALITY PRODUCT FROM BUG-O SYSTEMS • 280 TECHNOLOGY DRIVE • CANONSBURG, PA 15317-9564A DIVISION OF WELD TOOLING CORPORATION © Weld Tooling Corp. ROM 1:16 Litho in U.S.A. LIt-UBIII-BRO-0608

UNI-2900, 2902, 2904The UNI-2900 UNI-BUG III dual torch Angle Welding Kit is supplied with the mounts for two welding torches and

provides components to independently adjust either torch in the vertical and horizontal plane. The unit features programmable control for stitch or continuous welding and is designed for straight line welding of angles. The unit will mount and run on top of angles with a minimum height of 4" (102mm) and widths up to 4" (102mm). The unit will travel at speeds from 4 to 75 inches per minute (102-1905mm/min).

BUG-O SYStEMSWelding & cutting Automation Since 1948.

dimensions:technical data:

Power Requirement: UNI-2500, 2600, 2700, 2800, 2900 110 VAC/50-60/1 UNI-2502, 2602, 2702, 2802, 2902 240 VAC/50-60/1 UNI-2504, 2604, 2704, 2804, 2904 42 VAC/50-60/1

Welding Speed Range: 4 ipm to 75 ipm (102 to 1905 mm/min)

Skip Speed: 75 ipm (1905 mm/min)

Minimum Stiffener height: 2'' (50.8 mm)

Net Weight: 27 lb. (12.2 kg)

Shipping Weight: 36.5 lb. (16.6 kg)

www.bugo.com 1-412-331-1776

thE UNI-BUG III StItch WELdER

2.00''(51 mm)

2.00''(51 mm)

6.25''(159 mm)

8.00''(203 mm)

7''-9''(178-229 mm)

7.00''(178 mm)

11.50''(292 mm)

2

The UNI-BUG III will make continuous or intermittent stitch welds. The machine will mount and run directly on the work piece. The unit is available in a variety of kits. Each kit is designed to fit on a specific steel profile such as flat bar, angle, channel, I-beams and bulb flats (holland profiles).

The UNI-BUG III features stitch welding which is programmable by distance. If you require stitch welding simply set the selector switch to the intermittent weld setting and program the length of weld required, the length of skip and also the required delay for pre-flow and burn back. Through the use of an integrated weld contactor the UNI-BUG III will activate and deactivate your wire feeder automatically.

UNI-2500, 2502, 2504The UNI-2500 UNI-BUG III Single torch Kit is equipped for the mounting of a single torch and provides components

to manually adjust the torch in the vertical and horizontal plane. The UNI-BUG III provides programmable control for stitch or continuous welding and is designed to mount and run on the top edge of a flat bar or stiffener with a minimum height of 2" (50 mm) and a maximum width of 2" (50 mm). The machine will turn on a radius down to 6" (160 mm). The unit will travel at speeds from 4 to 75 inches per minute (102-1905 mm/min).

• Produce stitch or continuous welds • Programmable by distance • Runs directly on the work piece • Carriage attachments designed to run a variety of structural steel profiles.

UNI-2600, 2602, 2604The UNI-2600 UNI-BUG III dual torch Welding Kit is the same as the UNI-2500, but is equipped for the mounting of

two welding torches and provides components to manually adjust either torch in the vertical and horizontal plane.


3

UNI-2700, 2702, 2704The UNI-2700 UNI-BUG III Dual Torch Bulb Profile Welding Kit is equipped for the mounting of two welding torches and

provides components to independently adjust either torch in the vertical and horizontal plane. The unit features programmable control for stitch or continuous welding and is designed for straight line welding of bulb flats. This unit will mount and run on bulb sizes from 140 mm to 430 mm. The unit will travel at speeds from 4 to 75 inches per minute (102-1905 mm/min).


UNI-2800, 2802, 2804The UNI-2800 UNI-BUG III Dual Torch “T” Profile Welding Kit is equipped for the mounting of two welding torches

and provides components to independently adjust either torch in the vertical and horizontal plane. The UNI-2800-4 works on "T" profiles 2''-4'' (51-102 mm) range. The UNI-2800-6 works on "T" profiles 4''-6'' (102-152 mm) range. The unit features programmable control for stitch or continuous welding and is designed for straight line welding of “T” profiles. This unit will mount and run on top of “T” profiles with a minimum height of 2" (50 mm). The unit will travel at speeds from 4 to 75 inches per minute (102-1905 mm/min).

Produce uniform high quality welds with the:

PROGRAMMABLE UNI-BUG III StItch WELdER

A QUALITY PRODUCT FROM BUG-O SYSTEMS • 280 TECHNOLOGY DRIVE • CANONSBURG, PA 15317-9564A DIVISION OF WELD TOOLING CORPORATION © Weld Tooling Corp. ROM 1:16 Litho in U.S.A. LIt-UBIII-BRO-0608

UNI-2900, 2902, 2904The UNI-2900 UNI-BUG III dual torch Angle Welding Kit is supplied with the mounts for two welding torches and

provides components to independently adjust either torch in the vertical and horizontal plane. The unit features programmable control for stitch or continuous welding and is designed for straight line welding of angles. The unit will mount and run on top of angles with a minimum height of 4" (102mm) and widths up to 4" (102mm). The unit will travel at speeds from 4 to 75 inches per minute (102-1905mm/min).

BUG-O SYStEMSWelding & cutting Automation Since 1948.

dimensions:technical data:

Power Requirement: UNI-2500, 2600, 2700, 2800, 2900 110 VAC/50-60/1 UNI-2502, 2602, 2702, 2802, 2902 240 VAC/50-60/1 UNI-2504, 2604, 2704, 2804, 2904 42 VAC/50-60/1

Welding Speed Range: 4 ipm to 75 ipm (102 to 1905 mm/min)

Skip Speed: 75 ipm (1905 mm/min)

Minimum Stiffener height: 2'' (50.8 mm)

Net Weight: 27 lb. (12.2 kg)

Shipping Weight: 36.5 lb. (16.6 kg)

www.bugo.com 1-412-331-1776


2.00''(51 mm)

2.00''(51 mm)

6.25''(159 mm)

8.00''(203 mm)

7''-9''(178-229 mm)

7.00''(178 mm)

11.50''(292 mm)



Flexible, compact Drive and Oscillator combination forwelding in all positions.

UNIVERSAL BUG-O-MAUNIVERSAL BUG-O-MAUNIVERSAL BUG-O-MAUNIVERSAL BUG-O-MAUNIVERSAL BUG-O-MATICTICTICTICTIC

Affordable automation that increases production and improves quality.

The UNIVERSAL BUG-O-MATIC is a compact unit which combines a powerful drive and precision oscillatorall in one housing. The unit is lightweight and can easily be handled by one operator. The machine worksin all positions and can be used for vertical and overhead welds. By simply changing the carriage, the unitcan work on rigid rail, semi-flex rail, hi-flex rail or complete ring rails. The opening mechanism of the carriageallows the unit to be released or installed anywhere on the rail.

ROM 1:16 Litho in U.S.A.© Weld Tooling Corp.A DIVISION OF WELD TOOLING CORPORATIONA QUALITY PRODUCT FROM BUG-O SYSTEMS • 3001 WEST CARSON STREET • PITTSBURGH, PA USA 15204-1899

UNIVERSAL BUG-O-MATICWhile welding, adjustments can be made to the travel speed, amplitude and oscillation speed as well as dwell left anddwell right. While the machine is welding, the torch can be guided by a separate steering knob. Closed loop feedbackand dynamic braking allow the Bug-O-Matic to make precise starts, stops and travel at a constant speed.

MPD-1065 4-wheel carriage.Releasable, can be installed or releasedin any position anywhere on the rail.

BUG-5910 Ring Rail Carriage.4 wheels can be adjusted to the requiredring diameter. Releasable.

FMD-1100 Hi-Flex Carriage.Runs on high flexible SS-Rails as shownbelow. Releasable.

Carriages

Technical Data:

FMD-1050 Hi-Flex RailLength = 5' (1.5 m)

R - Minimum Radius30" (1,000 mm)

The above shown carriages can be used on the rails shown below:

Pendant Control Functions:

A. Pattern Selector SwitchB. Carriage Travel SwitchC. Carriage SpeedD. Dwell RightE. Dwell LeftF. Weave SpeedG. AmplitudeH. Weld ContactJ. Steering, Right & Left

G

B

H

C

FJ

E

DA

Dimensions

Magnet Bars and Vacuum Bars

Ring Rails DiameterBRR-1210-20 (20" 500 mm)BRR-1210-27 (27" 680 mm)BRR-1210-34 (34" 860 mm)BRR-1210-41 (41" 1040 mm)BRR-1210-48 (48" 1220 mm)

ARR-1080 L = 8' (2.4 m)HD-Rigid Aluminum RailARR-1085 L = 4' (1.2 m)HD-Rigid Aluminum RailAFR-3000 L = 8' (2.4 m)Semi-Flex Aluminum Rail



ARV-1080/1085Vacuum System

ARM-2380Support Bar withScrew Feet

ARM-2480Support Bar withScrew Magnet Feet

ARM-2120RE-Magnet w/Release

FMD-2325Magnet w/Release

FMD-1220/1230Vacuum System

R

For Rigid and Semi-Flex rail. For Ring Rail. For Hi-Flex rails.

Input Voltage: BUG-5700 120 VAC 50/60HzTravel Speed: 3-65 ipm (70 – 1670 mm/min.)Oscillation Speed: 4-98 ipm (100 – 2500 mm/min.)Vertical Load Capacity: 31 lbs. (14 kg.)Dwell Left/Right: 0-3 SecondsAmplitude: .078-1.37" (2-50 mm)Arc Position Control: Steering 2" right & leftNet Weight: 23 lbs. (10.5 kg.)

7.2"184 mm

5.5"143 mm

9.5"241 mm

LIT-UBM-BRO-1001

Non Metallic Weld Backings ForFull Penetration Welding.

Weld More Efficiently.

Achieve:• X-Ray quality welds.• Full penetration welding from one side• Uniform back bead of finished quality

Eliminate:• Defects and costly rework• Gouging and backgrinding• Eliminate material handling

BUG-O SYSTEMS weld backings are non metallic, nonhygroscopic, neutral, and unlike metal backing bars,do not become part of the finished weld. When properlypositioned and attached to the back side of a weldjoint, your welds can be free of defects eliminatingrework and cleanup associated with poor root welds.

One-sided one-pass and one-sided muti-pass weldsare possible with BUG-O SYSTEMS weld backings.Our backings support molten weld metal over a widerange of welding heats resulting in uniform back beadsof finished quality.



One-sided welding with Bug-O Systems MDS TravelCarriage.

BackView

FrontView

Achieve Full Penetration Welding From OneSide And Eliminate Gouging, Backgrinding And

Material Handling.

Front and back view of a single sided weld.

BUG-O SYSTEMSNon Metallic Weld Backings For

Full Penetration Welding.

BUG-O SYSTEMSA DIVISION OF WELD TOOLING CORPORATION


© Weld Tooling Corp. ROM 1:16 Litho in U.S.A.LIT-CSM-BRO-0905

CSM-1003

CSM-1002

CSM-1001

CSM-1004 CSM-1009

CSM-1006

CSM-1007

CSM-1008

CSM-1010

Other configurations are available. Please consult factoryfor more information.

3"25.4mm

0.05"1.27mm

0.27"6.86mm

0.50"12.7mm

0.90"22.86mm

3"25.4mm

24"609.6mm

0.70"17.78mm0.04"

1.02mm 0.25"6.35mm

1.03"26.16mm

3"25.4mm

24"609.6mm

24"609.6mm

0.04"1.02mm 0.43"

10.92mm0.26"

6.60mm

0.93"23.62mm

3"25.4mm

24"609.6mm 0.61"

15.49mm

0.51"12.95mm

23.62"600mm

2.24"57mm

0.31"8mm

24"609.6mm

3"25.4mm

0.61"15.49mm

0.52"13.21mm

23.62"600mm

2.24"57mm

.39"10mm

3"25.4mm

24"609.6mm 0.46"

11.68mm

0.70"17.78mm

3.5"88.9mm

0.44"11.18mm

0.32"8.13mm

1.23"31.24mm

24"609.6mm

0.04"1.02mm

bug-o welding and cutting

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