BUG-O Welding and Cutting

Affordable Automation for Welding, Cutting and Semi-Automatic Processes
AUTOMATIC HEIGHT CONTROL
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
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

With 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)
Technical Data:
Power Requirements: CAS-0100 CAS-0102 CAS-0104 4" (100 mm) 20 lb (9.1 kg) within 4" (100 mm) of the slides mounting plate. The slide uses a slip clutch to protect the motor from overloads. Slide: 9 lb. (4.1 kg) Control Box: 6 lb (2.7 kg) Slide: 5.00"W x 15.25"H x 2.38"D (127 mm x 387 mm x 60 mm) 8.00"W x 4.50"H x 3.63"D (203 mm x 114 mm x 92 mm) 120 VAC/50-60HZ/1PH 240 VAC/50-60HZ/1PH 42 VAC/50-60HZ/1PH
Vertical Travel: Load Capacity: Net Weight: Dimensions: Control Box:
A QUALITY PRODUCT FROM BUG-O SYSTEMS 280 TECHNOLOGY DRIVE CANONSBURG, PA 15317-9564 USA A DIVISION OF WELD TOOLING CORPORATION Weld Tooling Corp. ROM 1:16 Litho in U.S.A. LIT-AHC-BRO-1008
Reduces Material Handling, Cut Beams, Channels And Angles In Place.
BEAM BUG III
Affordable Track Cutting and Welding Systems. www.bugo.com
Bug-O Systems
BEAM BUG III

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) overrun. 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.)
1 4
6 3 2
8 2
9 12 5
10
11
1. Portable, lightweight, only 34 lbs. (15 kg) 2. Positive Rack and Pinion Drives 3. Infinitely Variable Speed Control of horizontal and vertical movement 2-50 ipm (50-1270 mm/min) 4. Manifold Control of gases 5. Push-button Clutch for horizontal travel 6. Independent Control of movement in three planes; x, y and z 7. Swivel Torchholder Assembly 2
8. 9. 10. 11. 12.
Circuit Breaker Limit Switches for flange rail Beam Rail Angle and Magnet Assembly Beam Clamp
BEAM BUG III

Technical Data:
Travel Speeds: 2-50 ipm (50 - 1270 mm/min) Flange: Dimensions: Net Weight: Shipping Weight: 22" (560 mm) 10"L x 10.50"W x 12.38"H (254 mm x 267 mm x 314 mm) W/O TORCH & TIPS 34 lbs (15.4 kg) W/TORCH & TIPS 38 LBS (17.2 kg) W/O TORCH & TIPS 41 lbs (18.6 kg) W/TORCH & TIPS 45 LBS (20.4 kg)
4.00" (102 mm) 10.00" (254 mm) 30.50" (775 mm) 30.50" (775 mm)
NOTE:
The BEAM BUG III must be used with one of the beam rails described on the next page.
10.50" (267 mm)
HOW IT WORKS:
BUG-1490-ACET BEAM BUG III 120 VAC ACETYLENE BUG-1490-PROP BEAM BUG III 120 VAC PROPANE BUG-1492-ACET BEAM BUG II 240 VAC ACETYLENE BUG-1492-PROP BEAM BUG II 240 VAC PROPANE
ONLY ONE RAIL SETTING REQUIRED
BEAM BUG III

ARR-9114 ARR-9214 ARR-9236
ARR-9114 BEAM RAIL for square cutting beams ONLY. Capacity: Cuts 2"-18" (50-450 mm) flanges and 14" (350 mm webs Length: 46 1/2" (1180 mm) Net Weight: 18 lbs (8 Kg) Shipping Weight: 28 lbs (13 kg) ARR-9214 SWIVEL MOUNTED BEAM RAIL for 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) webs Miter 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 RAIL same as above but, with greater capacity. Capacity: Cuts 2"-18" (50-450 mm) flanges and 66" (1675 mm) webs Miter Cuts On: 36" (900 mm) webs Length: 102" (2590 mm) Net Weight: 36 lbs (16 kg) Shipping Weight: 51 lbs (23 kg)
ARR-9120
ARR-9120 SWIVEL MOUNTED BEAM RAIL same as above but, with greater capacity. Capacity: Cuts 2"-18" (50-450 mm) flanges and 120" (3050 mm) webs Miter 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 RAIL includes two squaring bars and adjustable locks for miter cuts on webs and flanges36" (915 mm) of travel. Miter Cuts Flanges: 00-450 to 14" (350 mm) wide Miter Cuts Webs: 00-130 to 36" (915 mm) wide 00-450 to 24" (610 mm) wide Length: 65" (1651 mm) Net Weight: 50 lbs (23 kg) Shipping Weight: 75 lbs (34 kg) ARR-9046 ADJUSTABLE BEAM RAIL includes two squaring bars and adjustable locks for miter cuts on webs and flanges -36" (915 mm) of travel. Miter Cuts Flanges: 00-450 to 14" (350 mm) wide Miter 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)
ARR-9045 ARR-9046
A QUALITY PRODUCT FROM BUG-O SYSTEMS 280 TECHNOLOGY DRIVE CANONSBURG, PA 15317-9564 USA Weld Tooling Corp. ROM 1:16 Litho in U.S.A. LIT- BBIII-BRO-0808 A DIVISION OF WELD TOOLING CORPORATION
Welding and Cutting Solutions Since 1948.
Reduce the cost of weld preparation with the Bug-O Portable Plate Beveling Machine Model PBM-2000.
Produce clean machined bevels on plate or pipe.
The Bug-O Portable Plate Beveling Machine, PBM-2000, is a machining tool that allows anyone to produce 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 horsepower motor with a dual milling head that has 12 indexable cermetallic inserts which increase metal removal. With its specially designed handle, low noise, low vibration and a weight of 42 pounds the PBM-2000 is extremely ergonomic. Optional pipe beveling attachment available for 6-1/4" (159 mm) diameter or larger.
280 TECHNOLOGY DRIVE CANONSBURG, PENNSYLVANIA USA 15317-9564 PHONE: 1- 800-245-3186 http://www.bugo.com TELEFAX: 1- 412- 331- 0383
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. 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.
Specifications
Power Supply: Nominal Amperage: Maximum Amperage: Start Up Current: Horsepower: Cutting Speed: Angle Range: Bevel Width: Weight: 120 volts 14 amps 18 amps 11 amps 1-1/2 horsepower 1800 SFPM 150 to 600 3/4" (20 mm) max 42 lbs. (19.05 kg)
PBM-2000 (15-60) standard
A (In.) B (In.) R (In.) S (In.) D min min O (0) O (0) Options: Facing O=00 Pipe Beveling
16.5 (420 mm) 13 (330 mm) 12 (305 mm) 3/4 (20 mm) 6-5/16 (160 mm) 150-600 150-600
PBM-2100 Pipe Adaptor (optional)
YES YES
PBM-2051 Cutting Insert (12 required)
Pipe
A B
Plate
R S
D min S
A QUALITY PRODUCT FROM BUG-O SYSTEMS 280 TECHNOLOGY DRIVE CANONSBURG, PA USA 15317-9564 A DIVISION OF WELD TOOLING CORPORATION Weld Tooling Corp. ROM 1:16 Litho in U.S.A. LIT-PBM-BRO-0408
The BUG-GY
Automatic Fillet Welder.
Increase Welding Production. Improve Weld Quality.
Welding & Cutting Automation Since 1948.
BUG-GY Fillet Welder AFW-3000

The 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. The BUG-GY is self-guiding and requires little operator input once it is set up. It can be programmed for stitch welding by distance and features automatic weld back 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).
Controls:
A. Digital travel speed display. B. Weld length programming button. C. Skip length programming button. D. Reverse crater fill programming 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.
C D E I H J K L
F G
N
2

Optional 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 or 3/32 wire.
Lincoln Style Connector. AFW-2285-5/64 AFW-2285-3/32 Replacement Contact Tips: AFW-2291 1/16 wire size AFW-2292 5/64 wire size AFW-2293 3/32 wire size
Miller Style Connector. AFW-2290-5/64 AFW-2290-3/32

Features:
1. 2. 3. 4. 5. Lightweight. Easy to carry. Permanent magnet for powerful traction. Built-in programmable stitching by distance. 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:
Power Requirements: AFW-3000 AFW-3002 AFW-3004 Travel Modes:
Dimensions:
120 VAC/50-60/1 240 VAC/50-60/1 42VAC/50-60/1 1.Continuous 2. Stitch: weld crater fill skip
22" (559 mm)
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)
15" (381 mm)
15" (381 mm)
For more information on the BUG-GY call 800-245-3186 or 412-331-1776.

USA A QUALITY PRODUCT FROM BUG-O SYSTEMS 280 TECHNOLOGY DRIVE CANONSBURG, PA 15317-9564 Weld Tooling Corp. ROM 1:16 Litho in U.S.A. LIT- AFW-BRO-0708
A battery powered, magnetic travel carriage for welding in the vertical or horizontal position.
BUG-GY-VERT
Increase welding production, Increase welding production, improve weld quality and improve weld quality and eliminate operator fatigue. eliminate operator fatigue.
Bug-O Systems
Automated Cutting and Welding Systems. www.bugo.com
BUG-GY-VERT
The 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. Guide wheels on the BUG-GY-VERT automatically track the torch in the fillet joint. The BUG-GY-VERT is compact, lightweight and easy to position. It will accommodate most hand held welding guns. By providing consistent travel speed the BUG-GY-VERT can increase the productivity and the quality of welding applications in many areas of steel fabrication or shipbuilding.
BUG-GY-VERT Without Oscillation VFW-3150 110 volt - includes 1 battery and 1 charger. VFW-3152 220 volt - includes 1 battery and 1 charger.
BUG-GY-VERT With Oscillation VFW-3000 110 volt - includes 1 battery and 1 charger. VFW-3002 220 volt - includes 1 battery and 1 charger.
BUG-GY-VERT Controls With Oscillator.
Torch Holder Start
Oscillator Dwell Left
Speed Control Direction Power Switch Torch Trigger Switch Torch Contactor 14.4 Rechargeable Battery Stop Safety Chain Anchor Oscillator Power Switch Dwell Right Oscillation Width Oscillation Speed
Magnet Actuator 2
BUG-GY-VERT
Technical Data:
Power Supply: Position of Weld: Dimensions: Carriage to Work Clearance: Minimum Plate Thickness: Wheel Movement: Weight without Oscillator: 14.4V (2Ah-rechargeable battery) Vertical & Horizontal See page 4 .25" (6.5 mm) 3/16" (5 mm) 4 wheel drive 22 lbs. (11 kg.) 28 lbs. (14 kg.) 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 Weight with Oscillator: Travel Speed:
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 safety cables available. Contact the factory for additional details.
Accessories:
H01134-001-01-02 14.4 volt rechargeable battery.
H01113-001-01-03 110 volt battery charger. H01113-001-01-02 220 volt battery charger.
VFW-3210 Auxiliary Magnets For increased magnetic holding power and traction. 3
BMV-1510 110 volt Adaptor BMV-1512 220 volt Adaptor Power Adaptors - converts machine from battery power to 110 volt or 220 volt line power.
BUG-GY-VERT
The BUG-GY-VERT features "Torch Quick Connect" which allows the operator to easily remove or install the torch from the BUG-GY-VERT for quick nozzle cleaning, wire cutting and hand welding.
Dimensions:
12.625" 321 mm
1.250" (32 mm) .50" (13 mm)
3"/6.5" 76/165 mm
8.125" 206 mm 13.188"/16.688" 335/424 mm
8.188" 208 mm 16.250" 413 mm
Each unit will be delivered with one (1) battery and charger.
Bug-O Systems
Visit us online at: www.bugo.com A QUALITY PRODUCT FROM BUG-O SYSTEMS
280 TECHNOLOGY DRIVE Weld Tooling Corp. LIT- BUG-GY-VERT-BRO-0208
CANONSBURG, PA USA 15317-9564 Litho in U.S.A. ROM 1:16
Bug-O Gantry / Side Beam Automatic Welding Systems

BUG-O SYSTEMS
Automated Welding & Cutting Since 1948 www.bugo.com
Bug-O Gantry / Side Beam Automatic Welding Systems

Bug-O Gantry and Side Beam Units are custom designed assemblies that are used in a variety of applications such as automated seam welding, beam and stiffener fabrication as well as cutting applications such as stripping and edge preparation. A wide range of gantry and side beam carriage designs are available and can be used to suite a specific application. Systems are available in programmable or manually operated versions. Consult your Bug-O distributor for more information. Gantry Style Welding System
Side Beam Welding System
Mechanical torch tracking devices maintain proper torch position.
A QUALITY PRODUCT FROM BUG-O SYSTEMS 3001 WEST CARSON STREET A DIVISION OF WELD TOOLING CORPORATION Weld Tooling Corp. ROM 1:16
PITTSBURGH, PA USA 15204-1899 Litho in U.S.A. LIT- BRO-BG-0405
UNI-BUG Bulb Flat Welder
140-430 mm
The UNI-BUG Bulb Flat Welder will weld bulb angles with heights from 140 to 430 mm.
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 in bulkheads and areas where you can't start the machine at the end of the bulb flat.
3001 WEST CARSON STREET PITTSBURGH, PENNSYLVANIA USA 15204-1899 PHONE: 1- 800-245-3186 http://www.bugo.com TELEFAX: 1- 412- 331- 0383
For 140 to 280 mm.
Technical Data:
Power Requirements: UNI-1300 UNI-BUG Bulb Flat Welder UNI-1302 UNI-BUG Bulb Flat Welder UNI-1304 UNI-BUG Bulb Flat Welder Speed Range: Net Weight: 4-75 ipm (102-1900 mm/min) 28 lbs. (12.7 kg) 120 VAC 240 vac 42 VAC
Shipping Weight: 31 lbs. (14 kg)
* Spacer Block For 280 to 430 mm.

7.62 (194 mm) 6.25 (159 mm)
Dimensions shown without torch mounts

(Torch mounts shown on next page).
5.75 (146 mm)
10.50 (267 mm) 6.00 (152 mm)
Special assembly note:

When converting a UNI-BUG II to a BULB WELDER, be sure that both top rollers are mounted on the bottom of the base plate. (see drawing at right)
2.00 (51 mm) 8.00 (203 mm)
2.00 (51 mm)
4.6 (117 mm)
Tool Positioning Assembly On Bulb Flat Welder

UNI-1350 Dual Welding Group
ITEM 1 2 3 4 5 6 7 8 9 10 QTY 4 1 1 4 2 2 2 2 2 2 Part No. BUG-1853 BUG-1881 BUG-1891 FAS-0557 BUG-2708 BUG-5451 BUG-5462 CON-1020 FAS-0957 UNI-1036 Description Machined Rack 7 1/2" Cable Anchor w/Swivel Clamp Double Racker Mounting Angle (includes 2 of item #4) Soc Hd Cap Scr 1/4-20 x 3/4 lg Clamp 3.5" Rackholder Right Angle Clamp Swivel Clamp Assembly Flt Hd Soc Scr 1/4-20 x 3/4 lg Rackrider w/Post 7 1 2 1 6 7 3 5 8 10 4 1 5 4 6 10
A QUALITY PRODUCT FROM BUG-O SYSTEMS

3001 WEST CARSON STREET
_PITTSBURGH, PA 15204
ROM 1:16 Litho in U.S.A.
Weld Tooling Corp.
LIT- BFW-BRO-499
Return to Index
BORE WELDING SYSTEMS

PORTABLE BORE REPAIR SYSTEMS PRODUCE CONTINUOUS 3600 SPIRAL WELDS. REDUCE WELDING AND MACHINING TIME.
Welding & Cutting Innovations Since 1948.
BORE WELDER - FEATURES

FEATURES:
Smooth, high quality welding on internal bores from 1.25"-15" (32381 mm). BWS-2000: 1.25''-15'' (32-381mm) BWS-2000-045:1.8''-15''(46-381mm) Optional accessories for internal diameters from 16"-24" (406-610 mm), external diameters and face welding are also available. Easy operation. Simply measure diameter, find setting on the chart and set rotation knob. Adds axial feed and rotary motion to existing MIG welder. Telescoping extension tube allows multiple in-line welding with one easy set up. Reaches 24'' (609mm) into a bore with a 7'' (177mm) stroke. Extension tube is reversible to allow welding of two separate parallel bores. Interfaces with boring bars. Kit accommodates various size of welding wire: BWS-2000: .030 mm BWS-2000-045: .045 mm .035 mm diameter wire available by request.
Kit Includes:
Remote Weld Switch. Conduit Assembly & Support w/Aux. Support Rod. Tack Nut. Tool Kit. Large Diameter Torch Assembly. T Base w/Tack Plate. Extra Nozzles, Tips, and Diffusers to support 1.25" or 1.8'' to 15" (32-381 or 46381mm) diameters. (5 stub diffusers, 10 .8 mm stub tips, 5 stub nozzles, 10 .8 mm tips, 5 nozzles, 5 mini nozzles, 5 mini diffusers).
BORE WELDER - TECHNICAL DATA

TECHNICAL DATA: BWS-2000 Bore Welding System
Bore Welding System for .030''-.035'' Wire
Current Rating: Net Weight: 150 amp, 60%duty cycle 25 lbs. (11 kg.)
Shipping Weight: 70 lbs. (34 kg.) Wire Diameters: Diameter Range: .030 and .035 1.25'' to 15'' (32- 381mm) (up to 24'' [610mm] with optional accessories)
BWS-2000-045
Bore Welding System for .045'' Wire
Current Rating: Net Weight: 200 amp, 60%duty cycle 25 lbs. (11 kg.)
Shipping Weight: 70 lbs. (34 kg.) Wire Diameters: Diameter Range: .030 to .045 1.8'' to 15'' (46-381 mm) (up to 24'' [610mm] with optional accessories) One Quick Setup - will attach to your Boring Bar Kit.
BORE WELDER - ACCESSORIES

Optional Accessories to weld from 15'' to 24'' (381-610 mm): Item BWS-1042 BWS-A119 Description Quantity Extension Tube 2 8'' (203mm) Radial Support Extender 1 Additional Accessories Available: Additional Options Available: BWS-A129 Auto Skip Option BWS-A108 Centering Cone Set
BWS-A127 Face Torch Optional face torch attaches to your Bore Welder and will automatically weld faces from 0-24'' (0-610mm).
Boring Bar Adaptor Kits Boring Bar Adaptor Kits provide easy, one-step setup. (Part number varies depending on Boring Bar Kit.)
BWS-A114 O.D. Torch Attachment for performing external outside diameter welds. O.D. Torch 0-12'' (0-305mm)
Welding Tips
Stub Tips: BWS-1058 BWS-1059 BWS-1060 .030 (.8mm) .035 (.9mm) .045 (1.2mm)
9.63'' (245 mm) 6.34'' (160 mm)
Standard Tips: BWS-1061 .030 (.8mm) BWS-1062 .035 (.9mm) BWS-1063 .045 (1.2mm)
Welding Nozzles and Diffusers

Mini Nozzle: BWS-1092 Stub Nozzle: BWS-1066 diameters 1.25''-2'' (32-50mm) Use for small
5.88'' (150 mm)
32'' (812 mm) min. 48.56'' (1234 mm) max.
Standard Nozzle: BWS-1067 Use for large diameters Mini Diffuser: BWS-1093 1.25''-2'' (32-50mm) Diffuser: BWS-1057 Use with all torches
Call factory for specials, boring bar systems and components or power supply wire feeder options. 1-800-245-3186 or 412-331-1776
A QUALITY PRODUCT FROM BUG-O SYSTEMS 3001 WEST CARSON STREET PITTSBURGH, PA USA 15204-1899 A DIVISION OF WELD TOOLING CORPORATION Weld Tooling Corp. ROM 1:16 Litho in U.S.A. LIT- BWS-2000-BRO-0907
OPERATORS MANUAL
BWS-2000
PORTABLE BORE WELDING SYSTEM
Please record your equipment identification information below for future reference. This information can be found on your machine nameplate. Model Number Serial Number Date of Purchase Whenever you request replacement parts or information on this equipment, always supply the information you have recorded above.
3001 WEST CARSON STREET PITTSBURGH, PENNSYLVANIA USA 15204-1899 PHONE: 1- 800-245-3186 http://www.bugo.com TELEFAX: 1- 412- 331- 0383 LIT-BWS-IPM-O404
TABLE OF CONTENTS TITLE OF SECTION 1. PAGE 1 1 1 1 2 2 2 2 2 3 3
SAFETY INFORMATION --------------------------------------------------------1.1. Machine Safety --------------------------------------------------------1.2. Operator Safety --------------------------------------------------------1.3. General Safety Requirements-------------------------------------1.4. Additional Safety Information -------------------------------------MAJOR COMPONENTS AND THEIR FUNCTIONS ---------------------2.1. Conduit Assembly ----------------------------------------------------2.2. Torch ----------------------------------------------------------------------2.3. Torch Mover-------------------------------------------------------------2.4. Other Support Components ---------------------------------------2.5. Tools Provided ----------------------------------------------------------
2.
3. 4.
SPECIFICATIONS ----------------------------------------------------------------- 3 ALIGNMENT -----------------------------------------------------------------------4.1. Parallelism --------------------------------------------------------------4.2. Concentricity -----------------------------------------------------------4.3. Axial Positioning ------------------------------------------------------WELDING TORCH - USE, COMPONENTS, AND RANGE ------------5.1. Liner Stick-Out ---------------------------------------------------------5.2 Liner Stick-Out Adjustment ----------------------------------------5.3. Mini Components -----------------------------------------------------5.4. Stub Components -----------------------------------------------------5.5. Standard Components ----------------------------------------------5.6. Large Diameter Components -------------------------------------5.7. Outside Diameter Components ----------------------------------5.8. Attachment --------------------------------------------------------------5.9. Radial Adjustment ----------------------------------------------------5.10. Axial Adjustment ------------------------------------------------------4 4 5 6 6 6 6 6 6 7 7 7 7 7 8
5.
6. 7. 8. 9.
CONDUIT ASSEMBLY INSTALLATION ------------------------------------- 8 FINAL PREPARATION FOR WELDING ------------------------------------- 8 WELDING ---------------------------------------------------------------------------- 9 SPECIAL SITUATIONS ---------------------------------------------------------- 9 9.1. Welding in High Temperature Environments ----------------- 9 9.2. Single Plane Welding ------------------------------------------------- 9 MAINTENANCE -------------------------------------------------------------------- 9 10.1. Spindle -------------------------------------------------------------------- 9
10.
10.2. Extension Tube --------------------------------------------------------- 9 10.3. Remaining Components --------------------------------------------- 10 11. CARE ---------------------------------------------------------------------------------- 10
ILLUSTRATIONS: Torch Mover and Support Components ----------------------------------Use of Standard Torch ---------------------------------------------------------Use of Large Diameter and OD Torch -------------------------------------Set-Up Information --------------------------------------------------------------In-Line Bore Setups -------------------------------------------------------------Cones - Using For Alignment ------------------------------------------------Wire Stability ----------------------------------------------------------------------Use of the T Base -------------------------------------------------------------T Base Support Configurations -------------------------------------------
Fig 1 Fig 2 Fig 3 Fig 4 Fig 5 Fig 6 Fig 7 Fig 8 Fig 9
APPENDIX: Useful Information: 1. Welding Time - Single Revolution --------------------------------- A 2. Buildup Times ------------------------------------------------------------ A 3. Deposition Rates -------------------------------------------------------- A
1.
SAFETY INFORMATION. Many accidents are caused by operation and maintenance, which disregard basic safety rules. Carefully read and adhere to the safety measures and precautions described in this instruction 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 continuing operation. 1.1.2. Never leave the machine running unattended. Overtravel can result in machine damage and 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 the unit. Note:This refers to the electrical power to run the rotation function, not the welding 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. All electrical connections should only be made in accordance with the appropriate and applicable national and local electrical codes by a qualified electrician. Note: When using the BWS-2000 in a location where the power requirements listed in 1.1.6. above are not available, a 150 (minimum) volt-ampere isolation transformer should be used to provide 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 use of 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 the BWS-2000. 1.2.4. Anyone being exposed to the arc or its reflection should wear protective clothing over as much exposed skin as possible. Other areas should use a sun block cream with an appropriate SPF value. 1.2.5. Anyone close to the welding operation should wear heavy flame resistant clothing for protection from sparks and flame. 1.2.6. The operator should not use loose clothing which might get wrapped around the rotating members 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 adequate ventilation. 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
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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 the American Welding Society, Inc., 550 NW Lejeune Road, Miami, FL 33126, USA. Telephone Number is 1-800-443-9353. (2) Users outside the USA refer to the relevant safety regulations promulgated 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 the transmission 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 shielding gas for welding. 2.2.2. Standard Torch Extender. Can be inserted between the Torch Swivel and the Torch Body to 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, and shielding gas. 2.2.4. Tip. Attaches to the Diffuser, and conveys wire for the welding process. It also transfers electric 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 of bores 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 BWS2000 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.
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2.4. Other Support Components. Provide a connection between the Support Bracket and attachment 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 Base when aligning the BWS-2000 with Centering Cones. 2.4.3. Tack Nut. Supports the Support Rod. Does not allow adjustment of the Support Rod once tack welded in place. Typically used when the attachment surface is known to be perpendicular to the axis of the bore, and when other means of support are not available or are not practical. 2.4.4. T Base. Supports the Support Rod and provides a simple means for manual parallelism and concentricity adjustment. 2.4.5. Base Extender. Is bolted to the T Base and extends the point of attachment of the Support Rod 3 inches toward the center of the bore, thereby allowing the welding of larger bores. 2.4.6. Radial Support. Attaches at one end to the Support Bracket and at the other end to the Support Rod. It projects the BWS-2000 4 inches from the Support Rod and allows the welding of larger diameter bores. It also allows the BWS-2000 to be moved closer and farther 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 to be centered over the bore to be built up. 2.4.8. Rod Collar. Provides support for the BWS-2000 when the Support Bracket or Radial Support clamps are loosened. This is especially useful when setting up to weld a vertical axis 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. 140A 3.7. 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 BWS2000 using 1/8 NPT.
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ALIGNMENT OF THE BWS-2000 TO THE BORE BEING WELDED. Alignment is comprised of three major factors: (1) Parallelism - Positioning the axis of the BWS-2000 parallel with the axis of the bore being welded, (2) Concentricity - Positioning the axis of the BWS-2000 directly in-line with the axis of the bore, and (3) Axial Positioning - Positioning the torch in a beginning axial location where it can weld as 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 Tack Plate is within 5 of being perpendicular to the axis of the bore. Notes: (1) See Figures #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 angular positions around the Spindle centerline in order to facilitate the ease of attachment and use of the BWS-2000. This feature is particularly important when space is limited. 4.1.1.2. Attach the T Base to the Tack Plate by setting the Base over the Anchor Bolt so that the Anchor Bolt protrudes through the Base slot, installing a inch Flat Washer, 4 Spring Washers, and locking it into place with a -13NC Clamping Nut. 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 single Screw at the bottom of the T to get the perpendicular plane of adjustment aligned with the bore. See Figure #8. 4.1.1.5. Adequate parallelism in each of these planes of adjustment can be judged by inserting a straight edge into the bore, aligning it parallel to the bore axis, and sighting or measuring the distance between the Support Rod and straight edge for each plane. 4.1.1.6. A level can also be used to achieve parallelism if the axis of the bore is known to be either horizontal or vertical. 4.1.2. Centering Cones. The use of centering cones is a good choice when there are two or more in-line bores to be welded. The use of centering cones as described below achieves not 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 the tube and opposite-end cone to the center of the bore. Once so centered, lock the second 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 an appropriate rigid support. 4.1.2.5. After tightening all support clamping screws, the Centering Cones and tube can be removed and the Conduit Assembly inserted in the Spindle for welding. Note: An alternative but similar method involves the use of bushings instead of cones. In this instance, bushings with ODs nearly as large as the bores and IDs 1.25 inches in diameter, are inserted into the bores. A 1.25 inch diameter tube or rod is then inserted through the IDs of the bushings. The tube/rod is now centered in the bore. Proceed as in 4.1.2 above.
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4.1.3. Alignment from Boring Bar. If the boring bar is to be set-up before welding the bore, this method 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 larger diameter boring bar is used, remove the boring bar, install bushings in the boring bar bearing IDs, insert a 31.75 mm (1.25 in.) diameter tube in the bushings, and slip the BWS-2000 on the tube. 4.1.3.2. Weld or clamp the Swivel Base or Tack Nut while attached to the BWS-2000, to an appropriate 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 entire bearing 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 which allow attachment of the Support Rod and assure its alignment. Once so aligned, the Support Bracket can be directly attached to the rod and the BWS-2000s axis will be reasonably parallel to the bore to be welded. 4.2. Concentricity. Use of centering cones, as described above, provides concentricity of the BWS-2000 as well as parallelism. However, unassisted set up or use of a boring bar adapter generally requires some additional adjustment in order to achieve concentricity. This adjustment is done after parallelism 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 or nearly vertical, the use of a 1 inch diameter locking Rod Collar located under the radial support is recommended. Use of this collar when locked into the appropriate position on the Support Rod, allows the free rotation of the Radial Support without the nuisance 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 Hz electrical power. The Spindle should now be capable of rotating when the Rotation Direction 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 and manually moving the Spindle, or by unclamping the Tube Clamp and extending the Extension Tube. 4.2.1.5. Once into the bore, rotate the Torch until the Nozzle is pointing toward, and then directly away from the Support Rod. Note the distance from the end of the Nozzle to the bore wall for both of these positions. If these distances are not equal, loosen the Anchor Nut and slide the T Base until the distances are equal. Retighten the Anchor 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 first axis of centering, ie., perpendicular to a line running between the bore center and the Support Rod. 4.2.1.7. Note the distance of the Nozzle from the bore wall and again rotate the Torch 180 degrees and compare the Nozzle/wall distance. 4.2.1.8. Adjust the Nozzle/wall distances by unclamping the Support Bracket from the Support Rod, and swiveling the BWS-2000 around the Support Rod until the Nozzle/wall distance is equal at both positions. Reclamp the Support Bracket to the Support Rod. 4.2.1.9. The Torch should now be centered in the bore and the centerlines of the bore and the BWS-2000 parallel. Rotate the Torch 360 at the top and bottom of the bore to confirm. Note: Nozzle to wall distance consistency of from 1 to 1.2 mm (.04 to .05 in.) is generally adequate. 4.2.2. Boring Bar Adapter Assisted. Use of a boring bar adapter generally provides the first axis of centering and does not require the use of the Radial Support. Follow the instructions above from 4.2.1.6. thru 4.2.1.9. in order to achieve second axis centering.
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4.3. Axial Positioning. Several factors can affect the axial position of the various components, and therefore the axial range of the welding process. They include the: (1) Location of attachment of the Tack Plate or Swivel Base, (2) Position of attachment on the Support Rod, (3) Axial position of 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 the same plane as on end. When several in-line bores are to be welded, it might be desirable to attach the Tack Plate or Swivel Base between the bores, thereby allowing an easy reach to bores on either side. This is possible because the Extension Tube can be inserted in the Spindle with the torch coming out of either end of the BWS-2000. The only change that has to be made to accommodate reversing the position of the torch is swapping the locations 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 wherever necessary. 4.3.3. Axial Position of the Spindle. The axial position of the Spindle determines the length of stroke available for welding before repositioning is necessary. It should be considered along with other axial position contributors, and the length of the bore when determining the best combination. The axial position of the Spindle is changed by disengaging the Clutch 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 Spindle allows bores located approximately 1000 mm (40 in.) away from the Tack Plate mounting surface to be welded. This extension capability allows the quick movement of the torch from bore to bore. The position of the Extension Tube is changed by loosening the Tube Clamp 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 protrude beyond 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 940 mm (1.25 to 37 in.) and outside diameters up to 305mm (12 in.). Welding this range of diameters is achieved 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 Torch components are manufactured out of aluminum. Take care not to overtighten these components as damage to the threads may result. (2) The ID Torches are coated to prevent accidental arcing to the 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 a follows: (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 Torch Attachment Locknut and screwing the Torch either in or out as necessary to provide proper stickout. 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 bore diameters 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 of diameters as small as 45 mm (1.8 in.). They are capable of being used to weld diameters as large 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
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supports the tip and nozzle. Note: Attach only Diffuser numbers 1057 or 1093 to the Standard Torch. Use of other diffusers may cause damage to the liner and torch threads. 5.4.2. Tip, Stub (PN. 1058). Screws into the diffuser and provides transfer of electrical power from the diffuser to the welding wire. 5.4.3. Nozzle, Stub (PN. 1066). Screws onto the diffuser and directs the shielding gas. This nozzle is electrically isolated. 5.5. Standard Components. When used with the Standard Torch, these components allow the welding 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 lose their electrical isolation when used with this torch. 5.5.4. Standard Torch Extender. Use of the Standard Torch Extender extends the length of the Standard Torch by 100 mm (4 in.). Its use increases the diameter capability of the above components by approximately 75 mm (3 in.). It is attached at the swivel end of the Standard Torch, and requires use of a liner segment about 4 inches longer than is used without it. See Figure #2. 5.6. Large Diameter Components. The use of the Large Diameter Torch allows the welding of bores from 200 to 380 mm (8 to 15 in.). Use the same Diffuser, Tip, and Nozzle as are listed under Standard Components. If Torch Extenders are also used, the maximum diameter capability is extended 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 protrude approximately 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 to the Tip. Any of the Tips, Diffusers, or Nozzles listed above can be used with the Large Diameter Torch. Note: When using the Large Diameter Torch,, Tweco Diffuser number 35-50, and Nozzle number 21-62 are acceptable. 5.7. Outside Diameter Components. The use of the OD Torch, allows the build-up of outside diameters from 0 to 305 mm (0 to 12 in.) for a minimum length of 204 mm (8 in.). Special torch bodies can be provided to accommodate diameter and length requirements outside of the ranges listed above. All Tips, Diffusers, and Nozzles that are used with the ID Torches, can be used with the 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 during torch 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 diffuserattachment-hole approximately 29 mm (1.15 in.) for the standard Diffuser and 6 mm (.25 in.) for the Mini Diffuser, and the diffuser-attachment-hole is pointing in the direction of Torch adjustment, screw the Torch Lock Nut until it tightens against the Torch, thereby locking 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.
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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 Wirefeed Connector 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. Failure to 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 torchattachment-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 wire feeding setup will be straighter. Also, there will be much less likelihood of incomplete weld coverage of the bore. 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-2000 toward 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 welding applications - to attach the conduit to the Radial Support, Support Rod or other stationary object so that the conduit forms a large radius when exiting the Extension Tube or Spindle. This causes less friction for the welding wire traveling through the Conduit and less friction between the Conduit 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. An approximate setting can be read from the chart on the side of the BWS-2000. This chart is based on welding speeds of 500 mm (20 in.) per minute. Note: Rotation speeds will vary due to differences in supply voltage and electrical components. To check the actual welding speed divide 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 result when 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 your wirefeeder does not have a Jog Button, move the Weld Switch to the On position. Once the welding 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 are not disconnected, a dangerous welding flash may result when the welding wire exits the torch. (2) The Diffuser may have to be removed in order for the wire to get around the Liner bend just before the Diffuser attachment point. Once the wire is through the Liner, the Diffuser (and Tip) can be reinstalled. 7.7. Connect the welding current ground (-) lead to the part being welded. Note: Make sure that the ground 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 air has infiltrated the gas feed system.
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7.
8.
WELDING. 8.1. Make sure that all of the safety precautions mentioned in the Safety Information section of this manual 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. This will start the rotary and axial motion. 8.3. At the same time that the Rotation Direction Switch is activated, the Weld Switch can be activated. Note: At this time, the Clutch can be locked in the disengaged position for one Torch revolution to allow a single plane of weld to be deposited before axial motion begins. This generally 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, although successful welding can be done outside of these settings. 8.5. Adjust the rotation speed, voltage and wire speed settings as necessary to achieve the desired results. Be especially careful that the arc is playing at the intersection of the previous bead and the base metal. If the arc is playing on the previous bead or in the molten weld puddle, poor fusion to the base metal may result. 8.6. When approaching an area where weld should not be deposited - such as a keyway - move the Weld Switch toggle to the Off position to stop welding. Rotation will continue. Once the far side of 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 when necessary, and to be available when the build up of the bore is completed or the end of the stroke is reached. Note: The BWS-2000 does not automatically shut off when the end of its stroke has been reached. The Clutch will disengage briefly each revolution as the Spindle attempts to move axially. While no damage is likely for considerable time, such disengagement does cause excessive wear, and if occurring during welding will leave a substantial deposit of weld at one location. 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 extended periods in environments with temperatures of 93 Celsius (200 Fahrenheit) or greater, that the BWS-2000 housing be cooled by supplying compressed air to the housing interior through the Cooling Fitting. The air supplied should be dry, and regulated down to a pressure of about 35 Kilonewton per square meter (5 psi). The Cooling Fitting can be attached to by removing the Cooling 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-2000 housing. 9.2. Single Plane Welding. The BWS-2000 clutch can be locked in the disengaged position by moving the clutch lever to the detent location. If disengaged, the spindle will not move axially when rotated, thereby allowing face or fillet welding. It also allows a single plane of weld to be deposited on a cylindrical surface before axial motion begins. Moving the clutch lever out of the detent position while welding is taking place will allow axial motion to take place during the next revolution. Note: When single plane welding, it is generally desirable to move the Spindle Collar to 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 more frequently if in an excessively dirty environment. It can be moved from stop to stop so that most of 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 Tube OD. 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 it entirely 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 requires reasonable care in order to function as intended. 11.1. The BWS-2000 is designed to be corrosion resistant in order to function properly in humid environments. 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 wet could 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, thoroughly examine it - especially the Spindle threads and surface - for damage. Repair or replace any damaged 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 Components Figure #1

CONDUIT (2.1.2.) EXTENSION TUBE (2.1.3.) SPINDLE (2.3.2.) SPINDLE COLLAR (2.3.4.) CLUTCH LEVER DETENT CLUTCH LEVER (2.3.5.) ROTATION DIRECTION SWITCH (2.3.6.)
ROTATION SPEED KNOB (2.3.7.)
TORCH MOVER (2.3.)
HOUSING (2.3.1.)
SUPPORT BRACKET (2.3.9.) COOLING GAS FITTING (2.3.8.) ROD COLLAR (2.4.8.) SUPPORT ROD (2.4.1.) RECEPTACLE (2.3.11)
TUBE CLAMP (2.3.3.) TORCH SWIVEL (2.1.5.) SWIVEL LOCK (2.1.6.) TORCH (2.2)
WELDING SWITCH (2.1.7.)
SUPPORT ROD TIGHTENER (2.5.7.) T BASE (2.4.4.)
11.
Use Of Standard Torch
Standard Components With Torch Extender. Standard Components. Stub Components.

Diameter Range 45 to 145 mm (1.8 to 5.7 inches) Diameter Range 79 to 203 mm (2.75 to 8 inches)
Diameter Range 70 to 270 mm (2.75 to 11 inches)
Mini Components.
Diameter Range 32 to 50 mm (1.25 to 2 inches)
Swivel Lock (2.1.6)
Torch Lock (2.2.6)
Torch Extender BWS-1105 (2.2.2)
Adjust torch axially to achieve proper liner stickout.
12.
Diffuser BWS-1057 Tip BWS-1061
Adjust as needed.
Adjust liner stickout to 6.3 mm (.25") Diffuser BWS-1093 Diffuser BWS-1057 Tip BWS-1058 Nozzle BWS-1067 Nozzle BWS-1066 Tip BWS-1058 Nozzle BWS-1092
Torch Body BWS-1104 (2.2.1) (TYP)
Liner BWS-1039 (2.1.4) (TYP) Set stickout to 29 mm (1.15") and align torch so liner is pointing in the direction of pivot.
Diffuser (2.2.3)
Tip (2.2.4)
Nozzle (2.2.5)
Figure #2
Use Of Large Diameter and OD Torch

Outside Diameter Torch
Torch Attachment and Radial Adjustment Standard Components

Diameter Range 200 mm to 380 mm (8 to 15") Diameter Range 1 extension: 380 to 610 mm (15 to 24")
Extended Range Components
Diameter Range 12.7 to 305 mm (.5 to 12 inches)
Radial adjustment locknut
Torch attachment locknut
Adjust as needed
Adjust torch axially to achieve proper liner stickout
Torch Extension Tube BWS-1042
Torch Body BWS-A114
13.
Diffuser BWS-1057 (TYP) 29 mm (1.15") Nozzle BWS-1067 Tip BWS-1061
Torch Body BWS-A115
Liner BWS-1039 (align torch so that liner is pointing in the direction of pivot)
Liner Aligner BWS-1043
Figure #3
General Setup Information

Optional conduit support tube Alternative method of conduit support
BWS-2000
Extension tube clamp Radial support Support Clamp
Extension tube Optional conduit support tube
14.
Support Rod (align parallet ot bore centerline)
Torch pivot mechanism
Minimun distance to allow buildup of bore 340 mm (13.5")
Rubber strapsupports conduit to achieve gradual sweep of conduit at top of BWS-2000 Conduit (to wirefeeder)
WORKPIECE TO BE WELDED Swivel base (weld or clamp in place)
Figure #4
In-Line Bore Set-Ups
Side Attachment
15.
Central Attachment (Normal Torch Orientation)
Central Attachment (Inverted Torch Orientation)
Figure #5
Using Cones For Alignment
Lock screw (TYP)
Centering cone (TYP)
16.
Centering rod 31,75 mm dia. (1.25")
T TYP (3) Tack plate
NOTE: Weld or clamp Tack Plate in place and tighten all screws or nuts labeled T before removing Centering Rod.
Figure #6
Wire Stability
Unstable Wire Feeding Setups
Wire cast and conduit curvature are in opposite directions
Stable Wire Feeding Setups
Wire cast and conduit curvature are in the same directions
17.
Wire cast and conduit curvature are in opposite directions Wire cast and conduit curvature are in opposite directions
Wire cast and conduit curvature are in the same directions
NOTE: Welding wire in not straight. The direction it curves is called the wire cast. A represents wire cast.
Figure #7
Use of the BSW T Base

C B D A
180 mm (7")
Mount Detail
Support rod Anchor nut (1/2-13 NC) T Base T Base
Rod mount Positions
(4) Spring washers
19.
Workpiece Tack plate tack weld or clamp to workpiece
Tack Plate
Parallelism Adjustment (Objective - align support rod parallel to bore centerling)
Concentricity Adjustment (Objective - center BWS-2000 with workpiece bore) 1. Loosen anchor nut. 2. Slide T base to center torch in the E - F direction. 3. Tighten anchor nut. 4. Loosen support rod clamping nut. 5. Rotate BWS-2000 around support rod to center torch in the G - H direction. 6. Retighten support rod and clamping nut.
1. To adjust in directions A - B move screws 1 & 2. 2. To adjust in directions C - D move screw 3. 3. Loosen and retighten anchor nut as necessary to perform above adjustments.
Figure #8
T Base Support Configurations

180 mm (7")
Anchor Bolt Location
T base Support rod T base
Max bore O 165 mm (6.5")
152 mm (6") Max bore O 114 mm (4.5")
Support rod Support rod location #2
20.
254 mm (10")
Max bore O 520 mm (20.5") 356 mm (14")

Base extender
T base Support rod
Base Extender Added
Base extender
Max bore O 318 mm (12.5")
T base Support rod Base Extender & Radial Support Added
Radial Support
Figure #9
USEFUL INFORMATION APPENDIX 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 .0167 For .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 SYSTEM COMPONENT LIST

WeldingTips
Stub 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)
Support Components
Tack 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
Welding Nozzles and Diffusers

Mini 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 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 Components
Centering Cone Set: BWS-A108 45-160mm (1.8-6.4") Centering Tube: BWS-1044 1.8m (72")
Welding Torches and Accessories

Standard 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")
Miscellaneous
Liner: BWS-1039 1.5m (60") for torches Liner, Conduit Replacement BWS-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 70S6 BWS-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
MPD-1065 RELEASABLE CARRIAGE 12" (305 mm)
BUG-5260 CARRIAGE 18" (457 mm)
BUG-5250 CARRIAGE 12" (305 mm)
The BUG-O Systems Carriages are made of high-strength, lightweight aluminum alloy. The carriage wheels ride in opposed recessed grooves or ways, in the Aluminum Rigid Rails, locking the carriage to the rail in all positions. The pinion from the drive unit goes through the carriage and engages the rack on the rail, providing a positive drive. One set of wheels on each carriage is adjustable to allow for smooth accurate travel. The wheels contain permanently lubricated sealed bearings. All steel components are plated to resist corrosion. PATENTS WORLDWIDE
CARRIAGES
Close-up showing a front view of a carriage mounted on Aluminum Rail.
BUG-5250 CARRIAGE 12" (305 mm) Net Weight: 5 lbs. (2.26 kg) Shipping Weight: 7 lbs. (3.17 kg)
8.00" (203 mm)
Mounts a DC IV Drive Unit 100 lb (45 kg) carrying capacity.
12.00" (305 mm) 2.00" (50 mm)
BUG-5260 CARRIAGE 18" (457 mm) Net Weight: 8 lbs. (3.62 kg) Shipping Weight: 10 lbs. (4.53 kg)
8.00" (203 mm)
Mounts a DC IV Drive Unit. 100 lb (45 kg) carrying capacity with a DC IV mounted on the carriage. 150 lb (67.5 kg) carrying capacity when used as a trailer. Longer deck to mount accessories, wire feeder, etc.
18.00" (457 mm) 2.00" (50 mm)
8.00" (203 mm)
24.00" (609 mm) 2.00" (50 mm)
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 capacity with a DC IV mounted on the carriage.
200 lb (90 kg) carrying capacity when used as a trailer. Longer deck to mount accessories, wire feeder, etc.
CARRIAGES
8.00" (203 mm)
36.00" (914 mm) 2.00" (50 mm)
BUG-2785 CARRIAGE 36" (914 mm) Net Weight: 16.5 lbs. (7.50 kg) Shipping Weight: 23.0 lbs. (10.44 kg)
Mounts a DC IV Drive Unit. 100 lb (45 kg) carrying capacity with a DC IV mounted on the carriage.
200 lb (90 kg) carrying capacity when used as a trailer. Longer deck to mount accessories, wire feeder, etc.
8.00" (203 mm)
12.00" (305 mm) 2.00" (50 mm)
MPD-1065 Releasable Carriage Net Weight: 7.75 lbs. (2.52 kg) Shipping Weight: 9lbs. (4.09 kg)
Mounts a DC IV Drive Unit. 100 lb (45 kg) carrying capacity.
Releasable (can be installed anywhere along the track.
8.12" (206 mm)
12.00" (305 mm) 2.56" (65 mm)
BUG-5910 Split Carriage Net Weight: 7 lbs. (3.17 kg) Shipping Weight: 8 lbs. (3.62 kg)
Mounts a DC IV Drive Unit or a Modular Drive Unit. 100 lb (45 kg) carrying capacity.
Releasable (can be installed anywhere along the track. Runs on straight or BRR Ring Rail.
CARRIAGES
8.00" (203 mm)
12.00" (305 mm) 2.00" (50 mm)
BUG-2205 Carriage Trailer w/Hitch Net Weight: 6 lbs. (2.72 kg) Shipping Weight: 8 lbs. (3.62 kg)
100 lb (45 kg) carrying capacity
Used to carry accessories, wire feeder, etc.
8.00" (203 mm)
6.18" (157 mm) 2.00" (50 mm) 12.00" (305 mm)
MUG-1140 Spotting Car Net Weight: 6 lbs. (2.72 kg) Shipping Weight: 8 lbs. (3.62 kg)
Knob is used manually to move the carriage along the track.
Bottom knob locks carriage to a fixed rail position
4.00" (102 mm)
6.25" (159 mm)
9.00" (229 mm)
MUG-1148 Torch Spotter Net Weight: 3 lbs. (1.36 kg) Shipping Weight: 4 lbs. (1.81 kg)
Knob is used manually to move the carriage along the track.
Bottom knob locks carriage to a fixed rail position
A QUALITY PRODUCT FROM BUG-O SYSTEMS Weld Tooling Corp.
PITTSBURGH, PA USA 15204-1899 ROM 1:16 Litho in U.S.A.
LIT- CARR-BRO-199
Return to Index
CIR-O
1 9
2 3 8
6 4 5
7
1. BUG-5100-F drive unit provides the power with a solidstate variable speed control. 2. CIR-3040, CIR-4040 and CIR-5040 carriage insures accurate 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.
CIR-O machines are lightweight, heavy-duty, multipleuse circular drives. Each of the three sizes of machines has a positive rack and pinion drive and infinitely variable speed control which provides smooth, accurate travel in all positions. The carriage provides a mounting surface for a variety of different process tools. A single centerpunch mark is all that is needed to locate the machine on the workpiece. It is then ready to flame-cut, bevel or weld. Permanent magnets or vacuum cups can be purchased separately to hold it in place.
3. CON-3000, CON-4000, CON-5000 ring and gear assembly with its perfectly round cut gear makes every cut true. 4. OPTIONAL CIR-9002 offset leg and magnet assembly - four of these units are used to eliminate the blind spot under the ring. Each unit clamps onto a standard leg. An adjustable tip adaptor must be used to offset the cutting tip under the ring. 5. Standard 2" (50 mm) leg [four supplied with the machine]. 6. OPTIONAL CIR-9021 5" (127 mm) leg [use with template kit and CIR-9020 magnet foot]. 7. OPTIONAL CIR-9020 magnet foot [use with CIR-9021 5" (127 mm) leg] locks machine to work - four required. 8. Center location with stainless steel center pin. 9. Rotating post mount - this combination of modules provide accurate positioning of a torch for any single torch operation.
CIR-O HEAVY DUTY CIRCLE CUTTER

Capacities and Speed Ranges
DIAMETER DIAMETER
MM 75 150 250 350 650 750 850 950 1050 1140 1250 1420 75 150 250 350 450 550 850 950 1050 1150 1250 1350 1450 1625 75 150 250 350 450 550 650 750 1050 1150 1250 1350 1450 1550 1650 1825 MM/MIN 10-210 20-420 35-700 50-1000 90-1805 105-2100 120-2400 130-2640 50-3000 60-3200 175-3500 200-4000 7-140 14-280 23-460 32-650 42-840 50-1000 80-1600 87-1760 97-1950 105-2130 115-2300 125-2500 135-2700 150-3000 5-100 10-210 17-350 24-500 32-640 38-760 45-900 52-1050 73-1458 80-1600 87-1750 94-1900 100-2000 105-2150 115-2300 125-2500
Dimensions:
INSIDE RING
INCH 3 6 10 14 26 30 34 38 42 46 50 56 3 6 10 14 18 22 34 38 42 46 50 54 58 64 3 6 10 14 18 22 26 30 42 46 50 54 58 62 66 72
IPM .4-8 .8-16 1.4-28 2-39 3.5-70 4-80 4.5-92 5.2-105 5.7-115 6.3-125 6.8-135 7.6-155 .3-5 .6-11 .9-18 1.3-26 1.7-33 2-40 3.2-63 3.5-70 3.9-78 4.3-85 4.6-93 5-100 5.4-110 6-120 .2-4 .4-8 .7-13 1-19 1.3-25 1.5-30 1.8-37 2-41 2.9-57 3.2-63 3.4-68 3.7-75 4-80 4.3-85 4.5-90 4.9-100
CIR-III CIR-IV
NET WEIGHT 48 lbs. (21.8 kg) 65 lbs. (29.5 kg)
25.50" (648 mm) 33.87" (860 mm)
42.25" (1070 mm)
CIR 3 CIR 4 CIR 5
24" (610 mm) 32" (813 mm) 40" (1016 mm)
"X" = 8.18" (208 mm) with 2" legs "X" "X" = 11.18" (284 mm) with 5" legs NOTE: Torches, tips and magnets or vacuum cups must be ordered separately.
CIR-3303 CIR-3323 CIR-3313 CIR-4404 CIR-4424 CIR-4414 CIR-5505 CIR-5525 CIR-5515
120 VAC/50-60-1 240 VAC/50-60-1 42 VAC/50-60-1 120 VAC/50-60-1 240 VAC/50-60-1 42 VAC/50-60-1 120 VAC/50-60-1 240 VAC/50-60-1 42 VAC/50-60-1
CIR-3303 CIR-3323 CIR-3313 CIR-4404 CIR-4424 CIR-4414 CIR-5505 CIR-5525 CIR-5515
66 lbs. (30.0 kg)
90 lbs. (40.8kg)
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:
CIR-9030 CIR-9040 CIR-9050 CIR-III CIR-IV CIR-V CIR-3304 CIR-4405 CIR-5506 CIR-III CIR-IV CIR-V CON-1006
TEMPLATE KIT - consists of a sheet aluminum master template, alignment bars, spacer legs, tensioning assembly and torchholder. Pattern is cut in tempered hardboard and bolted to ring.
ANNULAR CARRIAGE - for special welding and cutting applications - when material to be cut or welded passes through the ring track.
OUTSIDE RING
128 lbs. (58.0 kg) 90 lbs. (40.9 kg)
CIR-V
INSIDE RING
PART NUMBER
POWER REQUIREMENT
PART NUMBER
SHIPPING WEIGHT
OUTSIDE RING
INSIDE RING
OUTSIDE RING
VACUUM MOUNTS - CON-1006 for use on non-ferrous material such as stainless, aluminum etc. Use with ARV-2020 Vacuum Pump Kit.
A QUALITY PRODUCT FROM BUG-O SYSTEMS 3001 WEST CARSON STREET PITTSBURGH, PA USA 15204-1899 A DIVISION OF WELD TOOLING CORPORATION ROM 1:16 Litho in U.S.A. LIT-CIRO-BRO-0307 Weld Tooling Corp.
CON-O Precision Contour Saddle Cutter

CON-O Precision Contour Burning and Beveling Machines Produce Elliptical Cuts and Bevels in Pipes and Cylinders.
The CON-O automatically follows symmetrical surfaces to produce smooth, accurate cuts and bevels. It is portable and easily taken to the work. The CON-O locates from a center-punch mark and is set to a radius mark. Powerful permanent magnets stabilize the machine (two outrigger support kits are supplied with the CON-3 and CON-4, four outrigger support kits are supplied with the CON-5).
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
CON-O PRECISION CONTOUR SADDLE CUTTER

Technical Data:
PART NUMBER: CON-3303 CON-3313 CON-3323 CON-4404 CON-4414 CON-4424 CON-5505 CON-5515 CON-5525 POWER REQUIREMENT: 120 VAC/50-60-1 42 VAC/50-60-1 240 VAC/50-60-1 120 VAC/50-60-1 42 VAC/50-60-1 240 VAC/50-60-1 120 VAC/50-60-1 42 VAC/50-60-1 240 VAC/50-60-1 NET WEIGHT: CON-3303, 3313, 3323 65 lbs. (29.5 kg) SHIPPING WEIGHT: 83 lbs. (37.6 kg)
33-7/8" (860 mm) 42-1/4" (1073 mm)
Dimensions:
CON-4404, 4414, 4424 80 lbs. (36.3
98 lbs. (44.5 kg)
CON-5505, 5515, 5525 105 lbs. (47.7 kg)
130 lbs. (59.0 kg)

CON-3 CON-4 CON-5 24" (610 mm) 32" (813 mm) 40" (1016 mm)
Capacities and Speed Ranges

DIAMETER INCH IPM
CON-3303 3 6 10 14 10 14 18 22 18 22 26 30 .4-8 .8-16 1.4-28 2-39 .9-18 1.3-26 1.7-33 2-40 1.3-25 1.5-30 1.8-37 2-41
DIAMETER MM MM/MIN
75 150 250 350 250 350 450 550 450 550 650 750 10-210 20-420 35-700 50-1000 23-460 32-650 42-840 50-1000 32-640 38-760 45-900 52-1050
CON-3 CON-4 CON-5 37" (940 mm) 45" (1143 mm) 53" (1346 mm) 1-3/4" (45 mm) 19" (483 mm)
CON-4404
CON-5505
1. BUG-5100-F drive unit provides the power with a solid-state variable speed control. 2. CON-3040, CON-4040, and CON-5040, carriage insures accurate work paths by meshing firmly with the gear. A quick-acting manifold with a short connection hose, centering pin and counter-balanced floating plate, for torch mount ing, are mounted on the carriage. 3. This combination of modules provides accurate positioning of the torch for saddle cuts and bevels. The guide wheel, diametrically opposite the torch tip, maintains accurate nozzle-to-work distance on symmetrically contoured vessels.
1 2 4
4. CON-3000, CON-4000, CON-5000 ring and gear assembly, with its perfectly round cut ring gear, makes every cut true.
5. Legs and alignment bars position machine on any symmetrical steel surface. 6. CON-1010 outrigger support kit. 7. Center locator with stainless steel center pin. NOTE: A cutting torch is not furnished with the machine unless specified separately.
IMPORTANT NOTICE Saddle 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). Maximum diameters practical will be reduced when bevel cuts are made. The above chart shows diameter for straight cuts.
A QUALITY PRODUCT FROM BUG-O SYSTEMS 3001 WEST CARSON STREET PITTSBURGH, PA USA 15204-1899 A DIVISION OF WELD TOOLING CORPORATION Weld Tooling Corp. ROM 1:16 Litho in U.S.A. LIT- CONO-BRO-0905
25-1/2" (648 mm)
AUTOMATIC CIRCLE BURNING AND WELDING

ON 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.

280 Technology Drive Canonsburg, PA USA 15317-9564 Telephone: 1-412-331-1776 1-800-245-3186 Fax: 1-412-331-0383 www.cypressweld.com
Cypress Makes The

Wire reel adaptor for 30 lb. (13.6 kg) spools on CW-5s. 60 lb. (27 kg) wire reels included on Cw-7s and 11s.
Strong permanent magnet motor and gear train insure smooth movement of the welding torch.
For sub-arc applications, a 25 lb. (11 kg) flux hopper is included on the CW-5AX, CW-7s and CW-11s.
Rise and fall cam, raises and lowers the torch to follow the contour of the pipe or vessel.
Welding gun and cable assembly.
Racking groups for horizontal and vertical adjustment of the welding gun. Motorized racking is available.
Torch angle adjuster (optional on CW-5) standard on all other machines.
Electric oscillators are available.
Weld Go Round.
Wire feed motor. (See chart for wire sizes page 5.)
Collector rings and brushes, for welding current.
Collector rings and brushes for rotation and controls.
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.
Volt meter and amp meter, allow the welder to control the weld parameters at the machine. (optional on the CW-5, included on all other models).
Rotation Speed Control. Direction and On-Off Switch.
3 jaw expandable chuck, 3 sizes available. Positions the machine on the nozzle.
No hose or cable wrap-up regardless of the direction of rotation!
Circle Welders
CW-5
The CW-5 (CWO-1500) Circle Welder has the same features as the CW-5 with Remote (CWE-1500). All controls for this model are located on the machine.
CW-5AX
The CW-5AX (CWO-1560) Circle Welder is designed for single pass or multi pass welding of couplings and nozzles on pipe and vessels. The unit is available for Sub Arc, MIG or Flux Cored process. The CW-5AX offers all the same features as the CW-5 but in addition incorporates a meter kit, torch angle adjuster and flux hopper.
CW-5 with Remote

CW-5 (CWE-1500) Circle Welder with Remote Control. The CWE-1500 is designed for single or multipass welding of couplings or nozzles on pipe and vessels utilizing MIG or Flux Core process, with gas shield. The machine is equipped with its own wire feeder, rotation drive motor, rise and fall cam assembly and welding gun. Horizontal and vertical racking to position 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, preflow and post-flow, burn back and wire feeder forward and reverse. Overlap is also adjustable. This control has both manual and automatic settings. In the manual setting, you can check all your controls and travel speed to make sure the machine is functioning properly. In the automatic setting, with one push of a button, the unit will start the weld process, weld completely around the workpiece, overlap the end of the weld, turn the weld off and return to the start position. It is ready for the next weld. The CW-5 is supplied with the following cables: 50'' (15.2 m) of gas hose, 50'' (15.2 m) hot lead, 50'' (15.2 m) control cable and all cables from the remote box to the circle welder. 4
CW-7
CW-7 Circle Welder (CWO-1700) is equipped for MIG, Flux Core and Sub Arc welding on vessels and domed heads. The CW-7 has a working range of 6"-24" (152-610 mm) O.D. nozzles with no cable wrap up for multi-pass welding. This unit is capable of using welding wire sizes from .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 wire feeder, gun and cable assembly, flux hopper, wire reel and meter kit. Mounts on 3-jaw chuck. (See chart below for welding capacities).
Circle Welders
CW-11 Circle Welder (CWO1100) is equipped for MIG, Flux Core and Sub Arc welding on large vessels, domed heads and flat surfaces. The CW-11 has a working range of 10"-50" (2541270 mm) O.D. nozzles with no cable wrap up for multi-pass welding. Remote control of amps and volts. The unit is capable of using welding wire diameters from .035''-1/8'' (.83.2mm).
CW-18
CW-18 Circle Welder (CWO-1800) is designed for welding of nozzles into vessels or domed heads utilizing SUB-ARC. The CW18 mounts on a 3-Jaw Chuck welding diameter 6" to 50" (152-1270 mm) O.D. It is capable of using welding wire diameters 3/32-7/32'' (2.45.6 mm).
CW-11
Circle Welder Capacities

Model CW-5 CWO-1500 MIG/MAG, CW-5 FCAW W/Remote CWE-1500 1-12" (25-300 mm) .035-1/16" (.8-1.6 mm) .035-3/32" (.8-2.4 mm) .035-3/32" (.8-2.4 mm) 3-130 ipm (75-3300 mm/min) 3-130 ipm (75-3300 mm/min) 4-137 ipm (100-3500 mm/min) 0-5" (0-125 mm) 0-5" (0-125 mm) 0-7" (0-175 mm) 300 amps 100% duty cycle 500 amps 100% duty cycle 500 amps 100% duty cycle Burn back control, horizontal and vertical adjustment gun and cable Same as CW-5 plus: meter kit, torch angle adjuster, flux hopper, nozzle and cone. Burn back control, horizontal and vertical adjustment gun and cable. Process Capabilities Welding Diameter Welding Wire Size Rotation Speeds Rise and Fall Cam Rating amps Standard Equipment
CW-5AX MIG/MAG, 1-12" CWO-1560 FCAW, SAW (25-300 mm) CW-7 MIG/MAG, 6-24" CWO-1700 FCAW, SAW (150-600 mm) CW-11 MIG/MAG,. 10-50" CWO-1100 FCAW, SAW (254-1270 mm)
Solid Wire .06-72 ipm 0-7" 500 amp CO2 Burn back control, horizontal .035-1/8" (0.8-3.2 mm) (0-175 mm) 400 amp and vertical adjustment gun (.8-3.2 mm) mixed gases and cable. 60% duty cycle Flux Cored Wire .068-.120" (1.7-3.0 mm) Solid Wire .06-72 ipm 0-7" 60% duty 3/32-7/32" (0.8-3.2 mm) (0-175 mm) cycle (2.4-5.6 mm) Burn back control, horizontal and vertical adjustment gun and cable.
CW-18 SAW CWO-1800
10-50" (254-1270 mm)
NOTE: Welding diameter capacities cannot exceed two thirds diameter of the workpiece.
Circle Welders
Accessories
CWO-1645 Torch Weaver Provides a pendulum-type motion to the gun for weave welding. The speed and stroke of oscillation are adjustable.
CWO-3023-1 Torch Angle Adjuster Allows the operator to adjust the angle of the gun precisely, without unclamping the holding devise.
CWO-5790 Cone Adaptor A tapered centering devise used to center the machine on nozzles. The range of the Cone Adaptor is 1-1/4" to 4" (32-102 mm) diameter.
CWO-3670 Step Adaptor for Threaded Outlets A stepped centering device used to center the machine on threaded I.D. weld-o-lets. The range of the Step Adaptor is 1/2" to 4" (13-102 mm) diameter. CWO-3675 Step Adaptor for Grooved Outlets 1 1/4" - 1 1/2" - 2" - 2 1/2" - 3", 4"
Chucks
CWO-3660 Lathe Chuck 2"-10" (50-254mm) lathe chuck for small fittings and nozzles. PART NO. CWO-3660 CWO-3661 CWO-3662 CWO-3663
3-Jaw Expandable Chuck Mounts and automatically centers the Circle Welder on nozzles with or without flanges. For use with all circle welders. WEIGHT 69 lbs. (31.3 kgs) 36 lbs. (16 kgs) 51 lbs. (23 kgs) 64 lbs. (29 kgs)
FOR NOZZLE I.D.s 2"-10" (50-254 mm) 8"-16" (204-405 mm) 10"-24" (255-610 mm) 24"-42" (610-1065 mm)
Circle Welders
Carriages
CWO-4530 Carriage May be used only with CW-5 CIRCLE WELDERS. The carriage, which is mounted on a standard monorail, is used to move the welder along a length of pipe.
CWO-4550 Motorized Carriage May be used with either the CW-5 CIRCLE WELDER or the CB-1P AIR PLASMA MACHINE. Provides motorized vertical travel of the machine. CWO-2020 Submerged Arc Flux Recovery System Continuously removes and recycles all unused flux. Available on any CW-5AX, CW-7, CW-11 and CW-18.
CWO-4540 Carriage This carriage, which is mounted on a standard monorail, is used with the CB-1P AIR PLASMA MACHINE. A winch holds the machine and prevents the machine from falling into the hole when the slug drops. This carriage may also be used with CW-5 CIRCLE WELDERS.
Flux Recovery System installed on a CW-11. 7
Circle Burners
CB-1P (CBO-1020) Plasma Circle Burner
CB-1P Plasma Circle Burner, for cutting beveled holes in lightwall pipe or vessels with wall thicknesses up to 3/8" (7 mm). This machine is supplied with a Thermal Dynamics air plasma power source, torch and 50' (15 m) leads. The unit operates on 220/50-60/1 power (3 phase also available). The CB-1P must be mounted on a carriage or fixture.
CB-1P
CB-2
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 permanent magnet base. Machine includes variable speed rotation, 2-hose oxyfuel machine torch, adjustable tip adaptor, vertical and horizontal torch adjustment and rise and fall cam.
CB-3
CB-3 Circle Burner (CBO-3000) Uses oxyfuel for square or beveled hole cuts (see chart for capacities). Unit includes 2-hose oxy-fuel machine torch, adjustable tip adaptor, variable speed rotation, vertical and horizontal torch adjustment and rise and fall cam. The CB-3 must be mounted on a column and boom, manipulator or fixture.
Circle Burner Capacities

Model Burning Diameter CB-2 1.5"-42" beveled holes (40-1066 mm) 4"-48" square cut (100-1220 mm) 1.5"-42" beveled holes (40-1066 mm) 4"-48" square cut (100-1220 mm) .5"-12" beveled holes (11-300 mm) Mounting manually operated magnet Process oxyfuel Rise and Fall Cam 0-7" (0-175 mm) Net Weight Use
225 lbs. vessels, large diameter pipe (102 kg)
CB-3
carriage or oxyfuel manipulator
0-7" (0-175 mm)
170 lbs. (77 kg)
domed heads, vessels, large diameter pipe, flat plate
CB1P
manually operated magnet
plasma
5" (127 mm)
170 lbs. (77 kg)
vessels, large diameter pipe
NOTE: Burning diameter cannot exceed two thirds diameter of the workpiece.
Saddle and Elbow Cutters

MM1 Programmable Pipe Cutter (SEO-3500)
The MM1 is a computer controlled machine that automates the cutting of profiles, holes and shapes on pipe with diameters from 4"-16" (100-400 mm). It rotates the pipe on its roller bed with a three jaw chuck while simultaneously moving a cutting torch back and forth along the pipes 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. *Oxy-fuel versions are available. *Optional: Machine cutting capacity can be increased to 24" (610 mm) diameter at factory.

Programmable SE-2PTD and SE-4PTD Pass Through Machines
The SE-2PTD and SE-4PTD 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 pipe. Both are suitable for plasma and oxy-fuel cutting and eliminates the need to make templates or layout complex cuts. SE-2PTD SEO-4250-OX Oxy-Fuel Version SEO-4250-PL Plasma Version SE-4PTD SEO-4400-OX Oxy-Fuel Version SEO-4400-PL Plasma Version NOTE: SEO series machines do not include torch or plasma machine. SEO-4400-3 AXIS SE-4PTD with third axis option as shown on left. An additional third axis-torch rotation is available. The programmed torch rotation only works with cuts:1, 2, 4 and 5 (see page 11).
SE-4PD Programmable Saddle and Elbow Cutter.

The SE-4PD is a programmable machine. It will cut saddles, laterals, miters, offsets (hillsides) and elbows using a micro-processor and handheld terminal. Oxyfuel or Plasma may be used. Cutting diameter 1"-12" (25300 mm). (Maximum length of pipe to be cut, 18" [450 mm]). The maximum rotation speed is 3.7 rpm, which is 47 ipm (1160 mm/min) on 4" (102 mm) O.D.s. SEO-4520-OX Oxy-Fuel Version SEO-4520-PL Plasma Version
Saddle and Elbow Cutter Capacities:

Model SE-2PTD SE-4PD SE-4PTD MM1 Process Plasma or Oxyfuel Plasma or Oxyfuel Plasma or Oxyfuel Plasma or Oxyfuel Pass Through 1" - 4" (25 - 102 mm) N/A 4" - 12 3/4" (102 - 324 mm) N/A Pipe Diameter Range 1" - 14" (25 - 356 mm) 1" - 12" (25 - 305 mm) 4" - 20" (102 - 508 mm) Standard Machine 4"-16" (102 - 406 mm) Optional 4"-24" (102 - 610 mm) Speed Rotation .3 3.7 rpm .3 3.7 rpm .2 3 rpm .2 3 rpm Range of Pipe Lengths that can be Cut 3"-18" (76 - 457 mm) 3"-18" (76 - 457 mm) 3"-20" (76 - 508 mm) 3"-38 ft. (76 mm - 11.6 m)
10

Capabilities
TYPE 1
SADDLE NOZZLE CUTS
TYPE 4
MITER CUT
TYPE 2 OFFSET
SADDLE NOZZLE CUTS (Hillside)
TYPE 5
HOLE CUTTING AT VARIOUS ANGLES
TYPE 3
LATERAL NOZZLE CUTS
SHAPE PROGRAM CUSTOM IRREGULAR SHAPES
Hand Held Terminal:
Example: Programming Sequence for Type 3 Cut.

1. Press the reset button on the machine. The hand held 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). 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. 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. 8. Press START on the machine to begin the cut. It couldnt be easier! When using Plasma, press B and enter the time delay required (which is stored until changed again).
11
Sprinkler Fabrication Equipment
TYPICAL SET UP FOR SPRINKLER FABRICATION

Length of Pipe + 6' (1.83 m) Eye Bolt 1/4" (6 mm) Cable 10 Harness snaps with swivel eyes to support cables and hoses. 3/8" (9.5 mm) x 3" (76 mm) Flat Bar 8" (203 mm) 4" x 8" x 1/4" (102 x 203 x 6 mm) Wall Welder Rectangular Tubing 8" (203 mm) Pipe
76" (2 m)
1-1/2" (38 mm) Pipe
30" (762 mm)
5.31" (135 mm) 1" (25 mm) 3/4" x 6" x 26" Bar (19 x 152 x 660 mm) Tack Weld 1/8" x 1" (3x25 mm) long on 16" (406 mm) centers top & bottom 1-1/2" (38 mm) Pipe
Burner
5" (127 mm) Pipe
36" (914 mm) 22" (559 mm)
Cast Iron Flanges
3" (76 mm) Pipe
Pipe Vise
40" (1 m)
Plasma Power Source
5' (1.5 m)
6' (1.8 m)
8' (2.4 m)
6' (1.8 m)
5' (1.5 m)
Welding Power Source
Sequence of Operation Position your pipe and move the CB-1P along the pipe to cut smooth, accurate holes. Position the CW-5 with a step adapter on the fitting and make the contour weld.
The approximate time for a cut is 6-10 seconds, depending upon diameter and thickness. The approximate time for a weld is 15-20 seconds. For detailed information please ask for our special sprinkler brochure.
CYPRESS WELDING EQUIPMENT, INC.

280 Technology Drive Canonsburg, PA USA 15317-9564 Telephone: 1-412-331-1776 1-800-245-3186 Fax: 1-412-331-0383 ROM 1:16 Weld Tooling Corp. http://www.cypressweld.com LIT-CGB-BRO-0308
Powerful Solutions For Welding And Cutting Automation.
Powerful Welding Travel Carriages Will 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.
The BUG-O DC IV is a dual speed range, positive rack & pinion drive, ready for mounting welding or cutting 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
280 TECHNOLOGY DRIVE CANONSBURG, PENNSYLVANIA 15317-9564 USA PHONE: 1- 412-331-1776 http://www.bugo.com FAX: 1- 412-331- 0383
BUG-O DC IV
Features:
C. Wing nut locks clutch. D. Cam Clutch engages and disengages the drive. E. Power Cord. F. Power Indicator Light.
C D G H K E J F
Two pinion gears are provided. The factory installed pinion engages the bull gear to provide a high torque, low speed range (A). The user can easily install the alternate pinion to bypass the bull gear and obtain a low torque, high speed range (B).
G. Forward-Off-Reverse Switch. H. Infinitely variable speed control. J. Circuit Breaker. K. Carriage.
Dimensions:
B A
8.13" 207 mm
Technical Data:
Power Requirement: DC IV: -60 watts at rated voltage: BUG-034_ BUG-044_ BUG-054_ 120 VAC/50-60/1 240 VAC/50-60/1 42 VAC/50-60/1
8.13" 207 mm
Net Weight: 18 lbs. (8 kg) Shipping Weight: 20 lbs. (9 kg)

12" 305 mm
Drive Load Chart

Continuous Pinion Gear Speed Used in/min Low Speed High Speed Low Speed High Speed Low Speed High Speed 1.5-30 8-160 .7-15 4-80 .5-10 2-50 Range mm/min 38-750 200-4000 19-380 100-2000 12-255 50-1250 Vert. Load LBS. 50 3 75 15 100 30 KG 22 50:1 1.4 34 100:1 7 45 150:1 14 BUG-0346 BUG-0446 BUG-0546 BUG-0345 BUG-0445 BUG-0545 BUG-0343 BUG-0443 BUG-0543 Gear Ratio 120/50-60/1 Model Number 240/50-60/1 42/50-60/1
A QUALITY PRODUCT FROM BUG-O SYSTEMS 280 TECHNOLOGY DRIVE CANONSBURG, PA 15317-9564 USA ROM 1:16 Litho in U.S.A. LIT-DCIV-BRO-0708 A DIVISION OF WELD TOOLING CORPORATION Weld Tooling Corp.
Flexible Automation of Cutting & Welding Applications Flexible Automation von Schwei- und Schneidarbeiten Automatizacin flexible para corte y soldadura Automatisation Flexible dapplications de Soudure et de Coupe
Plug in a Bug-O
For more detailed information on any product, visit our website where you can download a full product brochure. Phone: 1-412-331-1776 Fax: 1-412-331-0383
www.bugo.com
Six Ways Automating Your Welding & Cutting Can Save You Money!
Increase Production
The machine replaces the operator's hand to control the process.
Improve Quality
Precise speed and path control improve appearance and quality.
Reduce Material Handling

Take the small lightweight machine to the work. Work in all positions.
Reduce Distortion
Provides uniform heat input, puts the right amount of weld in the right place.
Improve Worker's Environment

Keeps the worker further away from the arc and reduces operator fatigue.
Adaptable
Flexible Modular Construction that adapts to your job. 2
Trackless Mechanization for Cutting & Welding

MINI VERT III
Compact Fillet Welder Battery Powered 4 Wheel Drive 110 or 220 volt charger Speed: 100-990 mm/min. 3.9-39 ipm Weight: 7.2 kg, 16 lbs.
BUG-GY-VERT II Fillet Welder with Oscillation

Battery Powered 4 Wheel Drive 110 or 220 volt charger Welds in all Positions Speed: 50-760 mm/min. 2-30 ipm Weight: 14 kg, 28 lbs.
BUG-GY
Fillet Welder with Programmable Stitch Welding and Reverse Crater Fill Optional Dual Torch Attachment Available 110, 220 or 42 volt Speed: 101-1524 mm/min. 4-60 ipm Weight: 18 kg, 40 lbs.
Trackless Mechanization for Cutting & Welding

UNI-BUG III
Programmable Stitch Welder. Runs Directly on the Work Piece. Carriage Options for the following structural profiles: Flat Bar Bulb Angle T Profiles L Profiles 110, 220 or 42 volt Speed: 102-1905 mm/min. 4-75 ipm Weight: 8.2 kg, 18 lbs.
STIFFENER WELDER
Dual Sided Fillet Welder with Wire Feeders and Programmable Stitch Function Stiffener Capacities: 102-457mm, 4''-8'' High 102-305mm, 4''-12'' Wide Speed: 0-900 mm/min. 0-36 ipm Weight: 113 kg, 250 lbs.
SUB-ARC TRACTOR
Heavy Duty Submerged-arc tractor for fillet and butt joints. Optional flux recovery unit is available. 4 Wheel Drive Speed: 127-2,540 mm/min. 5-100 ipm Weight: 116 kg, 255 lbs.
AUTOMATIC GIRTH WELDER

Self-propelled submerged arc welding system. Applicable for bottom-up or jack-up constructed single or double wall storage tanks. Speed: 10-290 cm/min. 4-114 ipm 4
Straight Line Cutting & Welding with Rails

GO-FER CUTTING KIT-PLASMA
Straight Line Cutting and Beveling Machine for Plasma 120, 240 or 42 volt Speed: infinitely variable from 200-2500 mm/min. 8-100 ipm Weight: 17.7 kg, 39 lbs.
GO-FER CUTTING KIT-OXY-FUEL

Straight Line Cutting and Beveling for Oxy-Fuel 120, 240 or 42 volt Speed: infinitely variable from 200-2500 mm/min. 8-100 ipm Weight: 17.7 kg, 39 lbs.
GO-FER WELDING KIT

Straight Line SemiAutomatic Welding 120, 240 or 42 volt Speed: infinitely variable from 50-1250 mm/min. 2-50 ipm Weight: 17.7 kg, 39 lbs.
Straight Line Cutting & Welding with Rails

TRAC-BUG OXY-FUEL
Straight Line Track Burning Machine for Oxy-Fuel 120, 240 or 42 volt Speed: infinitely variable from 100-1800 mm/min. 4-72 ipm Weight: 15 kg, 33 lbs.
TRAC-BUG-PLASMA
Straight Line Track Burning Machine for Plasma 120, 240 or 42 volt Speed: infinitely variable from 100-1800 mm/min. 4-72 ipm Weight: 15 kg, 33 lbs.
MODULAR DRIVE SYSTEM

Straight Line Welding 110, 220 or 42 volt Runs on all types of Bug-O Rail Speed: 51-3048 mm/min 2-120 ipm Weight: 13.2 kg, 29 lbs.
Straight Line Welding with Oscillation

UNIVERSAL BUG-O-MATIC
Compact Drive and Weaver Combination. Adapts to all Bug-O Rail. 120, 240 or 42 Volts Speed: 70-1670 mm/min. 3-66 ipm Weight: 10.5 kg, 22 lbs.

Linear Weaver 110, 220 or 42 Volt Adapts to all Bug-O Rail. Speed: 51-3048 mm/min 2-120 ipm Weight: 18 kg, 40 lbs.

Pendulum Weaver 110, 220 or 42 Volt Adapts to all Bug-O Rail Speed: 51-3048 mm/min 2-120 ipm Weight: 17.5 kg, 39 lbs.
Special Units
PORTABLE PLATE BEVELING MACHINE
Machines bevel angles on plate 120 or 220 volt Chamfering capacity up to 3/4'' (20 mm) Adjustable bevels from 30 to 60 Weight: 19 kg, 42 lbs.
PROGRAMMABLE SHAPE MACHINE
2 Axis Portable Programmable Cutting and Welding Machine 120, 240 and 42 volt Speed: 63-1250 mm/min 2.5-50 ipm Net Weight: 17 kg, 37 lbs.
PROGRAMMABLE GANTRY SYSTEM
2 Axis Cutting Machine 120 or 240 Volt Available in 2451 mm (97''), 3048 mm (120'') and 3632 mm (143'') widths. Process: Oxyfuel or Plasma Speed: 100-2000 mm/min 4-80 ipm
Carriages - Rails - Magnet Bars - Vacuum Support

Rigid Rails
Heavy Duty ARR-1080 2.37 m, 8' long sections ARR-1085 1.18 m, 4' long sections Extra Heavy Duty ARR-1250 2.37 m, 8' long sections ARR-1200 1.18 m, 4' long sections
Semi-Flex
Flexes to 5 m, 15' Radius AFR-3000 2.4 m, 8' long sections
Hi-Flex
Flexes to 760 mm, 30'' Radius FMD-1050 1.47 m, 57.7'' long sections
Ring Rails
Minimum Work Diameter of 230 mm, 9'' BRR-1180 1.20 m - 6.23 m 3'-11'' - 21'-5''
Carriages - Rails - Magnet Bars - Vacuum Support

Releasable Carriage
MPD-1065
Hi-Flex Carriage
FMD-1105
Swivel Magnet
For Rigid Rail ARM-2325
Magnet w/Release
For Semi-Flex Rail ARM-2425
On/Off Magnet
For Rigid Rail ARM-2500
Screw Feet Assemblies

For Bent Rail ARM-2380
Vacuum Bar Assembly

For Nonferrous Material ARV-1036
Vacuum Pump Kit

ARV-2020 1100 Volt/50-60 Hz ARV-2030 220 Volt/50-60 Hz
10
Fixture Building Equipment & Complete Fixtures

SUPPORTS & ACCESSORIES
MDS-1040 Machined Rack Welding Group
MDS-1050 Machined Rack Cutting Group
MDS-1075 Dual Torch Welding Group
MDS-1090 Dual Torch Cutting Group
PAN-1000 Panograph Torch Floater
PAN-1008 Welding Panograph
PAN-1072 Double Torch Panograph
PAN-2145-L, R Mechanical Corner Follower
PAN-2160 Mechanical Seam Follower 11
Hole & Circle Cutters

DC HOB-O HOLE BORER
Lightweight Precision Hole Borer, Beveler and Welder. 120, 240 and 42 Volt Cutting Diameter: 25-1200 mm, 1''-47'' Weight: 13.6 kg, 30 lbs.
CIR-O III
Precision Circle Burner, Beveler and Welder. 120, 240 and 42 Volt Cutting Diameter: 75-1422 mm, 3''-56'' Weight: 48 kg, 106 lbs.
CIR-O IV
Precision Circle Burner, Beveler and Welder. 120, 240 and 42 Volt Cutting Diameter: 75-1626 mm, 3"-64" Weight: 65 kg, 143 lbs.
CIR-O V
Precision Circle Burner, Beveler and Welder. 120, 240 and 42 Volt Cutting Diameter: 75-1830 mm, 3"-72" Weight: 90 kg, 198 lbs.
PIPE-BUG
Chain Driven Pipe Cutting Machine Manually Driven or Motorized, 110 or 220 volt Pipe Capacities: 76mm+ 3''+ Weight: (Manual) 16 kg, 34 lbs (Motorized) 26 kg, 56 lbs 12
Cypress Circle Cutters and Welders

CB-1P
Plasma Circle Burner For Cutting Beveled Holes 11-300 mm, 1/2"-12" in Pipe up to 7 mm, 3/8" Wall Thickness Includes Plasma Power Source. 60% Duty Cycle Rise and Fall Cam: 127 mm, 5" Speed: .2-11 rpm Weight: 77 kg, 170 lbs.
CB-2
Circle Burner with Magnetic Base Cutting Diameter: 40-1066 mm, 1.5"-42" beveled holes 100-1220 mm, 4"-48" square cut Process: Oxyfuel Rise and Fall Cam: 0-175 mm, 0-7" Weight: 102 kg, 225 lbs.
CIRCLE WELDERS
Nozzle Welding Units Available for MIG/MAG and Submerged Arc. Multiple Versions Available for Nozzle Diameters of 25-1270 mm, 1"-50". For Multi-pass and Multi-layer Welding.
13
Cypress Pipe Cutting & End Preparation Units

SE-2 PTD
PROGRAMMABLE PIPE CUTTER / PASS THROUGH Pass Through Pipe Cutting Diameters 25-100 mm, 1"-4" External Chuck of 100355 mm, 4"-14" 120 or 220 VAC Process: Oxyfuel or Plasma Net Weight: 157 kg, 346 lbs.
SE-4PD
PROGRAMMABLE PIPE CUTTER Cutting Diameters: 25-300 mm. 1"-12" Maximum Pipe Length: 450 mm, 18" 115 VAC Process: Oxyfuel or Plasma Weight: 91 kg, 201 lbs.
SE-4PTD
PROGRAMMABLE PIPE CUTTER / PASS THROUGH Pass Through Pipe Cutting Diameters: 100-325 mm, 4" to 12-3/4" External Chuck up to 500 mm, 20" 120 or 220 VAC Process: Oxyfuel or Plasma Weight: 320 kg, 705 lbs.
14
Cypress Pipe Cutting & End Preparation Units

MM1
Programmable Pipe Cutter With Pipe Bed 120 or 220 VAC Cutting Diameters 100-400 mm, 4"-16" Pipe Length Capacity up to 9.14 m, 30' Process: Oxyfuel or Plasma Cutting Diameter: 100-400 mm, 4"-16" O.D.
Capabilities of Cypress Pipe Cutting & End Preparation Units. Pre-programmed and Custom Cuts.
TYPE 1
Saddle Nozzle Cuts
TYPE 4
Miter Cut
TYPE 2
Offset Saddle Nozzle Cuts (Hillside)
TYPE 5
Hole Cutting at Various Angles
TYPE 3
Lateral Nozzle Cuts
Shape Program Custom Irregular Shapes
15
Fixture Building Equipment & Complete Fixtures

OVERLAY SYSTEM
Custom Configured System for Rebuilding and Resurfacing Material such as Vessel Walls and Boiler Tubes. 110, 220 or 42 volt Travel Speed: 50-3000 mm, 2-20 ipm Available in Programmable or Manual Indexing Versions and Working Envelopes.
BUG-O GANTRY WELDING SYSTEM

Custom Designed Systems for a Variety of Applications such as Seam Welding and Beam Fabrication.
BUG-O GANTRY SIDE BEAM CARRIAGE

Custom Designed Systems for a Variety of Applications such as Seam Welding and Beam Fabrication.
For more information visit our website at: www.bugo.com

A DIVISION OF WELD TOOLING CORPORATION Litho in U.S.A. 280 TECHNOLOGY DRIVE CANONSBURG, PA 15317 USA Weld Tooling Corp. LIT-BRO-ESS-1208 ROM 1:16
Fixtures & Positioning Equipment from Bug-O Systems

Welding And Cutting Solutions Since 1948 www.bugo.com
Positioning Equipment
Welding Positioners
DC Drive protected against high frequency. Turn Table tilts from 0-1200. Spindle has 1.38" through hole for pipe work or gas purge. 8 slot turntable provides quick mounting for holding fixture. Timer controlled weld period. Includes foot pedal.
Turning Roll Assembly

DC Drive protected against high frequency. Remote foot switch run/stop controller. Forward/stop/reverse switch with potentiometer for stepless speed adjustment.
BPG-450L Chuck sold separately. Chuck capacity 1/4"-17 1/2" (4 mm-450 mm)
E D
C E
B
Part # BPT-100A BPT-200A BPT-100B BPT-200B Part # BPT-450M Item 1 Phase 220V 990/660 2 (Max) 6 (Max) 17-11/16 0.12-2.5 1 1/2 300 1/6 0-135 0-60 25 24 25 21-1/4 280/127
B
Part # BTR-0100
A
Part # BTR-3504
Item
Power Input 1 Phase 110V 60 Hz Capacity (lb) (Horiz./Vert) 220/165 440/330 Rated Center of Gravity 4 Rated Eccentricity (in) 4 Table Dimension D (in) 12-5/8 Rotation Speed (rpm) A: 1~15/B: 0~4 Spindle Thru Hole (in) 1/1/2 Table Slot Bolt Size (in) 3/8 Earthing (amp) 300 Rotation Motor (hp) 1/20 1/12 Tilt Range (degree) 0-120 Welding Timer (second) 0-60 Overall Length A (in) 16-1/4 Overall Width B (in) 16-1/4 Overall Height C (in) 13-3/8 Center to Floor E (in) 10 Weight (lb/kg) A: 82/37 B: 88/40
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
Positioning Equipment
Torch Supports
Freestanding Torch Support FTS-1020 & FTS-1025
The Freestanding Torch Support FTS-1020 is a small manually operated torch manipulator. Rack and pinion movement on hardened V ways provides effortless and smooth positioning of cutting torch or welding gun. The T base comes with pre-drilled holes for quick installation into your fixture. The NEW FTS-1025 Free Standing Torch Support with Automatic Height Control is a compact, easy to use system, designed to maintain a constant torchto-work distance automatically. This system can be used for Sub-Arc, Innershield and MIG welding The actual weld current is sensed continuously using a shunt. The signal is filtered, amplified and compared to a set point value. Any error from the set point is noticed by the controller and it will raise the torch up or down to maintain precise torch to work distance automatically. Total Vertical Adjustment: 25'' (635 mm)
35.5'' (902mm)
FTS-1020 shown above.
Total Horizontal Adjustment: 25'' (635 mm) Net Weight: Application of FTS-1025 Automatic Height Control with Linear Weaver shown above. 35 lbs. (11.34 kg)
40.42'' (1.03 m)
Mini-Minipulator BUG-1965
The MINI-MINIPULATOR II includes solid state variable speed, vertical and horizontal DC drives, pendant control of up-off-down and forwardoff-reverse, limit switches on both drives, and a counterweight in column center. The base rotates 360 degrees.
93-1/2" (2.37 m)
100'' (2.54 m)
TECHNICAL DATA: Specifications: Power Requirement: BUG-1965 120 VAC/50-60/1 BUG-1966 220 VAC/50-60/1 BUG-1967 42 VAC/50-60/1 Vertical Travel: Minimum Height: 65'' (1651 mm) 21-1/2'' (546 mm) From Centerline of Horizontal Rail to Mounting Surface (Floor) 86-1/2'' (2197 mm) 64'' (1626 mm) Measured from Centerline of Column to End of Horizontal Rail 20 lbs. (10kg) 420 lbs. (191 kg) 500 lbs. (227 kg) 93-1/2''L x 15''W x 100''H (2375 mm x 380 mm x 2540 mm)
Maximum Height: Horizontal Travel:
Load Capacity: Net Weight: Shipping Weight: Dimensions:
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 welding operations. They also feature adjustable independent dwell settings for controlled penetration and undercut elimination.
CDS-6350 Stand Alone Linear Weaver

TECHNICAL DATA: Specifications: Power Requirement: CDS-6350 CDS-6352 CDS-6354 Weave Speed: Dwell: Weave Width: Steering: Net Weight: Weaver Dimensions: 120 VAC/50-60 Hz 240 VAC/50-60 Hz 42 VAC/50-60/1 4-100 ipm (102-2540 mm/min) 0-3 seconds each side 0-2'' (0-50 mm) 4'' - 2'' (100-50 mm) each side of center 17 lbs. (7.7 kg) 6.75''L x 5.00''W x 3.88''H (171 x 127 x 99 mm)
BUG-6350 Stand Alone Pendulum Weaver

TECHNICAL DATA: Specifications: Power Requirement: BUG-6350 BUG-6352 BUG-6354 Weave Speed: Dwell: Weave Width: Steering: 120 VAC/50-60 Hz 240 VAC/50-60 Hz 42 VAC/50-60/1 4-200 ipm (102-5100 mm/min) 0-3 seconds each side 0-2'' (0-50 mm) 4'' - 2'' (100-50 mm) each side of center 5.50''L x 3.00''W x 4.00''H (139 x 76 x 120 mm)
Net Weight of System: 21 lbs. (9.5 kg) Weaver Dimensions:
Steering Knob Oscillation Speed Control Oscillation Width Control
Left Dwell Weld Trigger Contact Switch
Right Dwell
Pattern Selection Power Switch
Weld Contact Cable
A QUALITY PRODUCT FROM BUG-O SYSTEMS A DIVISION OF WELD TOOLING CORPORATION
3001 WEST CARSON STREET PITTSBURGH, PA USA 15204-1899 Weld Tooling Corp. ROM 1:16 Litho. in U.S.A. LIT-PE-BRO-1007
FLAME CUTTING HANDBOOK
BUG-O SYSTEMS
BUG-O Systems Kits are assembled from modular components. Each kit was originally an adaptation to meet an actual problem. The concept is both practical and economical, and is quickly and easily adapted on the job site. Initially developed to carry cutting torches in a precise work path, the primary aim of the BUG-O System is movement at controlled speed and direction in any position. The secondary function is to provide suitable holding or clamping devices to make BUG-O integral with both the workpiece and the cutting or welding tool. BUG-O is more than a flame cutting system- its a revolution in welding procedures. Ingenious customers have developed hundreds of ways to cut time and costs by putting this system to work for them, and most of the these applications have saved the cost of the unit on the first job. With BUG-O Systems you can double your welding production! The nucleus of the BUG-O System of modular path and rate control components is the BUG-O. It is a self-propelled multipurpose carriage and rail system with infinitely variable speeds. A steel pinion meshes with a machine-cut steel rack to provide a positive drive. The BUG-O is locked onto a rail, which is mounted on the work. The BUG-O unit is suitable for use with the most advanced electric welding processes. It is also the practical way to carry any process requiring precision movement; in applications such as gouging, spraying, guiding ultrasonic inspection and others.
PRECISION HOLE BORING, BEVELING AND WELDING

HOB-O cuts, bevels or welds in any position.. any plane or angle. Carry the tool to the work. HOB-O weighs only 30 lbs. (18.6 kg) can be moved and placed in minutes by one man. Powerful magnets lock it to the workpiece . exactly where you want it. Easily adjustable, the HOB-O flame bores holes from 1'' to 8'' (25-200mm) diameter, inside the machine and 14-1/2'' to 48'' (368-1220mm) diameter, outside. Self-propelled, it has an infinitely variable speed control to suit any application. HOB-O gives you the precision of drilling the speed of flame boring and the convenience of a portable tool costing less than one 4'' high speed drill bit.
A DIVISION OF WELD TOOLING CORPORATION 3001 WEST CARSON STREET PITTSBURGH, PA USA 15204 PHONE: 1- 800-245-3186 www.bugo.com FAX: 1- 412- 331- 0383
PREFACE
This booklet has been prepared to show how to operate and maintain Gas Cutting equipment. Specifically, it shows how to set up, light, set travel speed and position the Cutting Torch for a quality cut.
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
INTRODUCTION GAS CUTTING OF FERROUS (CARBON STEEL) METALS

Gas cutting is a process of preheating carbon steel to its combustion temperature, then burning it rapidly by means of a regulated jet of oxygen. A cutting torch is used for this operation. The process is primarily a chemical one. It is based on the chemical relationship of oxygen to iron metals that have been heated to a temperature of 1400 to 1600 F (760 to 871 C). Only the metal within the direct path of the oxygen jet is affected. In cutting, a kerf is formed. This is a narrow slit having uniformly smooth and parallel walls. A skilled workman using a BUG-O and a machine cutting torch can maintain the following tolerances with respect to squareness and straight alignment of the cut surface: 1/32nd of an inch (.79mm) on plate thickness up to 4 inches (100mm) and 1/16th of an inch (1.58mm) on plate thicknesses from 4 to 12 inches (100 to 300 mm). In actual gas cutting, the iron or steel removed from the kerf is not entirely burned or consumed by the oxygen. About 30 to 40 percent of the metal is washed out of the cut as unconsumed or metallic iron due to the eroding effect of the oxygen jet.
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
SAFETY INSTRUCTIONS
EVERY TIME a machine cutting torch is used the following safety and operation precautions MUST BE PRACTICED! Deviation from the following safety and operation instructions can result in fire, explosion, damage to the apparatus or injury to the operator. 1. Inspect the inlet connections, valves, and torch head 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 OIL OR GREASE IS PRESENT! Have your manufacturers repair center clean the torch or repair any damage. 2. Inspect the torch head. The tapered seating surface must be in good condition. If dents, burrs or burned seats are present, the seat must be resurfaced. If the torch is used with poor setting surface, backfire or backflash may occur and damage the equipment. 3. Select the required size and type of cutting tip. Inspect the tip seating surface for damage. REMEMBER- these seating surfaces prevent premature mixing of gases that can cause fire and explosions. If the tapered seats on the tip are damaged, DONT USE IT! Inspect the preheat and cutting oxygen holes. Spatter can stick on or in these holes but can be removed with a tip cleaner. 4. Insert the tip in the Cutting Torch head and tighten securely. 5. Adjust the regulator delivery pressures according to the size and type of tip being used. 6. IMPORTANT: Always purge out the cutting oxygen passages by opening the cutting oxygen valve (at least five seconds before lighting the torch.) Open the fuel valve approximately one-half turn and ignite the gas with a spark lighter. Adjust the fuel valve until the flame clears the end of the tip about inch (13mm), then reduce slightly to return the flame to the tip.
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7. Slowly open the preheat oxygen valve until a neutral flame is established (a sharp inner cone). SPECIAL NOTE FOR TWO HOSE MACHINE TORCHES ONLY: After the neutral flame has been established as described, open the cutting oxygen valve. Note that the preheat flames change slightly from neutral to a carburizing flame with a feather. With the cutting oxygen flowing, adjust the preheat oxygen valve until the preheat flames are again neutral. 8. If you experience a backfire or backflash (a hissing sound when the flame is burning inside the cutting torch) IMMEDIATELY turn off the preheat oxygen valve, then shut off the torch fuel valve. Allow the cutting torch to cool before attempting to re-use it. If trouble persists, call your manufacturers repair center. 9. WHEN YOU FINISH YOUR CUTTING OPERATION: a. First shut off the oxygen preheat valve, then shut off the torch fuel valve. If this procedure is reversed, a pop may occur. The pop throws carbon soot back into the torch and may 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 oxygen regulator counter-clockwise until the adjusting spring pressure is released. e. Open the torch fuel valve and release the pressure 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 is strongly recommended to reduce the possibility of mixing gases in the hoses and regulator. Mixed gases will rapidly burn once the torch is lighted. These combustible gases can explode in the hoses, regulators or cylinders, resulting in serious injury to the operator.
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INSTRUCTIONS AND PRECAUTIONS FOR GAS CUTTING

A. SAFETY 1. Before handling or using any flame cutting equipment, understand and apply at all times the safe-practice instructions in this manual. a. b. Be sure work areas are free of flammable and combustible or explosive materials. Always wear protective personal equipment. (1) A close-fitting hat with hair tucked in. (2) Flame retardant clothing. Shirt- collar buttoned close around neck; pockets with flaps buttoned; full length sleeves, fastened at the wrist. Trousers- must cover top of shoesno 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 15 inches (203 to 381 mm) long is generally used on BUG-O machines. 3-hose torches are recommended for heavy cutting on steel thicknesses up to 36 inches (914mm). Torch valves, bodies and racks should be in good condition and have no gas leaks. (If a torch is damaged in any way, it should be sent to the supplier for repair.)
b.
c.
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2. HOSES a. Use inch (6.4mm) twin and single hose (red for gas and green for oxygen) with B size fittings. The (notched) fitting is for gas and the smooth fitting is for oxygen.
b.
Fitting should be clamped tightly so there will be no gas or oxygen leakage. However, avoid stripping the threads of the clamps and fittings. Hoses with kinks, burned spots or small cuts are very dangerous, and will affect the quality of the cut. If hose is damaged, should be spliced or scrapped. NEVER USE TAPE TO STOP A LEAK. It is dangerous, and could cause a fire or explosion which could seriously injure the operator or others. For a three-hose torch, the oxygen hose has a 3/8 (10mm) to '' (13mm) inside diameter to allow a greater volume of oxygen flow for cutting. The 50-foot (15.2m) standard length of hose should be used. Additional lengths of 25 feet (7.6m) can be added. It is important for the operator to know the exact total length of hose connected to the torch so the regulator gage can be set with the correct pressure. Increase oxygen pressure 5 pounds (3515 Kg/M) and gas pressure 1 pound (703 Kg/M) for each additional 25 feet (7.6m) of hose.
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c.
d.
e.
f.
3. REGULATORS a. Regulators are reducing valves used to reduce the high supply pressure to that which is desired. The gage on the regulator indicates the pressure at which gas is supplied to the torch.
b. The Regulators should be handled with care. Damaged regulators will give inaccurate pressure readings which will affect the quality of the cut. The needle should read 0 before pressure is applied. c. Grease or oil should never be used on regulator fittings because they can cause burning or explosion of lines. d. Gas and oxygen outlets should be blown out to remove grit or dust, before attaching to the regulator. e. If needle on gage appears to be stuck when pressure is applied, tap lightly with your finger. If this does not cause the needle to move, the gage should be sent to the repair department.
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4. TIPS a. The proper care of a tip will allow many feet of burning before it wears out.
b. Tip cleaners should be used periodically to insure that holes are not plugged and that there are no burrs to deflect the gas. c. The seat of the tip should be smooth to make a tight seal. If the seat is damaged, it will have a nick or nicks. This allows gas to escape and produces 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 placed in special holding racks.
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5. BUG-O SYSTEM (PORTABLE) a. The BUG-O should be in good condition so it will travel smoothly and at a steady speed.
(1) Check the wheels to make sure there are no burrs or spatter stuck to them. They should be smooth and clean and rotate freely. (2) The speed adjustment knob should turn smoothly to allow speed-up or slow-down from one setting to the other. (3) The track ways or grooves should be periodically brushed clean. This removes particles that could obstruct the wheels and ruin the cut. The track should be straight with no burrs or nicks in the grooves. (4) If the BUG-O or track is damaged or does not work well, have it repaired.
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(5) The gears in the machine may eventually become worn, permitting excessive backlash. With the machine on the track, and the clutch engaged the BUG-O should not move more than 1/8 inch (3mm) back and forth when hand pressure is applied in these directions. C. START UP PROCEDURE 1. HOOKING UP a. Secure cylinders in upright position. Blow out gas and oxygen supply station outlets to remove any dust and grit particles. b. Attach regulators to outlet. Finger tighten connections. Use a wrench to make snug. Be careful not to strip the threads. c. Attach hoses to regulators. Finger tighten connections. Use a wrench to make snug. Be careful not to strip the threads. d. Place BUG-O in approximate position to make cut. e. Insert torch into holder on the BUG-O. f. Attach hoses to the torch. Finger tighten connections. Use a wrench to make snug. Be careful not to strip the threads.
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g. (1) Valves on torch should be closed. (2) Turn valve on regulators counterclockwise until it moves freely so no pressure will register. (3) Open acetylene cylinder valve turn. Open oxygen cylinder valve all the way. (4) Slowly open gas and oxygen valves on torch and turn wide open. (5) Slowly turn in regulator valve until desired pressure is reached on gas and oxygen. (See torch manufacturers tables for recommended oxygen and gas pressures.) (6) Close valves on torch. 2. BURNING TIPS a. b. c. Select tip (see torch manufacturers table for recommended tip sizes). Inspect tip. Use tip cleaners to insure holes are clean and square on used tips.
3. BUG-O a. b. c. Brush off dust/dirt form track grooves, work surfaces and magnet plates. Place rail on work parallel to cut-line. Position torch over cut-line. Adjust speed to approximate burning speed.
(1) Set indicator on 20, 30 or 40 on dial. (2) Place torch tip inch (6.4mm) above plate and mark with soap stone. This is the starting point. (3) Using the second hand on a watch, start the travel machine when the second hand is on 12.. Let the machine travel for one minute, then stop by throwing the switch.
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(4) Using a soap stone, mark the spot where the tip stopped. Measure the distance between the two marks-This is inches (mm) per minute travel. (5) Repeat a different dial positions to establish correct speed settings. (6) See tables for recommended travel speed settings. 4. LIGHTING THE TORCH AND SETTING THE PREHEAT FLAME a. b. c. d. e. f. Adjust cutting goggles over eyes. Put on gloves. Open gas valve turn. Open preheat oxygen valve 1/8 turn. Put striker at tip end and light torch. Adjust preheat flame to neutral by turning oxygen and gas valves one at a time and watching the blue flame cones for sharpness.
5. ADJUSTING THE PREHEAT FLAME FOR MAKING A SQUARE EDGE CUT a. A simple rule to follow when a square edge is desired is to have the preheat flame come out as a whisper or a shoooosh rather than having a rush of gas and oxygen come out with such a force that the preheat flame has a shrill whistling sound. The whispering preheat flame has just enough heat to keep the leading edge and sides of the cut barely melting. Little sparkles will be present around the top surface of the hole which indicates that a correct preheat flame is used to give a square edge to the top of the cut. The whistling preheat flame has too much heat that keeps the leading edge and sides melting and will cause a rolled edge to the top of the cut.
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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 is too cold. If edge starts to melt too much (a fluid puddle the same diameter as the tip end), the preheat flame is too hot. c) To adjust the too hot preheat flame (so that just enough heat is put into the plate to have a square edge on top of cut):
2)
(1) Both the oxygen and gas valves must be slowly closed to reduce the preheat flame. First, close the oxygen valve slightly until the blue flame gets longer. Then close the gas valve until the blue flame shortens to the correct original length. (2) Watch plate edge until fluid puddle is approximately the size of the torch tip. d. It is better to start with a cold preheat flame and slowly increase the oxygen and gas flow until a small molten fluid puddle appears on the starting edge of the plate. 6. START CUTTING (See para. C for detailed procedure for making a starting hole.)
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a. With acetylene, natural of propane gas the tip end should be placed about 1 to 3 times the length of the blue flame cones away from the plate surface (about 1/8 or 3/8'' [3 or 10 mm] high). For MAPP gas the tip should be maintained from to 3/4'' (6 to 19mm) from the plate. b. The torch should be square with the plate. Do not tilt torch.
c. The top of the plate should be preheated for a distance of 1-1/2'' to 2'' (38 to 50mm) by moving the torch slowly back and forth over the area. d. Bring torch to edge of plate so of the preheat flame is touching the plate. e. Hold at this position until a molten puddle starts to form (a little extra preheat oxygen sometimes is necessary to start this action and 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 travel along plate and immediately open the cutting oxygen valve to start cut.
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h. If travel is not started immediately, the bottom 1/3 of the cut will pocket and gouge due to the expanding oxygen gas and the molten slag, the same as too slow a travel speed would make. The top of the cut should always lead the bottom of the cut even if its only 1/16 (1.6mm) on an inch. This prevents the opening or kerf from being clogged with slag. It is better that the cut be made a little on the fast side, which would give a rippled wave appearance, rather than on the slow side which would require repairing or reburning. 7. OBSERVING THE CUT a. Minor adjustments may have to be made to insure good smooth cut. (1) The high quality cut is shown in Sketch #1. Top edge is square, face smooth, side scale pulls away from the sides, bottom slag comes off clean with a little tap, torch tip height and travel speed is correct.
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(2) In sketch #2 the top edge has a roll. Too hot a preheat flame has melted away the edge and rounded the corners. To avoid this, the preheat flame must be reduced by slightly closing the preheat oxygen valve and the gas valve. Keep repeating this procedure until edge cut is square.
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(3) Gouges or pockets have formed at the bottom or 1/3 of cut shown in Sketch #3. This was caused by using too high a pressure on the cutting oxygen or too slow travel. Pressure should be reduced or travel speed increased. Excess oxygen will expand and gouge the hot area of burn towards the bottom of the cut.
D. PROCEDURES FOR MAKING A STARTING HOLE 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 a regulator setting of 80 to 85 PSI (KG/M). b. The pre heat flame should be set a little hotter than for the normal cut to get the surface heated and melting faster.
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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 a molten puddle from the preheat flame, the cutting oxygen valve is opened and the torch raised to 1-1/2 to 2'' (38 to 50mm) above the surface to prevent the molten metal from clogging the cutting nozzle or tip. e. CAUTION: The torch holder should be firm without play, so that the torch will not vibrate during the raising motion. f. As soon as the material is pierced, lower torch to cutting position (3/8'' to '' 10mm-13mm) and start carriage travel.
E. OBSERVE THE CUT BEING MADE In this series for sketches, a correct cut as well as undesirable cuts and their causes are illustrated. 1. This sketch shows the result of using correct cutting techniques. The face of the cut is flat and regular, and the draglines are smooth, uniform and practically vertical. This is an excellent surface which can be welded without machining.
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2. The travel speed was a little too fast in this cut. This is shown by the angle (or rake) of the dragline. The surface of such a cut is rippled but reasonably smooth. It required a minimum of grinding to be welded without machining.
3. In this cut, the travel speed was a little too slow. This caused an accumulation and sticking of molten slag which resulted in the irregular surface. Gouging and pockets such as these will have to be built back by welding. They must then be machined or hand ground before the cut surface can be used as a proper weld joint.
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4. The torch was too far from the work in this cut. It produced excessive melting at the top edge of the cut. A thin layer of scale will stick approximately 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 chipped to 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 the preheat flame to burn inside the top portion of the cut. This produced an unstable cutting action and resulted in the rough (small pockets or gouges) edges at the top quarter of the cut. Areas such as these must be machined or ground to make them suitable for welding.
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6. Too much pressure on the cutting oxygen produces a cut of this type. The combustion and melting of the steel always follows the pattern of the oxygen jet. Excessive or high oxygen pressure causes undue expansion of the gas as it leaves the torch tip. This results in excessive turbulence which gives the distorted and unsightly cut shown. Scale is thick and sticks to the surface. Top portion of cut is undercut. Slag is stuck to the bottom of the cut. A cut such as this also must be machined or ground to make it suitable for welding.
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7. High preheat flame was used in this cut. The top surface is melted and rolls over the edge as small globs of metal. This cut must be machined of ground to make it suitable for welding.
8. A dirty or slag-clogged tip was used in this cut. It caused the oxygen stream to lose its parallel form. As a result, the surface of the cut is no longer clear and regular. This surface will require machining or grinding to make it suitable for welding.
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F. BEVEL CUTTING In this series of sketches a 3-inch (76.2mm) carbon steel plate was beveled to show what can happen when proper and improper techniques are used in Bevel Cutting. More preheat is required for beveling than for vertical cutting. Thats because the angle of the tip to the plate surface causes the heat to bounce off. When selecting a tip for Bevel Cutting, the depth of the cut rather than just the plate thickness should be considered. The PAN-1000 Panograph Torch Floater is recommended for bevel cutting on both flat and wavy material. The Panograph Torch Floater maintains constant nozzle-to-work distance which assures a uniform bevel!
30
1. This section is uniformly smooth on edges and surface and represents a quality cut.
31
2. This section is very bad. (a) Very high preheat has melted and rolled the top edge. (b) Travel speed was too slow causing gouges and slag sticks to the bottom of the cut.
3. This section is slightly cupped just below the top edge because of excess oxygen pressure. The slight beading along the top edge indicated that a little too much preheat was used.
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CUTTING NOTES:
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MACHINE CUTTING TIP CHART (Fill in figures from torch manufacturers literature.)
PLATE THICKNESS CUTTING O2 PRESSURE
FUEL GAS PRESSURE
IN.
1/16 1/8 1/4 3/8 1/2 3/4 1
MM.
2 3 6 10 13 19 25
1-1/4 32 1-1/2 38 2 3 4 5 6 7 8 9 10 11 12 51 76 102 127 152 178 203 229 254 279 305 2-1/2 64
WELD TOOLING CORP. 2007

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KERF WIDTH
TIP SIZE
CUTTING SPEED
Powerful Solutions For Welding And Cutting Automation
CNC Cutting Machine Burns Virtually Any Shape Or Pattern.

Download NC or CAD drawings into the Programmable Gantry System.
The Programmable Gantry System provides coordinated motion in two axis, using three drives: two synchronized motors drive the main carriages along the X-axis, and one drives the Y-axis crossbeam carriage. The machine can be easily programmed to repeat any contour or pattern for either cutting or welding 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 starts, stops, delays, repeats and rapid traverse. Ten programs can be stored in machine memory at any one time. A PC option is available which includes a connecting cable and a software program. With this, the operator can create any number of shapes on a PC and store them on disk. Selected shapes can then be downloaded into the machine as needed. The Programmable Gantry System is shipped in major subassemblies that are easy to assemble and install on your burning table.
PATENTS WORLDWIDE
280 TECHNOLOGY DRIVE CANONSBURG, PENNSYLVANIA 15317-9564 USA PHONE: 1- 412-331-1776 http://www.bugo.com FAX: 1- 412-331- 0383
Programmable Gantry System

The CNC Gantry System is a two-axis gantry that has dual side synchronized drives running on parallel tracks, and a second axis drive carrying a cutting torch that runs on a crossbeam. It can be used for flame or plasma cutting, or for welding, of a variety of shapes which are programmed and stored in memory. The machine memory stores ten different programmed shapes, numbered 0 to 9. At any time, one of these shapes is current, and will stay current even when the power is shut off and turned back on, until the shape number is changed by the operator. All programming is done with the handheld terminal provided, or by downloading from a PC using the PC option. The terminal plugs into a connector on the control box, and can be removed at any time. It is not needed to run the machine. Shapes or patterns are constructed using segments. To do this, select the type of segment required and its quadrant from the programming chart, and enter it on the terminal keypad. Any one shape can have up to 50 segments. Other functions such as weld/oxygen, on/off, time delay, or repeat another shape a number of times, also count as one segment each if used.
Handheld Terminal Functions: 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 whole shape does not have to be re-entered. C. CHANGE SHAPE NUMBER; press "C" on the terminal to change the current shape number. The program switches to the new number in memory, and to whatever 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 each segment one by one each time you press enter. E. END OF SEGMENT SLOWDOWN; press "E" to set the 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.
BUG-O Ready
The different types of segments that can be loaded into the machine are as follows:
Clockwise 90 Clockwise Partial Arcs
Counter Clockwise 90
Counter Clockwise Partial Arcs
X or Y Axis
Inclined Lines
Other functions besides the moves shown above are: Weld Contact/Solenoid On/Off, Pause, Delay, Repeat another shape, Full ellipse and Rapid Traverse.

Operation:
When the machine is plugged in and the power turned on, this is the reference, start or home position. There are three options (the handheld terminal is not needed for the first two): 1. MOVE: To change the start position, push the STOP/PAUSE button (A), move the machine manually to the required position using toggle switches (B) and (C), and push the reset button (D). 2. RUN: Set the speed knob (E) and push the START/RUN button (F) to cut/weld a shape. 3. PROGRAM: The programming operation requires the use of the handheld terminal or downloading from a PC.
A F
Gantry Control Box

C
COMPUTER SOFTWARE
The gantry 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 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 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.
3
Technical Data:
Power Requirements: Travel Speed: Maximum Segment Dimension: PGS-1000-_*120 VAC/50-60 Hz/1 PGS-1002-_*240 VAC/50-60 Hz/1 4-80 in/min (100-2000 mm/min) 72" (1800 mm) Within Limits of Travel
Minimum Dimension Increment: Inches: 0.01" Metric: 0.1 mm Delay Increment: Maximum Delay: 0.01 seconds 99.99 seconds
* Available in 3 Standard Sizes: 8, 10 and 12 ft. PGS-100_-8 Actual C to C is 96.5'' (2451 mm) L L PGS-100_-10 Actual C to C is 120'' (3048 mm) L L PGS-100_-12 Actual C to C is 143'' (3632 mm) L L

Features:
ENCODER ENCODER
WEST DRIVE
EAST DRIVE
CARRIAGE 36" (914 mm)
CARRIAGE 36" (914 mm)
HANDHELD PENDANT CABLE CARRIER SUPPORT CABLE CARRIER
HEAVY DUTY ALUMINUM RIGID RAIL
XXY CONTROLS
ENCODER
FACE RAIL COLUMN 18" (457 mm) CARRIAGE 12" (305 mm) CROSS DRIVE HEAVY DUTY RACKING GROUP
A QUALITY PRODUCT FROM BUG-O SYSTEMS 280 TECHNOLOGY DRIVE CANONSBURG, PA 15317-9564 USA ROM 1:16 A DIVISION OF WELD TOOLING CORPORATION Weld Tooling Corp. Litho in U.S.A. LIT-PGS-BRO-1108
DC General Welding Kit

Features:
A
A. B. C. D. E. F. BUG-O DC IV Cable Mounting Assembly Machined Rack Welding Group Heavy Duty Rigid Rail Magnet Bar Swivel w/Release Tool Kit
B E C D
BUG-1950 Includes: 1 BUG-0343
Technical Data:
Power Requirements: BUG-1950 BUG-1951 BUG-1952 120VAC/50-60/1 240VAC/50-60/1 42VAC/50-60/1
DC IV General Welding Kit 120 VAC (120/50-60/1) BUG-O DC IV *1.5-30 ipm (38-760 mm/min) Includes: 1 BUG-9444 Tool Kit Cable Mounting Assembly Machined Rack Welding Group Heavy-Duty Rigid Rail 8' (2.37 m) Heavy-Duty Rigid Rail 4' (1.18 m) Swivel Magnet Plate w/Release DC IV General Welding Kit 240 VAC Same as above except with BUG-0443 DC IV General Welding Kit 42 VAC Same as above except with BUG-0543
Travel Speed: Load Capacity:
*1.5-30 ipm (38-760 mm/min) 50 lbs (22.7 kg) Vertical 120 lbs (54.4 kg) Horizontal 60 lbs. (27.3 kg)
1 BUG-2975 1 BUG-5440 1 ARR-1080 1 ARR-1085 5 ARM-2325 BUG-1951 BUG-1952
Net Weight of Kit:
Shipping Weight of Kit: 79 lbs. (36 kg)
*NOTE: With the bypass pinion installed, the DC IV will have an increased speed range (8-160 ipm: 200-4000 mm/min), however, vertical load carrying capability 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 ForwardOff-Reverse Travel Switch and Weld Contactor Switch.
Available Separately:
BUG-9865 Stepping module bolts to DC Drive. When limit switch is tripped, module provides adjustable-timed power (0-3 seconds) to the DC Drive. BUG-2205 Carriage Trailer with Hitch
BUG-9770 Limit Switch Kit Will stop the drive at end of travel.
280 TECHNOLOGY DRIVE CANONSBURG, PENNSYLVANIA USA 15317-9564 PHONE: 1- 800-245-3186 http://www.bugo.com FAX: 1- 412- 331- 0383
DC Heavy-Duty Welding Kit

C
Features:
A B F
A. B. C. D. E. F. BUG-O DC IV Cable Mounting Assembly H.D. Welding Group Heavy Duty Rigid Rail Magnet Bar Swivel w/Release Tool Kit
E D
Technical Data:
Power Requirements: BUG-1950-HD 120VAC/50-60/1 BUG-1951-HD 240VAC/50-60/1 BUG-1952-HD 42VAC/50-60/1 Travel Speed: Load Capacity: *1.5-30 ipm (38-760 mm/min) 50 lbs (22.7 kg) Vertical 120 lbs (54.4 kg) Horizontal 60 lbs (27.3 kg) 1 BUG-2975 1 BUG-5275 1 ARR-1080 1 ARR-1085 5 ARM-2325 BUG-1951-HD Shipping Weight of Kit:79 lbs (36 kg) BUG-1952-HD BUG-1950-HD Includes: 1 BUG-0343 DC IV Heavy Duty Welding Kit (120/50-60/1) BUG-O DC IV *1.5-30 ipm (38-760 mm/min) Includes: 1 BUG-9444 Tool Kit Cable Mounting Assembly H.D. Welding Group Heavy-Duty Rigid Rail 8' (2.37 m) Heavy-Duty Rigid Rail 4' (1.18 m) Swivel Magnet Plate w/Release DC IV General Welding Kit-HD 240 VAC Same as above except with BUG-0443 DC IV General Welding Kit 42 VAC Same as above except with BUG-0543
Net Weight of Kit:
*NOTE: With the bypass pinion installed, the DC IV will have an increased speed range (8-160 ipm: 200-4000 mm/min), however, vertical load carrying capability 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 ForwardOff-Reverse Travel Switch and Weld Contactor Switch.
Available Separately:
BUG-9865 Stepping module bolts to DC Drive. When limit switch is tripped, module provides adjustable-timed power (0-3 seconds) to the DC Drive.
BUG-9770 Limit Switch Kit Will stop the drive at end of travel.
BUG-2205 Carriage Trailer with Hitch
A QUALITY PRODUCT FROM BUG-O SYSTEMS 280 TECHNOLOGY DRIVE CANONSBURG, PA USA 15317-9564 A DIVISION OF WELD TOOLING CORPORATION Weld Tooling Corp. ROM 1:16 Litho. in U.S.A. LIT-GW-BRO-0108
BUG-O ALL TIME GIRTH WELDERS

Self-propelled welding system for field storage tank welding.
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

Features:
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. 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.
Specifications
Model BGW-1000 Single Side Weld BGW-2000 Double Side Weld BGW-1000-LNG Single Side Weld Double Shell Cryogenic Storage Tanks Top Down Constructed Storage Tanks Application Tank Diameter Welding Thickness Travel Speed
BGW-1000 shown above.

Shell Plate Height 6'-10' (1.8 - 3.0 m) Min. 15' (4.5m) 5/16''-1 9/16'' (8-40mm) 4-114 ipm (100-2900 mm/min) 7'-13' (2-4 m) 6'-10' (1.8-3.0m) Wire 3/32'' (2.4mm) 1/8'' (3.2mm) Approx. Weight 2,094 lbs. 950 kg 3,968 lbs. 1800 kg
Conventional Storage Tanks
2 x 1/16" (2 x 1.6mm) (Tinytwin Arc)
1,984 lbs. 900 kg 2,425 lbs 1100 kg
BGW-1000-D Single Side Weld
A QUALITY PRODUCT FROM BUG-O SYSTEMS 3001 WEST CARSON STREET PITTSBURGH, PA USA 15204-1899 A DIVISION OF WELD TOOLING CORPORATION Weld Tooling Corp. Litho in U.S.A. LIT-GIRTHW-BRO-0707 ROM 1:16
Produce machine quality welds and cuts in any plane or position with a portable drive on magnetic track.
The versatile GO-FER III Kits make straight line welding and cutting more efficient and economical.
Bug-O Systems
Affordable Track Cutting and Welding Systems.
GO-FER III OXY-FUEL KIT / GOF-3250-OX

The GO-FER III Oxy-Fuel Kit is used for straight line cuts and weld preparation beveling. The kit comes complete with the exception of a torch. The Bug-O Torch Holder will accept any standard 1-3/8" (35 mm) diameter machine torch with a 32 pitch gear rack. The Quick-Action Gas Manifold mounted to the rear of the machine is used as a strain reliever for the torch and also gives the operator the ability to turn on and off the pre-heat gases without having to readjust the gas flow of the torch.
Twin Hose Assembly 32" (812 mm)
Quick-Action Manifold Convenient Carrying Handle Heavy Duty 8' (2.37 m) Rigid Rail
Positive Rack and Pinion Drive
Tool Kit Torchholder Assembly
Spacer Bar Assembly (2)
On/Off Magnet Plate Assembly (2)
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 Assembly 2 ARM-2505 Spacer Bar Assembly 1 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 the following sub assemblies: 1 GOF-3025 2-Hose Manifold 1 CIR-1010-3 Twin Hose Assembly 1 BUG-5451 Rackholder with Short Handle 1 PAN-1015 Rack 22.62" (574 mm) 1 BUG-5462 Right Angle Clamp 1 BUG-5188 Torchholder Assembly 1 BUG-9444 Tool Kit 2
GOF-3252-OXSame as above except with 240 VAC GO-FER III GOF-3242-OX GOF-3254-OXSame as above except with 42 VAC GO-FER III GOF-3244-OX Net Weight of Kit: Shipping Weight of Kit: 39 lbs. (17.7 kg) 50 lbs. (22.7 kg)
GO-FER III WELDING KIT / GOF-3250-WD

The GO-Fer III Welding Kit is an economical straight-line welding travel carriage. The all position Fits-All Clamp will accept and accommodate any hand held welding gun and allow the operator to position the torch at any angle they desire. The racking group allows for in process torch adjustment for the vertical and horizontal plane. A built in torch trigger contactor allows the operator to activate the wire feeder from a switch on the top of the Drive unit.
Cable Anchor
Contactor / Cable Anchor
Convenient Carrying Handle Heavy Duty 8' (2.37 m) Rigid Rail Positive Rack And Pinion Drive Tool Kit
Y-Z Racking Group w/Fits-All Clamp Spacer Bar Assembly (2) On/Off Magnet Assembly (2)
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 Assembly 2 ARM-2505 Spacer Bar Assembly 1 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 the following sub assemblies: 1 BUG-5485 Contactor / Cable Anchor 1 BUG-5451 Rackholder with Short Handle 1 PAN-1015 Rack 22.62" (574 mm) 1 BUG-5462 Right Angle Clamp 1 BUG-5188 Torchholder Assembly 1 BUG-9444 Tool Kit 1 BUG-5166-8 8" Tube Rack w/Clamp 1 BUG-2708 Fits-All Clamp 1 BUG-9180-4 Rod 7/8" x 4" 1 CON-1020 Swivel Clamp 3
GOF-3252-WD
Same as above except with 240 VAC GO-FER III GOF-3242-WD Same as above except with 42 VAC GO-FER III GOF-3244-WD 39 lbs. (17.7 kg) 50 lbs. (22.7 kg)
GOF-3254-WD
Net Weight of Kit: Shipping Weight of Kit:
GO-FER III PLASMA KIT / GOF-3250-PL

The G0-Fer III Plasma Kit is specifically designed to work in conjunction with a plasma machine. Its travel speed of 8-100 inches per minute (203-2640 mm/min) and its direct rack and pinion drive make it ideal as an all position portable cutting machine for a plasma torch. The torch holder will accept any standard 1-3/8" (35 mm) diameter machine torch that has a 32 pitch gear rack. A built in trigger contactor for initiating the cut makes the GO-FER a convenient self contained package.
Contactor / Cable Anchor
Convenient Carrying Handle Heavy Duty 8' (2.37 m) Rigid Rail Positive Rack and Pinion Drive
Torchholder Assembly Spacer Bar Assembly (2)
Tool Kit
On/Off Magnet Plate Assembly (2) NOTE: A shielded gun and cable assembly must be used to reduce hi-frequency interference. 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 Assembly 2 ARM-2505 Spacer Bar Assembly 1 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 the following sub assemblies: 1 BUG-5485 Contactor / Cable Anchor 1 BUG-5451 Rackholder with Short Handle 1 PAN-1015 Rack 22.62" (574 mm) 1 BUG-5462 Right Angle Clamp 1 BUG-5188 Torchholder Assembly 1 BUG-9444 Tool Kit GOF-3252-PL Same as above except with 240 VAC GO-FER III GOF-3242-PL GOF-3254-PL Same as above except with 42 VAC GO-FER III GOF-3244-PL Net Weight of Kit: Shipping Weight of Kit: 4 39 lbs. (17.7 kg) 50 lbs. (22.7 kg)
GO-FER III ACCESSORIES

GOF-3142 Radius Cutting Attachment: Enables GO-FER III to be quickly changed from a straight line to a circlecutting machine. Size Range: 8" to 96" (203 mm to 2438 mm) diameter.
Panograph Assemblies
Panographs are spring-loaded devices that maintain torch stand-off and compensate for plate surface irregularities.
PAN-1007 Welding Panograph Assembly
PAN-1010 Cutting Panograph Assembly
MUG-1119-32 3-Hose Assembly
BUG-9898 3-Hose Quick-Acting Manifold CIR-1010-3 2-Hose Assembly
GOF-3025 2-Hose Quick-Acting Manifold
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 The addition of these 4 items provides a vertical racking motion for hand held guns.
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.
Rails & Attachments

ARR-1085 4' (1.18 m) Heavy Duty Rigid Rail ARR-1080 8' (2.37 m) Heavy Duty Rigid Rail
AFR-3000 Semi-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.
ARM-2505 Spacer Bar for ARR Rail only.
ARM-2425 Swivel Magnet for AFR-3000 Rail only. 250 lbs. Holding Power
ARM-2500 On-Off Magnet Plate Assembly for ARR Rail only. Holding power 100 lbs. (45 kg) Can be switched on and off for rapid set-up.
Vacuum Systems For Non-Ferrous Metals

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.
ARV-2020 120 Volt/50-60 Hz ARV-2030 220 Volt/50-60 Hz 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. ARV-1080 Vacuum Kit for ARR-1080 8' (203 mm) Rigid Rail. ARV-1085 Vacuum Kit for ARR-1085 4' (102 mm) Rigid Rail.
ARV-1080 Vacuum Kit for AFR-3000 8' (203 mm) Semi-Flex Rail.
A QUALITY PRODUCT FROM BUG-O SYSTEMS 280 TECHNOLOGY DRIVE CANONSBURG, PA USA 15317-9564 A DIVISION OF WELD TOOLING CORPORATION Weld Tooling Corp. ROM 1:16 Litho in U.S.A. LIT-GOFER-BRO-0908
Affordable Automation for Welding, Cutting and 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 B C D E F G BGV-1165 BUG-2708 BUG-3320-8 BUG-3320-15 BUG-5186 BUG-5188 CON-1020 Clamp Block Clamp H.D. Tube Rack 8" (203 mm) H.D. Tube Rack 15" (381 mm) Right Angle Clamp Torch Holder Assembly Swivel Clamp Assembly
A F
G D E
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 B C D E F BUG-3320-15 BUG-3310-8 BUG-5188 BUG-5184 BUG-5182 BUG-5280 H.D. Tube Rack 15" (381 mm) H.D. Tube Without Rack Torch Holder Assembly Tube Clamp Assembly Right Angle Clamp Tube Mounted Rackholder
F A
B D E
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 B C D BGV-1165 BUG-3320-15 BUG-5182 BUG-5188 Clamp Block H.D. Tube Rack 15" (381 mm) Right Angle Clamp Torch Holder Assembly
C B D
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 - PANOGRAPHS

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-1160 H.D. CUTTING PANOGRAPH

A B C D E F G BGV-1165 BUG-3320-8 PAN-1033 BUG-2915 PAN-1140 PAN-1170 BGV-1180 Clamp Block Assembly 3" (74 mm) H.D. Tube Rack Rod Clamp Torchholder Assembly H.D. Spring Tube Assembly Mounting Arm Assembly Clamp Assembly
PAN-1150 H.D. WELDING PANOGRAPH

H I J K L M BUG-3310-8 BUG-5188 BUG-5182 PAN-1145 BUG-2708 CON-1020 H.D. Tube Without Rack Torchholder Assembly Right Angle Clamp Swivel Wheel Assembly Clamp Swivel Clamp Assembly
E I J
L I J G F H K
K G A B
Net Wt: 10 lbs. (4.5 kg) Shipping Wt: 12 lbs. (5.4 kg)
A BUG-3340 CORNER FOLLOWER
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. A B C D E F G H I J K L M BGV-1165 BUG-3320-8 BUG-2708 PAN-1140 PAN-1170 BGV-1180 BUG-3310-8 BUG-5188 BUG-5182 CON-1020 BUG-3265 MUG-1515 BUG-5274 Clamp Block Assembly 3" (74 mm) H.D. Tube Rack Clamp H.D. Spring Tube Assembly Mounting Arm Assembly Clamp Assembly H.D. Tube Without Rack Torchholder Assembly Right Angle Clamp Swivel Clamp Assembly Spatter Guard Assembly Collar 7/8'' (22.2m) V Wheel Assembly
E J L G
D I
K, M C
F A B
Net Wt: 11 lbs. (5.0 kg) Shipping Wt: 13lbs. (5.9 kg)
NOTE: Drawings are for part numbers only! For actual set up see instructions provided with product. 2
HEAVY DUTY TOOL POSITIONING SYSTEM - ASSEMBLIES

For those who wish to build their own Heavy Duty Rack System, the following parts are available:
At 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. Standard Lengths Available (Specify Length) 8" (203 mm) 15" (381 mm) 24" (609 mm) 30" (760 mm) 44" (1120 mm)
BUG-3320-_" (Specify Length) H.D. Tube Rack
At one end of the Heavy Duty Tube Rack are four mounting 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.
BUG-5179 Clamp Assembly
BGV-1180 Clamp Assembly
BUG-5164 Clamp Assembly
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)
BUG-5169-_" (Specify Length) Rack w/Torchholder
BUG-5166-_" (Specify Length) Rack w/Clamp
BUG-5138-_" (Specify Length) Rack w/Clamp
PAN-1140 H.D. Spring Tube Assembly

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).
BUG-5274 "V" Wheel Assembly
PAN-1145 Swivel Wheel Assembly
HEAVY DUTY FOLLOWER ASSEMBLIES mount onto the end of the PAN-1140 and ride on the work surface. The BUG-5274 is for following corners and the PAN-1145 is designed for flat surfaces. 3
HEAVY DUTY TOOL POSITIONING SYSTEM - ACCESSORIES
MUG-1515 Collar 7/8" (22.2 mm)
BUG-5188 Torchholder Assembly w/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]
1-3/8" (35 mm)
Lengths 3" (76 mm) 4" (102 mm) 8" (203 mm) 10" (254 mm) 18" (457 mm)
Lengths 8" (203 mm) 15" (381 mm) 24" (609 mm) 30" (769 mm) 44" (1120 mm)
CON-1020 Swivel Clamp Assembly [for 7/8" (22.2 mm) rod]
BUG-9180_ 7/8" (22.2 mm) Rod (Specify Length) Additional lengths available.
BUG-_3310 1-3/8" (35 mm) H.D. Tube w/o rack. (Specify Length) Additional lengths available.
1-3/8" (35 mm) BUG-5186 Right Angle Clamp
1-3/8" (35 mm)
7/8" (22.2 mm)
1-3/8" (35 mm) BUG-5184 Tube Clamp Assembly 1-3/8" (35 mm)
BUG-5182 Right Angle Clamp
PAN-1164 Spacer Block (used w/limit switch) 1-3/8" (35 mm)
BUG-5245 Welding Gun Mounting Assembly
7/8" (22.2 mm)
1-3/8" (35 mm) BUG-2915 Torch holder BUG-5189 Clamp Block Assembly BUG-5280 Tube Mounting Rackholder
7/8" (22.2 mm) BUG-5462 Right Angle Clamp Assembly [for 7/8" (22.2 mm) Rods
BUG-3320-_H.D. Tube Rack (Specify Length)
Standard Lengths Available (Specify Length) 8" (203 mm) 12" (305 mm) 15" (381 mm) 24" (609 mm) 30" (760 mm) 44" (1120 mm)
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.
BGV-1165 Clamp Block Assembly 3.5" (89 mm)
A QUALITY PRODUCT FROM BUG-O SYSTEMS 280 TECHNOLOGY DRIVE CANONSBURG, PA 15317-9564 USA ROM 1:16 Litho in U.S.A. LIT-HDTPS-BRO-0608 A DIVISION OF WELD TOOLING CORPORATION Weld Tooling Corp.
DC HOB-O HOLE BORER

A Lightweight Precision Hole Borer, Beveler, And Welder That Is Easy To Use!
The DC HOB-O lightweight hole borer is easily carried to the work, and is quickly centered on the workpiece - 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 holes from 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 to protect it from direct flame and heat.
PATENTS WORLDWIDE
DC HOB-O HOLE BORER

Technical Data:
Power Requirements: HOB-2303 HOB-2323 HOB-2313 120 VAC/50-60/1 240 VAC/50-60/1 42 VAC/50-60/1
Dimensions:
Dimensions: Net Weight: Shipping Weight: Speed: Capacity: Drives:
15.06"L x 28.50"W x 10.50"H (383 mm x 724 mm x 267 mm) 30 lbs. (13.6 kg) 35 lbs. (15.9 kg) See Chart See Chart The HOB-O Drive Unit is a solid-state DC drive. Capacities and Speed Ranges (HOB-5100-F 150:1 Ratio)
28.50" (724 mm)
14.00" (356 mm)
15.06" (383 mm)
DIA. INCH
INCH SPEED IPM
DIA. mm
METRIC SPEED mm/min.
1 4 8 15 20 25 30 35 40 45 48
.4-8 1.6-33 3.3-66 6-125 8-160 10-200 12-250 14-290 16-330 18-375 20-400
25 100 200 380 500 600 750 900 1000 1100 1200
10-200 40-800 80-1600 150-3000 200-4000 250-5000 300-6000 370-7500 400-8000 450-9000 500-10000
10.50" (267 mm)
1.68" (43 mm)
Attachments:
The HOB-2080 Blind Area Kit allows you to make smooth accurate cuts while eliminating blind area interference when using the DC HOB-O Hole Borer. It will cut holes from 8" up to 141/2" (203 mm to 368 mm). It is lightweight and attaches easily onto the machine.
1.15" (30 mm)
.18" (5 mm)
Speed range can also be found from formula: Minimum speed per minute = (0.4 x diameter). Maximum speed per minute = (8 x diameter). NOTE: Individual machines may operate at speeds lower than minimum shown in chart.
HOB-1140 Vacuum Base can also be mounted on all HOB-O units for use on nonferrous materials. The vacuum feet adjust to the work surface. Use with ARV1020 Vacuum Pump Kit.
The slug in No. 1, clean scrap, easily handled and readily sold.
A QUALITY PRODUCT FROM BUG-O SYSTEMS Weld Tooling Corp.
LIT- HOB-BRO-698
Return to Index
HOB-O BLIND AREA KIT

Make smooth accurate cuts while eliminating blind are interference.
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 lightweight and attaches easily on the machine. Set the hole radius, 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. PATENTS WORLDWIDE
BLIND AREA KIT

To install a Blind Area Kit on a HOB-O: 1. Remove 3 Ring Bolts (A). Caution be sure to keep Ring Spacers (B) in the correct position over the holes in the Ring Gear. 2. Install new Magnet Ring (C) with 4 CON-1005 Legs (D) facing away from Ring Gear. Reinstall the 3 Ring Bolts (A) through Spacers (B) and tighten securely. 3. Install the 4 Offset Leg and Magnet Foot Assemblies (E). NOTE: These may be rotated to any position and locked using the screw provided (F). 4. Replace original 6" Center Pin with the new HOB-2081 Center Pin (G). 5. Install an adjustable Tip Adaptor BUG-1259 (not supplied) on torch and insert tip. NOTE: This Adaport is required to reach under the HOB-O. 6. Rotate Offset Legs & Magnet Feet (E) to outside of machine and lock. 7. Push Centering Assembly (H) into center of machine and lock. 8. Loosen Knob Screw (J) (which locks pin) to release Center Pin (G). 9. Allow Center Pin (G) to project beneath base of machine and place in center-punch mark. "Ride" machine down to the work on the center pin and be sure it seats firmly on the magnets. The entire machine is now centered. Do not hammer or you will knock out the alignment. 10. Set torch on angle and rotate Adjustable Tip Adaptor so that cutting tip is perpendicular to the work surface adjust to diameter required. 11. Set Rack Stop for diameter required back torch away and ignite. When cut is started, switch on Travel Motor, then move rack slowly against stop. Lock rack.
H J B C G
D A E
Parts List
Quantity Supplied in Kit
A B C D E F G K
FAS-0957 HOB-1042 HOB-1044 CON-1005 CIR-9002 FAS-2553 HOB-2081 ARM-2218
Flt Hd Soc Scr 1/4-20 x 3/4 On Original Machine Ring Spacer Magnet Ring 1 Leg 4 Offset Leg & Magnet Foot 4 Soc Hd Cap Scr 1/4-20 x 1-1/2 4 Center Pin 1 Sleeve-Magnet Cover 4
3001 WEST CARSON STREET HOB-BAK196
Weld Tooling Corp. 1998
Return to Index
Affordable automation that increases production and improves quality.
Light'n Bug
Multi-Purpose Burning & Welding Travel Carriage
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.
280 TECHNOLOGY DRIVE CANONSBURG, PENNSYLVANIA 15317-9564 PHONE: 1- 412-331-1776 http://www.bugo.com FAX: 1- 412- 331- 0383
USA
Light'n Bug
LBG-1000 Oxy-Fuel 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 LBG-1002 LBG-1004 Dimensions: 120V 240V 42V Lightn Bug Oxy-Fuel Lightn Bug Oxy-Fuel Lightn Bug Oxy-Fuel
13.3" L x 7.3" W x 10.5" H (338 mm L x 185 mm W x 267 mm H)
Speed Range: 4-85 ipm (100-2160 mm/min) Net Weight: Shipping Weight: 28.5 lbs (13 kg) 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 LBG-1502 LBG-1504 Dimensions: 120V 240V 42V Lightn Bug Plasma Lightn Bug Plasma Lightn Bug Plasma
LBG-1500 Plasma Cutting Kit
NOTE: A shielded gun and cable assembly must be used to reduce hi-frequency interference.
Light'n Bug
LBG-1200 Welding Kit
A 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 contactor 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 LBG-1202 LBG-1204 Dimensions: 120V 240V 42V Lightn Bug Welding Lightn Bug Welding Lightn Bug Welding
Light'n Bug
Accessories
TRB-1250 72" (183 cm) Rail.
7.00" (178 mm) 6.00" (152 mm)
.313" (8 mm)
72.00" (1828 mm)
LBG-1010 Radius Attachment
LBG-1015 Fillet Attachment 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 The addition of these 4 items provides a vertical racking motion for hand held guns.
LBG-1020 Freehand Steering Attachment
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.
Dimensions:
10.25" 260 mm
13.25" 337 mm
6" 152 mm 7.25" 184 mm

280 TECHNOLOGY DRIVE
CANONSBURG, PA 15317-9564 USA Litho in U.S.A. LIT- LB-BRO-0908
Weld Tooling Corp.
ROM 1:16
BUG-O SYSTEMS 280 Technology Drive Canonsburg, PA 15317 Phone: 412-331-1776 www.bugo.com
Powerful Solutions for Welding and Cutting Automation with Precision and Versatility!
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.
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 the only product in the industry that allows the user to configure one machine for various automated applications, now and in the future!
Future development has been engineered into the system allowing its modular components to be easily upgraded. As tomorrows 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 2
Shown Above - Vertical Weld
Shown Above - Overhead Weld with Pendulum Oscillator
Assembling a Modular Drive System is Easy!
Control Modules
MDS-1002 Straight Line Module
Choose from the options below to fit your application.

MDS-1004 Programmable Stitch Module MDS-1005 Weaver Control Module
Master Drive Units

MPD-1000 MPD-1002 120 VAC 240 VAC
Choose from the following options: Cutting MDS-1050 Machined Rack Cutting Group Welding MDS-1040 Machined Rack Welding Group
Carriages
Weave Welding (Use MDS-1005 Weaver Control Module) WPD-1100 Linear Weaver or WPD-2100 Pendulum Weaver II
FMD-1105 Hi-Flex Carriage
MPD-1065 12" Releasable Carriage
BUG-5910 Tube Carriage
Rails
FMD-1050 Hi-Flex Rail
ARR-1080 Aluminum Rigid Rail 8' ARR-1085 Aluminum Rigid Rail 4'
AFR-3000 Semi-Flex Rail
BRR-1180 Bent Rigid Rail
Attachments
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.
FMDVacuum Cups
FMDMagnets
ARVVacuum Cups
ARMMagnets
Control Modules
A 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
The MDS-1002 Straight Control Module provides direction and speed control for continuous cutting or welding. The MDS-1004 PROGRAMMABLE MODULE provides stitch controls for welding or cutting 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-1002 Straight Module
MDS-1005 Weaver Control Module *MDS-1004 Programmable Stitch Module
*MDS-1004: Program Stitch by distance, automatic stop and/or return to start at the end of the cycle, independent timers for puddle-buildup.
Master Drive Unit
At 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 Hz MPD-1002 240 VAC/50-60 Hz MPD-1004 42 VAC/50-60 Hz
4
MPD-1000 Master Drive Unit
Carriages
Aluminum Rigid and Semi-Flex Rail Carriages
Two 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 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.
Hi-Flex Carriages
Order reference: FMD-1105 Drive Carriage
Bent Aluminum Rigid Rail Carriages
For 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

* Note: see Rails and Attachments brochure for information on BUG-O Systems rails.
Weaver Control Module
The 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 Module Order reference: MDS-1005
Features:
DIGITAL READOUT AMPLITUDE STEERING CONTROL DWELL LEFT
WEAVE SPEED
DWELL RIGHT
SPEED CONTROL DIRECTION SWITCH
MODE SELECTOR SWITCH POWER OFF-ON SWITCH
WELD CONTACT
Digital display is factory set at cm/min; Field convertible to in/min.
MDS-1005 Weaver Control Module
Weld Patterns:
1. 2. 3. 4. 6 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.
WPD-1100 Linear Weaver
The 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 Weaver Order reference: WPD-1100
WPD-2100 Pendulum Weaver
The 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 Weaver Order reference: WPD-2100
PENDULUM MOUNTING GROUP PENDULUM WEAVER ELECTRONICS BOx MASTER DRIVE UNIT
WEAVER CONTROL MODULE
LINEAR WEAVER CROSS ARM
LINEAR WEAVER GUN MOUNTING GROUP
WEAVER CLUTCH (KNOB ADJUSTMENT) MASTER DRIVE UNIT CARRIAGE CARRIAGE WEAVER CONTROL MODULE PENDULUM GEAR BOx
Features:
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.
Accessories
Racking Groups
There are two machined rack torch mounting groups in the Modular Drive System, one for plasma or oxyfuel cutting and the other for welding.
Machined Rack Cutting Group

Order reference: MDS-1050
Remote Control Cable
Installs 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)
Machined Rack Welding Group

Order reference: MDS-1040
Spacer w/Screws
Provides height required to position racking group for plasma cutting applications. Order reference: PAN-1001
Quick Action Manifold
Allows quick ON/OFF of preset torch and eliminates hose strain. Order reference: MDS-3025 2-Hose MDS-9898 3-Hose Hose Assemblies: CIR-1010-3 2-Hose MUG-1119-32 3-Hose
Universal Limit Kit
Installs 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 Applications FMD-1045 For Hi-Flex Rail Applications (not shown)
Weld Contact Cable

Order reference: MDS-1085 10' MDS-1085-25 25' MDS-1085-50 50'
Extended Mounting Plate
Mounts to front of the carriage for use with dual cutting or welding groups, heavy duty racking, etc. Order reference: MDS-1045
Handle with Cable Anchor

Keeps welding cables and contact wires away from the work surface, eliminating drag. Order reference: MPD-1035
A QUALITY PRODUCT FROM BUG-O SYSTEMS 280 TECHNOLOGY DRIVE CANONSBURG, PA 15317-9564 USA LIT- MDS-BRO-1208 ROM 1:16 Litho in U.S.A. A DIVISION OF WELD TOOLING CORPORATION Weld Tooling Corp.
MODULAR DRIVE SYSTEM PROGRAMMABLE SHAPE MACHINE PACKAGE

Portable Two Axis Shape Machine Cuts In All Positions!
The Modular Drive 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. 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 create your own custom shapes, and store and edit any number of them on disk. Selected shapes can then be downloaded to the machine as needed. The Modular Drive Programmable Shape Machine is compact and portable and can be easily carried throughout your facility or job site. The system can be configured to run on all types of Bug-O rail. 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. PATENTS WORLDWIDE
3001 WEST CARSON STREET PITTSBURGH, PENNSYLVANIA USA 15204-1899 PHONE: 1- 412-331-1776 http://www.bugo.com FAX: 1- 412- 331- 0383
MDS - PROGRAMMABLE SHAPE MACHINE

The MDS 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 20 different programmed shapes. All programming is done with the provided handheld terminal. 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.
Handheld Terminal Functions:

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 current 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. The different types of segments that can be loaded into the machine are as follows:
Clockwise 90 Clockwise Partial Arcs Counter Clockwise Partial Arcs Inclined Lines
Counter Clockwise 90
X or Y Axis
Other functions besides the moves shown above are: Weld Contact/Solenoid On/Off, Pause, Delay, Repeat another shape, Full ellipse, and Rapid Traverse.

5 6 8 2 1 7 PARTS LIST
ITEM QTY 1 1 1 1 1 1 2 1 3 1 4 1 5 1 6 1 7 1 8 1 PART NUMBER MPD-1000 MPD-1002 MPD-1004 MDS-1165 WPD-1100-40 BUG-6050 MDS-1170 MDS-1172 MPD-1035 BUG-5188 DESCRIPTION Master Drive Unit 120 VAC Master Drive Unit 240 VAC Master Drive Unit 42 VAC Shape Control Module Linear Weaver W/ 40'' ( 1m) Cross Arm Hand Held Terminal Gas Solenoid 120 VAC Gas Solenoid 240 VAC Handle w/ Cable Anchor Torch Holder Assembly
Carriages
For Rigid and Semi-Flex rail For Ring Rail For Hi-Flex Rails
MPD-1065 4-wheel carriage. Releasable, can be installed or released in any position anywhere on the rail.
BUG-5910 Ring Rail Carriage. 4 wheels can be adjusted to the required ring diameter. Releasable.
FMD-1105 Hi-Flex Carriage. Runs on high flex rail as shown below. Releasable.
The above shown carriages can be used on the rails shown below: ARR-1080 L = 8' (2.4 m) HD-Rigid Aluminum Rail ARR-1085 L = 4' (1.2 m) HD-Rigid Aluminum Rail AFR-3000 L = 8' (2.4 m) Semi-Flex Aluminum Rail Magnet Bars and Vacuum Bars ARM-2325 Magnet w/Release ARM-2425 Magnet w/Release ARV-1080/1085 Vacuum System Ring Rails BRR-1210-20 BRR-1210-27 BRR-1210-34 BRR-1210-41 BRR-1210-48 Diameter (20" 500 mm) (27" 680 mm) (34" 860 mm) (41" 1040 mm) (48" 1220 mm) FMD-1050 Hi-Flex Rail Length = 5' (1.5 m) R - Minimum Radius 30" (1,000 mm)
Custom sizes are available.
R
ARM-2120 RE-Magnet w/Release FMD-2325 Magnet w/Release FMD-1220/1230 Vacuum System
ARM-2380 Support Bar with Screw Feet
ARM-2480 Support Bar with Screw Magnet Feet

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 Start/ manually to the required position using the joy Run 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. Manual Jog Y Axis Manual Jog X Axis Stop/ Pause Reset Speed Control
Technical Data:
Travel Speed: Cross Travel: Max. Segment Dimension: Min. Increment Dimension: 5-100 ipm (127-2540 mm/min) 24" (610 mm) 72" (1800 mm) Within Limits of Travel .01" (0.1 mm)
Bug-6140 PC Option This Windows based software package provides Computer-Aided Programming for Shape Machines and other BUG-O programmable machines. The software will run on any PC with the Windows Operating System. A cable is provided to interface the BUG-O to the PC's serial port. (A USB to RS-232 serial adaptor can be used if a serial port is not available). The program enables easy creation and editing of a shape while viewing it on screen. When a shape is loaded into the program the segment list is shown on the left, and the shape diagram on the right. Selecting (mouse-click) a segment in the list highlights the corresponding segment in the diagram. Buttons are provided to select Add, Edit, Insert or Delete a segment. A print function lets you print out the Segment List and/or Shape Diagram. Any number of shapes can be saved and stored on disk. Saved shapes can be loaded from disk into memory slots corresponding to the 20 shape numbers in the BUG-O machine. The software is distributed as a single SETUP file, which when run will install the program on your PC.
Delay Increment: .01 seconds
A QUALITY PRODUCT FROM BUG-O SYSTEMS 3001 WEST CARSON STREET PITTSBURGH, PA USA 15204-1899 A DIVISION OF WELD TOOLING CORPORATION Weld Tooling Corp. ROM 1:16 Litho in U.S.A. LIT-MDSPSM-BRO-1008
Mini-Vert III The Power Tool For Welding.

Compact Battery Powered Welding Travel Carriage.
MINI-VERT III
The Bug-O Systems Mini-Vert III is held on the workpiece with strong permanent magnets. It will travel and carry a welding gun in flat or vertical positions producing continuous uniform fillet welds. The Mini-Vert III features a quick torch mount which allows the welding gun to be rapidly moved from one side of the machine to the other, enabling the operator to weld the entire work piece from end to end. The Mini-Vert III is shipped with one (1) battery and one (1) battery charger.
FEATURES:
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 autotravel Start/Stop.
MINI-VERT III
DIMENSIONS:
10.6" (270mm)
8.4" (21mm)
13.5" (345mm)
BMV-3000 MINI-VERT III 120 VAC BMV-3002 MINI-VERT III 220 VAC
TECHNICAL DATA:
Power Supply: Drive: Clearance: Manual Torch Adjustment: Carrying Capacity: 14.4V, 3Ah battery 4 wheel drive 3/32" (2.4mm) Horizontal/Vertical 3/4"-3/4" (20-20mm) Wall - Vertical 15 lbs. (7kg) Wall - Horizontal 15 lbs. (7kg) Downhand/flat position 50 lbs. (22.7kg) Bi-directional 3.9-39 ipm (100-990mm/min) 13.5" x 8.4" x 10.6" (345 x 210 x 270mm) 16 lbs. (7.2kg) without battery
Travel: Speed: Dimensions: Weight:
MINI-VERT III
Accessories:
BMV-1510 110 Volt BMV-1512 220 Volt An adaptor is available for the Mini-Vert III that plugs into the battery pack adaptor so the machine can run directly from a 110, 240 VAC line power.
Mini-Vert III Controls:
Cable Anchor
Auto-Travel Start Switch Speed Control Direction
Battery Quick Disconnect Clamp Power Switch
Cross Slide
A DIVISION OF WELD TOOLING CORPORATION Weld Tooling Corp.
3001 WEST CARSON STREET PITTSBURGH, PA USA 15204-1899 ROM 1:16 Litho in U.S.A. LIT- MINI-VERT-BRO-0806
Economical, Automated Pipe Cutter Saves Layout and Fit-Up Time.

MM1 Programmable Pipe Cutter
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 its roller bed with a three jaw chuck while simultaneously moving a cutting torch back and forth along the pipes 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 machines 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 USA Telephone: 1-412-331-1776 1-800-245-3186 Fax: 1-412-331-0383 http://www.cypressweld.com
MM1 Programmable Pipe Cutter - Technical Data

Technical Data:
Cutting Diameter: Load Capacity: Dimensions: Input Power: Net Weight: Shipping Weight: Programming Custom Shapes. Types of Cuts: 4"-16" O.D. (10-40 cm) A. Pipe Program 1600 lb. (725 kg) 1. Saddle Cuts 137"L x 36"W x 55"H 2. Offset from Center-Line (Hillside) (348 cm L x 91 cm W x 140cm H) 3. Lateral Cuts 4. Miter Cuts 115 VAC / 240 VAC 5. Hole Cuts 550 lbs (250 kg) 800 lbs. (363 kg) B. Shape Program 1. Custom Irregular Shapes
PART NUMBER DESCRIPTION SEO-3500 MM1 120V SEO-3502 MM1 240V (See detail below.)
3-Jaw Chuck Cable Carrier
Linear Drive with Torch Holder
Rail Assembly ARR-1080
Pipe Rollers SEO-3590
Adjustable Table SEO-5480
Bed Extension SEO-3390
Part No. SEO-3500 SEO-3500-1 SEO-3500-2 SEO-3500-3 SEO-3500-4
Description 120VAC
Pipe Bed 6' (1.83 m) 120VAC 120VAC 120VAC 120VAC
Pipe Cut Length 7' (2.13 m) 14' (4.27 m) 13' (3.96 m) 22' (6.71 m) 21' (6.40 m) 30' (9.14 m) 29' (8.84 m) 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. 2
MM1 Programmable Pipe Cutter - Programming

Main Control Panel
Remote Pendant Connection Pendant Control Connection Speed Control Start / Resume
Contact Output
Stop/Pause Reset Manual Jog
Mirror Image Switch
CBO-4170 MM1 Remote Pendant

Power Cord Power Indicator Light Power On / Off Circuit Breaker
CBO-4160 MM1 Panel with Remote
Programming With The Handheld Terminal

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.)
MM1 Programmable Pipe Cutter - Programming

Capabilities
TYPE 1
SADDLE NOZZLE CUTS
TYPE 4
MITER CUT
age
TYPE 2 OFFSET
SADDLE NOZZLE CUTS (Hillside)
TYPE 5
TYPE 3
LATERAL NOZZLE CUTS
TIME DELAY
PERCENT SPEED
WAIT FOR AUXILIARY START MODES BUTTON
WELD/OXY PIPE CUT NUMBER OFF REPEAT WELD/OXY ANOTHER ON STEP
For 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.
Programming Arbitrary Shapes
MM1 Programmable Pipe Cutter - Accessories

CWO-7635 Powermax 1250 Includes the following: Interface cable to the Cypress Pipe Cutter 50' (15.24 m) Machine Barrel Torch Power Requirements: Auto voltage runs on 200600 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 BUG-1274 3-Hose Machine Torch 10" Consumable Kit for (254 mm) Cutting Torch is CWO-7635 the same for AcetylenePropane-Natural Gas. Only the tip changes.
Oxy-Acetylene Tips
Part No. BUG-1270-000 BUG-1270-00 BUG-1270-0 BUG-1270-1 BUG-1270-2 BUG-1270-3 BUG-1270-4 Tip Size 000 00 0 1 2 3 4 Plate Thickness Light Gauge to 3/16 3/16-3/8 3/8-5/8 5/8-1 1-2 2-3 3-6 Oxygen PSIG 15-20 20-25 35-40 35-40 40-45 45-50 50-75 Fuel Gas PSIG 5-15 5-15 5-15 5-15 5-15 5-15 10-15 Orifice Drill Size #68 #64 #60 #56 #52 #48 #42
* For tips to cut 6" to 15", please consult factory.
Oxy-Propane, Natural Gas Cutting Tips

Part No. BUG-4070-000 BUG-4070-00 BUG-4070-0 BUG-4070-1 BUG-4070-2 BUG-4070-3 BUG-4070-4 BUG-4070-5 BUG-4070-6 Tip Size 000 00 0 1 2 3 4 5 6 Plate Thickness Light Gauge to 3/16 3/16-3/8 3/8-5/8 5/8-1 1-2 2-3 3-6 6-8 8-12 Oxygen PSIG 15-30 20-30 30-40 35-50 40-55 45-60 50-75 65-80 70-90 Fuel Gas PSIG 5-15 5-15 5-15 5-15 5-15 5-15 5-15 5-15 5-15 Orifice Drill Size #68 #64 #60 #56 #52 #42 #42 #35 #30
MM1 Programmable Pipe Cutter - Dimensions

Dimensions:
55" (1397mm)
137" (3480mm)
36" (914mm)
MM-1 Application Photos

280 Technology Drive Canonsburg, PA 15317-9564 USA Telephone: 1-412-331-1776 1-800-245-3186 Fax: 1-412-331-0383 http://www.cypressweld.com LIT-MM1-BRO-0908
Custom configured systems for your specific application to increase arc-on time and weld quality.
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.
All Position Overlay System
Custom configured systems for your specific application to increase arc-on time and weld quality.
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.
Master Drive Anchor Bolt Hi-Flex Rail
Height Control Box
Gun Pendulum Weaver Auto-Height Power Slide
Master Drive (stepper) Control Vertical Drive And Weaver Control
Vertical Rail With Support
13 Feet C/L to C/L
Sensor Slave Drive
Target Magnets Hi-Flex Rail
280 TECHNOLOGY DRIVE CANONSBURG, PA 15317-9564 A QUALITY PRODUCT FROM BUG-O SYSTEMS A DIVISION OF WELD TOOLING CORPORATION Weld Tooling Corp. ROM 1:16 Litho in U.S.A. LIT-BRO-APO-0808
Pipe-Bug
Motorized & Manual Chain Driven Pipe Cutting Machines From Bug-O Systems.
THE PIPE-BUG
BUG-O Systems Pipe-Bug provides a quick, economical way to cut and bevel pipe. One machine can be fitted to cut any size pipe beginning at a 3" (7.6mm) diameter. Triple link chain and precise control of chain tension on the traveling wheels give the Pipe-Bug the straightest cutting capability of any type of chain machine available. For pipe diameters above 18" (457mm) or cuts that must be made with the machine in the horizontal position, use of a guide strip is recommended. (see page 4)
Manual Pipe-Bug. Part # 05-0520-000 Weight: 34 lbs. (16kg) Shipping Weight: 39 lbs. (18kg)
Motorized Pipe-Bug 110V. Part # 05-0520-M00 Weight: 42lbs (19kg) Shipping Weight: 47 lbs. (22kg) Motorized Pipe-Bug 230V. Part # 05-0520-ME2 Weight: 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 and clean-up time.
2
Torch and chain sold separately.
THE PIPE-BUG - Chain Kits

Pipe-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. Chain lengths can be shortened or lengthened to fit different diameters. Description Chain Kit For Part Number 01-0520-008 01-0520-010 01-0520-012 01-0520-016 01-0520-020 01-0520-024 01-0520-030 01-0520-036 01-0520-042 01-0520-048 Net Weight 4 lbs. (1.8kg) 4 lbs. (1.8kg) 5 lbs. (2kg) 6 lbs. (2.7kg) 7 lbs. (3kg) 8 lbs. (3.6kg) 9 lbs. (4kg) 11 lbs. (5kg) 13 lbs. (5.9kg) 14 lbs. (6.4kg)
8" 10" 12" 16" 20" 24" 30" 36" 42" 48"
(219mm) pipe (273mm) pipe (330mm) pipe (408mm) pipe (508mm) pipe (609mm) pipe (762mm) pipe (914mm) pipe (1066mm) pipe (1219mm) pipe
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 Chain Length 3" 76mm 24.44" 621mm 14" 355mm 55.125" 1400mm 26" 660mm 91.375" 2320mm 4" 114mm 28" 710mm 16" 408mm 62.25" 1580mm 28" 711mm 98" 2490mm 6" 168mm 33.875" 860mm 18" 457mm 68.375" 1735mm 30" 762mm 103.125" 2620mm 8" 219mm 39.75" 1010mm 20" 508mm 72.875" 1850mm 32" 812mm 111" 2820mm 10" 273mm 46" 1170mm 22" 558mm 79.25" 2013mm 34" 864mm 117.67" 2989mm 12" 330mm 52.375" 1330mm 24" 609mm 85.4375" 2170mm 36" 914mm 123.54" 3138mm
Pipe Diameter Chain Length
Pipe Diameter Chain Length
For pipe diameters and chain lengths not listed consult factory.
THE PIPE-BUG
Guide Strips for extra precision on larger pipe. For larger pipe sizes [above 18" (457mm)] the use of a Guide Strip is recommended. Guide Strips reduce set up times as the Pipe-Bug does not have to be rotated around the pipe to align the chain on the pipe. Selecting the right Guide Strip. Pipe-Bug Guide Strips are sold in sections. There are four basic sections - the head, tail, short center and long center sections. To choose the right Guide Strip find your pipe size in the left column then order the type and quantity of head, tail and short and long sections as indicated in the column.
Head Pipe Range (in/mm) 18-32/610-813 18-36/864-914 18-48/1118-1219 18-52/1270-1321 18-58/1372-1473 18-64/1524-1625 18-72/1674-1829 Quantity Required 1 1 1 1 1 1 1 Tail Quantity Required 1 1 1 1 1 1 1 2 1 2 1 Short Center Long Center Section Section Quantity Quantity Required Required 1 1 1 2 1 2 2
Pipe-Bug Guide Strip

Description 18"-32" (457-813mm) Guide Strip Kit 18"-48" (457-1219mm) Guide Strip Kit Head Section Tail Section Short Center Section Long Center Section Part Number 05-0520-012 05-0520-013 05-0520-013B 05-0520-013D 05-0520-013C 05-0520-013A Net Weight 12 lbs. (5.4kg) 15 lbs. (6.8kg) 4.7 lbs. (2kg) 3.6lbs. (1.6kg) 3.2lbs. (1/5kg) 4.3 lbs (2kg)
BUG-O SYSTEMS
Welding & Cutting Automation Since 1948.
www.bugo.com A QUALITY PRODUCT FROM BUG-O SYSTEMS
PITTSBURGH, PA 15204 Litho in U.S.A.
Weld Tooling Corp.
ROM 1:16
LIT- PIPEBUG-BRO-0804
Flexible, Modular Motion Control.
Custom Configurations From Standard Components.
Rails and Attachments
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)
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 Rails (ARR) & Corresponding Attachments

Heavy Duty Rigid Rail ARR-1080 & ARR-1085
A C D B
A. 2.75" (70 mm) B. 4.0" (102 mm) C. .375" (9.5 mm) D. .875" (22 mm)
ARR-1080 8' (2.37 m) 93-7/16" Actual Length ARR-1085 4' (1.18 m) 46-9/16" Actual Length
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.
Extra Heavy Duty Rigid Rail ARR-1250 & ARR-1200

A C D B
A. 2.75" (70 mm) B. 4.0" (102 mm) C. .375" (9.5 mm) D. .875" (22 mm)
ARR-1250 8' (2.37 m) 93-7/16" Actual Length ARR-1200 4' (1.18 m) 46-9/16" Actual Length
Drive Carriages For Aluminum Rigid Rail.

For Modular Drive And Universal Bug-O-Matic.
8.00" (203 mm)
For DC IV Drives.
8.00" (203 mm)
Releasable (can be installed anywhere along the track).
12.00" (305 mm) 2.00" (50 mm)
12.00" (305 mm) 2.00" (50 mm)
MPD-1065 Releasable Carriage Net Weight: 7.75 lbs. (3.52 kg) Shipping Weight: 9 lbs. (4.09 kg)
BUG-5250 Carriage 12" (305 mm) Net Weight: 5 lbs. (2.26 kg) Shipping Weight: 7 lbs. (3.17 kg)
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.
Swivel Magnet ARM-2325 Holding Power 250 lbs. (113 kg)
Fixed Magnet ARM-2265 Holding Power 200 lbs. (91 kg)
Spacer ARM-2505 Use with ARM-2500 only.
On/Off Magnet ARM-2500 Holding Power 100 lb. (45 kg)
Short Magnet ARM-2248 Holding Power 200 lbs. (91 kg)
Rail Alignment Tool ARR-1090 Gauging device for rapid alignment of rails to joint.
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. 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.
ARV-1036 Vacuum Bar Assembly ARV-1085 Vacuum Kit for ARR-1085 4' (1.18 mm) Rigid Rail.
ARV-1060 Leap Frog Kit For ARV-1080 & ARV-1085. Used to reposition rail without losing vacuum.
ARV-2020 120 Volt/50-60 Hz ARV-2030 220 Volt/50-60 Hz 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.
ARV-1080 Vacuum Kit for ARR-1080 8' (2.37 mm) Rigid Rail.
Bent Rigid Rail (BRR), Ring Rails & Corresponding Attachments

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 dont want to order a complete ring, on larger IDs or ODs you can Leapfrog the rail around the vessel. Use at least four (4) magnets or vacuum cups on each piece of BRR-1180.
Pieces of Rail Needed To Form Complete Ring
Maximum Outside Diameter of Workpiece
Maximum Inside Diameter of Workpiece
Bent Rigid Rail BRR-1180 A C D B

A. 2.75" (70 mm) B. 4.0" (102 mm) C. 375" (9.5 mm) D. 875" (22 mm)
Individual sections of Bent Rigid Rail - BRR-1180.
2 3 4 5 6 8 10
3'-11" (1.20 m) 6'-1" (1.85 m) 8'-2" (2.49 m) 10'-2" (3.10 m) 12'-5" (3.79 m) 16'-8" (5.08 m) 20'-11" (6.08 m)
4'-5" (1.35 m) 6'-7" (2.00 m) 8'-8" (2.64 m) 10'-8" (3.25 m) 12'-11" (3.94 m) 17'-2" (5.23 m) 21'-5" (6.23 m)
Complete Ring Rail Assemblies

Ring Rails and Tube Size Ranges
Work Diameters (1) (2) (3) (4) (5) Part Number BRR-1210-20 BRR-1210-27 BRR-1210-34 BRR-1210-41 BRR-1210-48 Inches 9-16 16-23 23-30 30-37 37-44 Ring Inside Diameter
MM Inches MM 230-400 20 500 410-580 27 680 590-760 34 860 770-940 41 1040 950-1120 48 1220
Work Diameter
Ring ID
* Ring Rails do not include attachments. BRR-1210-_
Magnet Attachments
A 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 Supports
Vacuum Supports may be used instead of magnets to mount the Ring Rail on non-magnetic work pieces. Each Vacuum Support System requires a Vacuum Pump Kit for operation.
20" 27" 34" 41" 48" Dia. Dia. Dia. Dia. Dia. Vacuum Support System Vacuum Support System Vacuum Support System Vacuum Support System Vacuum Support System
Carriage For Bent Rigid Rail.

8.12" (206 mm)
ARV-1240-20 ARV-1240-27 ARV-1240-34 ARV-1240-41 ARV-1240-48
Mounts a DC IV Drive Unit, Modular Drive Unit and Universal Bug-O-Matic. Releasable (can be installed anywhere along the track). Runs on straight or BRR Ring Rail.
Screw Feet Assemblies ARM-2380
12.00" (305 mm)
2.56" (65 mm)
Magnet Plate Assemblies ARM-2480
ARV-2020 120VAC Vacuum Pump Kit ARV-2030 220VAC Vacuum Pump Kit
BUG-5910 Split Carriage Net Weight: 7 lbs. (3.17 kg) Shipping Weight: 8 lbs. (3.62 kg)
Semi-Flex Rail AFR-3000 & Corresponding Attachments

SEMI-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. A C B A B C D 2.75" 4.0" .33" .500" (70 mm) (102 mm) (8.5 mm) (12.7 mm) D 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.
Minimum Radius 15' (5 m) 8' (2.37 m)
Rack Adjusting Tool

8' (2.37 m)
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.
Carriages For AFR-3000 Rail.

For Modular Drive And Universal Bug-O-Matic. For DC IV Drives
8.00" (203 mm)
8.00" (203 mm)
12.00" (305 mm) 2.00" (50 mm)
12.00" (305 mm)
Releasable (can be installed anywhere along the track).
2.00" (50 mm)
Mounts a DC IV Drive Unit.
MPD-1065 Releasable Carriage Net Weight: 7.75 lbs. (3.52 kg) Shipping Weight: 9 lbs. (4.09 kg)
Magnets and Rail Alignment Tool For AFR-3000 Rail.

Swivel Magnet 250 lbs. Holding Power
ARM-2425
Vacuum Attachments For AFR-3000 Rail.

Standard Vacuum Support Kit: ARV-1080 Vacuum Kit For AFR-3000 Semi-Flex Rail. 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.
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.
ARV-1080 Vacuum Kit on AFR-3000 8' (203 mm) Semi-Flex Rail
Fixed Magnet 200 lbs. Holding Power

ARM-2465
Rail Alignment Tool Gauging device AFR-1090 for rapid alignment of rails to joint.
4
ARV-2020 120 Volt/50-60 Hz ARV-2030 220 Volt/50-60 Hz
Hi-Flex Rail (FMD) & Corresponding Attachments

Note: Only for Universal Bug-O-Matic and Modular Drive. 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.
R 30" (760 mm)
FMD-1050 Hi-Flex Rail Without Magnet Assemblies

3.995" (102 mm) .080" (2 mm) .250" (6.4 mm)
FMD Hi-Flex Rail can flex inside or outside to a minimum radius of 30" (760 mm).
R 30" (760 mm)
57.722" (1.47 m) Actual Length
Carriages For Hi-Flex Rail
FMD-1105 Drive Carriage with 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-2155 Hi-Flex Rail with 8 magnets.
FMD-1056 Hi-Flex Rail Stiffener

Converts Hi-Flex Rail To Rigid Rail.
FMD-2150 Hi-Flex Rail with 8 R. E. magnets.
Magnets, Vacuum Accessories and Rail Alignment Tool For Hi-Flex Rail
FMD-1020 Rail Alignment Tool Gauging device for rapid alignment of rails to joint. FMD-2325 Flex Magnet Assembly with release. Holding Power 200 lbs. (91 kg) ARM-2120 Channel Magnet with release. Holding Power 150 lbs. (68 kg)
FMD-1036 VAC Support Bar For Hi-Flex Rail. ARV-2020 120 Volt/50-60 Hz ARV-2030 220 Volt/50-60 Hz
FMD-1220 Vacuum Support for (1) FMD-1050* FMD-1230 Vacuum Support for additional FMD-1050* *FMD-1050 rail sold separately.
Carriages & Fixture Building

Specialty Carriages For ARR Rail.
8.00" (203 mm)
Fixture Building
Cross Beam Assemblies
Longitudinal 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.
18.00" (457 mm)

2.00" (50 mm)
BUG-1040-1 4' (1.18 m) long BUG-1040-2 8' (2.37 m) long

Mounts a DC IV Drive Unit. Longer deck to mount accessories, wire feeder, etc.
Special lengths are available on request, contact sales office.
8.00" (203 mm)
24.00" (609 mm)
2.00" (50 mm)
BUG-2790 Carriage 24" (609 mm) Net Weight: 11 lbs. (5 kg) Shipping Weight: 15 lbs. (6.80 kg)
8.00" (203 mm) 36.00" (914 mm)
Splicing Plates
2.00" (50 mm)
BUG-2785 Carriage 36" (914 mm) Net Weight: 16.5 lbs. (7.50 kg) Shipping Weight: 23.0 lbs. (10.44 kg)
BUG-1053 Splicing Plates are used with the BUG-1040-1 and BUG-1040-2 longitudinal rail sections. Order one splice plate per joint.
Vertical columns for BUG-1040-1 or BUG-1040-2 longitudinal rail sections are available in three lengths.
BUG-1053 Splice Plate
Optional Carriages for ARR.

8.00" (203 mm)
20" (500 mm)
BUG-1040-1 Rail
BUG-1045-1 Column
BUG-1045-1 Vertical Column BUG-1045-2 Vertical Column BUG-1045-3 Vertical Column

Used to carry accessories, wire feeder, etc.
20" (500 mm) 40" (1000 mm) 60" (1500 mm)
12.00" (305 mm)

2.00" (50 mm)
BUG-1096 Yoke Carriage
BUG-2205 Carriage Trailer w/Hitch Net Weight: 6 lbs. (2.72 kg) Shipping Weight: 8 lbs. (3.62 kg)
8.00" (203 mm)
6.18" (157 mm)

2.00" (50 mm)
12.00" (305 mm)
Knob is used manually to move the carriage along the track. Bottom knob locks carriage to a fixed rail position.
MUG-1140 Spotting Car Net Weight: 6 lbs. (2.72 kg) Shipping Weight: 8 lbs. (3.62 kg)
For use on BUG-1040_ Cross Beams.
A QUALITY PRODUCT FROM BUG-O SYSTEMS 280 TECHNOLOGY DRIVE CANONSBURG, PA 15317-9564 USA A DIVISION OF WELD TOOLING CORPORATION Weld Tooling Corp. ROM 1:16 Litho in U.S.A. LIT- R&A-BRO-0608
SE-4PD, SE-2PTD Programmable Saddle, Elbow and Shape Cutter for Pipes. & SE-4PTD Now you can make Saddle Cuts, Offset Cuts, Laterals, Miters, Holes and Shapes quickly, easily, and economically.
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.

280 Technology Drive Canonsburg, PA 15317-9564 USA Telephone: 1-412-331-1776 1-800-245-3186 Fax: 1-412-331-0383 http://www.cypressweld.com
MODEL SE-2PTD
PLASMA VERSION:
PART NUMBER SEO-4250-PL SEO-4252-PL DESCRIPTION SE-2PTD 120V Plasma SE-2PTD 240V Plasma
Linear Drive has 18" (457 mm) of Work Area Travel Cable Support Post Oxy-Fuel Manifold with Solenoid Kit: Turns Cutting Oxy On and Off Automatically! Ground Ring 5" (127 mm) I.D Hole Through
OXY-FUEL VERSION:
PART NUMBER SEO-4250-OX SEO-4252-OX DESCRIPTION SE-2PTD 120V Oxy-fuel SE-2PTD 240V Oxy-fuel
Mirror Image Switch
3 Jaw Chuck
Contact Relay: Turns Plasma Cutting Torch On and Off Automatically! Programming Pendant Ground Brushes
Adjustable Pipe Support
Technical Data:
Cutting Diameter: Rotation Speed: Dimensions: Input Power: Net Weight: Shipping Weight: Types of Cuts: Pipe Program: Pass through 1" to 4 3/4" (25 mm to 120 mm) O.D. Min: Max: 0.3 rpm 3.7 rpm 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)
40"L x 19"W x 35"H (1016 x 483 x 889 mm) 120/50-60/1 or 220/50-60/1 345 lbs. (157 kg) 420 lbs. (191 kg) 1. Saddle Cuts 2. Offset (Hillside) 3. Laterals 4. Miter Cuts, Single Cut 3. Piece Elbow 5. Hole Cuts Standard Any Arbitrary Shape
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.
Shape Program:
MODEL SE-4PTD
PLASMA VERSION:
PART NUMBER SEO-4400-PL SEO-4402-PL DESCRIPTION SE-4PTD 120V Plasma SE-4PTD 240V Plasma
OXY-FUEL VERSION:
PART NUMBER SEO-4400-OX SEO-4402-OX DESCRIPTION SE-2PTD 120V Oxy-fuel SE-2PTD 240V Oxy-fuel
Mirror Image Switch Linear Drive has 18" (457 mm) of Work Area Travel Oxy-Fuel Manifold with Solenoid Kit: Turns Cutting Oxy On and Off Automatically! Ground Ring 12 3/4" (324 mm) Pipe will Pass Through Machine
3 Jaw Chuck Cable Support Post Contact Relay: Turns Plasma Cutting Torch On and Off Automatically!
Adjustable Pipe Support Programming Pendant Ground Brushes
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: Dimensions: Input Power: Net Weight: Shipping Weight: Types of Cuts: Pipe Program: Min: 0.2 rpm Max: 3 rpm 52 1/2"L x 24 1/4"W x 33"H (1334 x 616 x 838 mm) 120/50-60/1 or 220/50-60/1 705 lbs. (320kg) 900 lbs. (409 kg) 1. Saddle Cuts 2. Offset (Hillside) 3. Laterals 4. Miter Cuts, Single Cut 3. Piece Elbow 5. Hole Cuts Standard Any Arbitrary Shape 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 his own plasma equipment. 3 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) Short sections of pipe up to 14" (355 mm) dia. can be mounted off the chuck face.
Shape Program:
MODEL SE-4PD
PLASMA VERSION:
PART NUMBER SEO-4520-PL SEO-4522-PL DESCRIPTION SE-4PD 120V Plasma SE-4PD 240V Plasma
Mirror Image Switch Linear Drive has 15" (381 mm) of Work Area Travel
OXY-FUEL VERSION:
PART NUMBER SEO-4520-OX SEO-4520-OX DESCRIPTION SE-4PD 20V Oxy-fuel SE-4PD 240V Oxy-fuel
Cable Support Post 3 Jaw Chuck Contact Relay: Turns Plasma Cutting Torch On and Off Automatically!
Oxy-Fuel Manifold with Solenoid Kit: Turns Cutting Oxy On and Off Automatically!
Rotary Ground
Programming Pendant
Rotary Ground Bracket
Hose Nut Oxygen, Hose Nut Nipple Hose Nut Fuel Gas Hose Clamp
3-Hose Assembly 5' (1.5 m)
Technical Data:
Cutting Diameter: Rotation Speed: Dimensions: Input Power: Net Weight: Shipping Weight: Types of Cuts: Pipe Program: 1"-12" O.D. (25 mm to 304 mm). Min: 0.2 rpm Max: 3.7 rpm 38"L x 15.25"W x 22.25"H (965 x 387 x 565 mm) 115 VAC 200 lbs. (91kg) 300 lbs. (136 kg) 1. Saddle Cuts 2. Offset (Hillside) 3. Laterals 4. Miter Cuts, Single Cut 3. Piece Elbow 5. Hole Cuts Standard Any Arbitrary Shape 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 its roller bed with a three jaw chuck while simultaneously moving a cutting torch back and forth along the pipes 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.
Shape Program: Capacity: 4
ACCESSORY KITS
PLASMA KIT The 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-2PTD SEO-4560 Plasma Kit 120 VAC SEO-4562 Plasma Kit 240 VAC Plasma Kits for SE-4PTD SEO-4470 Plasma Kit 120 VAC SEO-4472 Plasma Kit 240 VAC Plasma Kits for SE-4PD SEO-4570 Plasma Kit 120 VAC SEO-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 SEO-4482 Oxy-Fuel Kit 120 VAC 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.
MAIN CONTROL PANEL & PROGRAMMING

Main Control Panel
Start / Resume Stop / Pause Manual Jog
Contact Output Reset Speed Control
Pendant Control Connection
Power Cord Power Indicator Light
Power On / Off Circuit Breaker
Programming With The Handheld Terminal

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 2). 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.)
PROGRAMMING CONTD.
For 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.
Programming Arbitrary Shapes
TIME DELAY
PERCENT SPEED
WAIT FOR AUXILIARY START MODES BUTTON
WELD/OXY PIPE CUT NUMBER OFF REPEAT WELD/OXY ANOTHER ON STEP
Capabilities
TYPE 1
SADDLE NOZZLE CUTS
TYPE 4
MITER CUT
TYPE 2
OFFSET SADDLE NOZZLE CUTS (Hillside)
TYPE 5
TYPE 3
LATERAL NOZZLE CUTS
ACCESSORIES
CWO-7635 Powermax 1250 Includes 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 Oxy-Acetylene Machine Torch 10" (254 mm) BUG-4072 3-Hose Propane/Natural Gas Machine Torch 10" (254 mm)
Oxy-Acetylene Tips
Part No. BUG-1270-000 BUG-1270-00 BUG-1270-0 BUG-1270-1 BUG-1270-2 BUG-1270-3 BUG-1270-4 Tip Size 000 00 0 1 2 3 4 Plate Thickness Light Gauge to 3/16" (4.8mm) 3/16"-3/8" (4.8-9.5mm) 3/8"-5/8" (9.5-15.9mm) 5/8"-1" (15.9-25.4mm) 1"-2" (25.4-50.8mm) 2"-3" (50.8-76.2mm) 3"-6" (76.2-152.4mm) Oxygen PSIG Fuel Gas PSIG Orifice Drill Size 15-20 5-15 #68 20-25 5-15 #64 35-40 5-15 #60 35-40 5-15 #56 40-45 5-15 #52 45-50 5-15 #48 50-75 10-15 #42
* For tips to cut 6" to 15" (152.4-381 mm), please consult factory.

Part No. BUG-4070-000 BUG-4070-00 BUG-4070-0 BUG-4070-1 BUG-4070-2 BUG-4070-3 BUG-4070-4 BUG-4070-5 BUG-4070-6 Tip Size 000 00 0 1 2 3 4 5 6 Plate Thickness Light Gauge to 3/16" (4.8mm) 3/16"-3/8" (4.8-9.5mm) 3/8"-5/8" (9.5-15.9mm) 5/8"-1" (15.9-25.4mm) 1"-2" (25.4-50.8mm) 2"-3" (50.8-76.2mm) 3"-6" (76.2-152.4mm) 6"-8" (152.4-203.2mm) 8"-12" (203.2-304.8mm) Oxygen PSIG Fuel Gas PSIG 15-30 5-15 20-30 5-15 30-40 5-15 35-50 5-15 40-55 5-15 45-60 5-15 50-75 5-15 65-80 5-15 70-90 5-15 Orifice Drill Size #68 #64 #60 #56 #52 #42 #42 #35 #30

280 Technology Drive Canonsburg, PA 15317-9564 USA Telephone: 1-412-331-1776 1-800-245-3186 Fax: 1-412-331-0383 ROM 1:16 Weld Tooling Corp. http://www.cypressweld.com
SE-2-4PTD-BRO-1208
Now You Can Make Saddle Cuts, Offset Cuts, Lateral Miters and Elbows Quickly, Easily and Economically.
SE-4P
Programmable Saddle and Elbow Cutter
The Programmable Saddle and Elbow Cutter is a computer controlled machine that automates the end preparation of pipes for fabrication. It rotates a pipe in a three jaw chuck while driving a cutting torch back and forth along the pipes axis. The cutting torch traces the path of intersection of the pipe with another pipe of the same or larger diameter.

A SUBSIDIARY OF WELD TOOLING CORPORATION
P.O. BOX 690168, HOUSTON, TEXAS 77269 Telephone: 1-281-469-0746 http://www.cypressweld.com
Fax: 1-281-469-9354
SE-4P
TECHNICAL DATA:
Cutting Diameter: 1"-12" O.D. (25-304 mm) Rotation Speed: 0.2-3.7 rpm Dimensions: 38"L x 15.25"W x 22.25"H (965 x 387 x 565 mm) Types of Cuts: 1. Saddle Cuts 2. Offset (Hillside) 3. Laterals 4. Miter Cuts; single cut or 3 piece elbow 5. Hole Cuts Input Power: 115 VAC Net Weight: 200 lbs (91 kg) Shipping Weight: 300 lbs. (136 kg)
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. The machine can be delivered with plasma torch leads and power source. The customer may provide his own plasma equipment.
TYPE 1
TYPE 2
SADDLE CUTS TYPE 3 TYPE 4
OFFSET SADDLE CUTS (Hillside)
LATERAL
MITER CUT
SE-4P
STOP START

JOYSTICK - To Position Torch To HANDHELD TERMINAL
ROTATION GROUND for Plasma Cutting
RESET POWER CORD PILOT LIGHT POWER ON/OFF SPEED CONTROL CIRCUIT BREAKER
HANDHELD TERMINAL:
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 1-4, Page 2). 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. 7. Enter the ANGLE in degrees. 8. Press START on the machine to begin to cut. It couldnt be easier! When using Plasma, press B and enter the time delay required (which is stored until changed again.)
3
SE-4P

A SUBSIDIARY OF WELD TOOLING CORPORATION
P.O. BOX 690168, HOUSTON, TEXAS 77269 Telephone: 1-281-469-0746 Fax: 1-281-469-9354 http://www.cypressweld.com
SE-4P-499
Return to Index

Burn Virtually Any Shape, Weld Any Pattern, Quickly And Easily, In Any Position
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.
PATENTS WORLDWIDE

The 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.
Handheld Terminal Functions:

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 BUG-O of segments and data for each segment. Ready 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 current 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. The different types of segments that can be loaded into the machine are as follows:
Clockwise 90 Clockwise Partial Arcs Counter Clockwise Partial Arcs Inclined Lines
Counter Clockwise 90 X or Y Axis
Other functions besides the moves shown above are: Weld Contact/Solenoid On/Off, Pause, Delay, Repeat another shape, Full ellipse, and Rapid Traverse.

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. STOP/PAUSE
SPEED MANUAL/ JOG/MOVE
START/RUN RESET
Technical Data:
Power Requirements: BUG-6150 BUG-6152 BUG-6154 120VAC/50-60/1 240VAC/50-60/1 42VAC/50-60/1
COMPUTER SOFTWARE
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.
Travel Speed: Cross Travel: Max. Segment Dimension: Min. Increment Dimension:
2.5-50 ipm (63-1250 mm/min) 24" (610 mm) 72" (1800 mm) Within Limits of Travel .01" (0.1 mm)
Delay Increment: .01 seconds Net Weight Of Drive Unit: Dimensions Of Drive Unit: 37 lbs. (17 kg) 15.0"L x 8.25"W x 10.0"H (381 mm x 210 mm x 255 mm)

BUG-6200 Includes: 1 BUG-6150 1 BUG-6090 1 BUG-6155 BUG-6202 BUG-6204 BUG-6201 Includes: 1 BUG-6150 1 BUG-6080 1 BUG-6145 BUG-6203 BUG-6205 PROGRAMMABLE SHAPE OXY-FUEL CUTTING KIT 120VAC/50-60/1 Programmable Shape Machine and Handheld Terminal 2.5-50 ipm (63-1250 mm/min) Q.A. Manifold w/Solenoid 120 VAC Cutting Group PROGRAMMABLE SHAPE CUTTING KIT 240VAC/50-60/1 PROGRAMMABLE SHAPE CUTTING KIT 42VAC/50-60/1 PROGRAMMABLE SHAPE WELDING KIT 120VAC/50-60/1 Programmable Shape Machine and Handheld Terminal 2.5-50 ipm (63-1250 mm/min) Relay Box w/Cable Anchor [To Control Arc On/Off] Welding Group PROGRAMMABLE SHAPE WELDING KIT 240VAC/50-60/1 PROGRAMMABLE SHAPE WELDING KIT 42VAC/50-60/1
BUG-6210
Includes: 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 BUG-6214 PROGRAMMABLE SHAPE MACHINE 240VAC/50-60/1 PROGRAMMABLE SHAPE MACHINE 42VAC/50-60/1
PROGRAMMABLE SHAPE PLASMA CUTTING KIT 120VAC/50-60/1
*Rail is not included with kits.
BUG-6155 Cutting Group
BUG-6145 Welding Group
BUG-6080 Relay Box w/Cable Anchor
BUG-6090 Cutting Solenoid Accessory 120VAC
A QUALITY PRODUCT FROM BUG-O SYSTEMS 280 TECHNOLOGY DRIVE CANONSBURG, PA 15317-9564 USA A 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 ship building and steel construction.
PUL-TON pulling device for hull section joining.
MINI-BULB-ALIGN a tool for aligning stiffeners.
PUL-JAK/MAX-JAK tools for pushing and pulling.
BULB-MOV-R grippers for holland profiles.
BULB-LIFT-R lifting clamps for holland profiles.
BULB-ALIGN a tool for aligning stiffeners when joining sections.
Shipyard Fit-Up Tools

Tools for pushing and pulling. A tool for aligning stiffeners when joining sections. Grippers for holland profiles.
PUL-JAK-7, PUL-JAK-12
The PUL-JAK is a versatile tool designed to suit the needs of a plate fitter. Due to its design, light weight and simple construction the PUL-JAK is very handy when working in restricted spaces or when working alone. The main application of the PUL-JAK is fitting bulkheads and frames in hull construction. Two models are available with capacities of 10 or 12 ton. Weight: 13.5 lbs. (6kg)
BULB-MOV-R-1.5, BULBMOV-R-3.0, BULB-MOV-R-5.0

The BULB-MOV-R is a light and handy tool for attaching a chain block quickly to a holland profile in steel fabrication without need to weld an eye piece. Gripping is based on the wedging effect, which causes MOV-R to clamp firmly on the holland profile under pull from the eye. The MOV-R is not designed for lifting applications. The innovative design and the special material provide a high safety factor against breakage. The MOV-R comes in three sizes with capacities of 1.5, 3 and 5 tons. Weight: Tara 1.5 - 6.10 lbs. (2.8kg), Tara 3.0- 10.5 lbs. (4.7kg), Tara 5.0- 13.25 lbs. (6.0kg)
A 20 ton pulling tool.

MAX-JAK-20
The MAX-JAK-20 is the name for the heavy duty tool for producing pulling forces up to 20 ton in installation work. Typical application in ship building is the joining of hull sections. Maximum allowed pushing force is 5 ton. Weight: 29 lbs. (13kg)
BULB-ALIGN
The application of the BULB-ALIGN will result in remarkable time saving when aligning holland profile stiffeners. Welding and removing of fastening lugs for the jack as well as grinding the spot are not needed any more. BULB-ALIGN is fastened just by inserting a wedge. The adjusting screw makes it possible to use the same tool on holland profiles of different sizes. Weight: 22 lbs. (10kg)
Pulling device for hull section joining.
Lifting clamps for holland profiles.
A tool for aligning stiffeners.
PUL-TON
The PUL-TON is a tool for converting the pushing force of a standard jack into a pulling force. All standard jacks such as Enerpak, Simplex, OTC and Power Team can be used. The recommended maximum capacity is 25 tons. Weight: 55 lbs. (24.9kg)
MINI-BULB-ALIGN
A tool for aligning stiffeners at the section joints. The MINI-BULB-ALIGN works on 100 to 120 mm holland profiles. It can be used in right hand and left hand modes. Weight: 25 lbs. (11kg)
BULB-LIFT-R-1, BULB-LIFT-R-2
The LIFT-R is a lifting appliance designed exclusively for holland profiles. It shall not be used for lifting other sections or plates. The BULB-LIFT-R-1 fits holland profiles of size 80-220 mm. Weight: 17 lbs. (7.7kg)

PITTSBURGH, PA USA 15204-1899 Litho in U.S.A.
Weld Tooling Corp.
ROM 1:16
BUG-O SYSTEMS
Welding & Cutting Automation Since 1948. www.bugo.com 1-412-331-1776
SIX WAYS
Automating Your Welding and Cutting Can Save You Money!
Advantages
of
Automating
Your
WELDING & CUTTING
1 INCREASE
Production
The machine replaces the operators hand to control the process.
2 IMPROVE
Quality
Precise speed and path control improve appearance and quality.
2 2
3 REDUCE
Material Handling
Take the small light-weight machine to the work. Work in all positions.
4 REDUCE
Distortion
Provides uniform heat input, puts the right amount of weld in the right place.
5 IMPROVE
Workers Environment
Keeps the worker further away from the arc and reduces operator fatigue.
6 ADAPTABLE
Adapts to your job.
Flexible Modular Construction
A QUALITY PRODUCT FROM BUG-O SYSTEMS 280 TECHNOLOGY DRIVE CANONSBURG, PA USA 15317-9564 Litho in U.S.A. LIT-SIXWAY-BRO-0508 ROM 1:16 Weld Tooling Corp.
DC SPEED WEAVING KIT
The DC SPEED WEAVING KIT combines a DC-IV drive unit and a Speed Weaver II for those straight line welding applications that require oscillation. Rack and pinion drive along with heavy duty rigid rail and magnets make all-position operation possible. The weaver is normally mounted to the carriage. A swivel mount is also provided for mounting the weaver so that it can swivel around 2 axis (see photo). This enables the kit to perform fillet welds.
PATENTS WORLDWIDE
DC SPEED WEAVING KIT

Technical Data: Specifications
Power Requirements: BUG-1916 BUG-1917 BUG-1918 120 VAC/50-60/1 240 VAC/50-60/1 42 VAC/50-60/1
Travel Speed: Load Capacity: Net Weight Of Kit:
1.5-30 ipm (38-780 mm/min) 30 lbs. (14 kg) VERTICAL 100 lbs. (45 kg) HORIZONTAL 91 lbs. (41.5 kg)
Shipping Weight Of Kit: 101 lbs. (46 kg)
BUG-1916 Includes: 1 BUG-0343 Includes: 1 BUG-9444 1 BUG-5300 1 BUG-5195 1 BUG-2975 1 ARR-1080 1 ARR-1085 5 ARM-2325 BUG-1917
DC SPEED WEAVING KIT (120/50-60/1) BUG-O DC-IV 1.5-30 ipm (38-750 mm.min) Tool Kit SPEED WEAVER II Weaver Swivel Mount Cable Mounting Assembly H.D. Rigid Rail 931/2" (2.37 m) H.D. Rigid Rail 461/2" (1.18 m) Magnet Bar, Swivel w/Release Same as above except with: 240 VAC BUG-O DC IV 240 VAC SPEED WEAVER II Same as above except with: 42 VAC BUG-O DC IV 42 VAC SPEED WEAVER II
Weld 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 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 dwell time 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-1918
Factory Installed Options: BUG-1760 Digital readout. Displays speed of machine in inches/minutes (cm/m for 42 VAC and 240 VAC).
1.
2.
3. 4.
Weld Tooling Corp.
LIT- SOL-BRO-497
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Make Precision Weave Welds Quickly, Easily, And Economically!

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.
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
The SPEED WEAVER II with solid-state of weld weaving by ensuring accurate control design eliminates relays and limit switches. of amplitude and constant speed, up to 150 Integrated circuits control all functions, and the ipm (3800 mm/min). SPEED WEAVER II extends the usefulness
12 1 2
11
10 9 8
3 4 5
Controls:
1. 2. 3. 4.
Stroke Width Adjustable Rack Circuit Breaker Power Switch
5. 6. 7. 8.
Weld Contactor Switch AC Outlet Mode Selector Switch All-Position Torch Support Group
9. 10. 11. 12.
Crossrail Dwell Right Dwell Left 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.
2
The BUG-5300 SPEED WEAVER II mounts directly onto the various BUG-O carriages. It can also be supplied with the SFX-1255 SuperFlex weaver mount accessory, which is used to mount the SPEED WEAVER II directly onto Super-Flex rail when attached to the SuperFlex carriage.
SPEED WEAVER II
Technical Data:
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: Cycles Per Minute: Stroke: Cycles: 0 to 3 Seconds Each Side; Calibrated Maximum; (Zero Dwell Left and Right) .125" .25" .5" 1.0" 2.0" (3 mm) (6 mm) (12 mm) (25 mm) (50 mm) 160 120 85 60 37
Weld Patterns:
A rotary mode selector switch allows you to choose the following patterns:
1.
2.
3. 4.
Cube Dimensions: 8.5"L x 8.75"W x 6.5"H (216 mm x 222 mm x 160 mm) Net Weight: Shipping Weight: 19 lbs. (8.6 kg) (Not including rail and torch mounting.) 22 lbs (10 kg) (Not including rail and torch mounting.)
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.
SAMPLE WELD BUG-5300 SPEED WEAVER II MOUNTED ON A BUG-O DC DRIVE BUG-5195 WEAVER SWIVEL MOUNT FOR FILLET WELDS Mounts To Weaver
BUG-5195 Weaver Swivel Mount
Mounts To Carriage 3
SPEED WEAVER II
BUG-1916 DC SPEED WEAVING KIT (120/50-60/1)
Includes: 1 BUG-0343 Includes: 1 BUG-9444 1 BUG-5300 1 BUG-5195 1 BUG-2975 1 ARR-1080 1 ARR-1085 5 ARM-2325 BUG-O DC-IV 1.5-30 ipm (38-750 mm/min) Tool Kit SPEED WEAVER II Weaver Swivel Mount Cable Mounting Assembly H.D. Rigid Rail 93-1/2" (2.37 m) H.D. Rigid Rail 46-1/2" (1.18 m) Magnet Bar, Swivel w/Release
BUG-1917 DC SPEED WEAVING KIT (240/50-60/1) BUG-1918 DC SPEED WEAVING KIT (42/50-60/1)
Net Weight of Kit: Shipping Weight of Kit: 91 lbs. (41.5 kg) 101 lbs. (46 kg)
BUG-1910 ROL-O WEAVING KIT (120/50-60/1)

Includes: 1 BUG-2990-F Includes: 1 BUG-9444 1 BUG-5300 1 BUG-5195 1 BUG-1540 DCD ROL-O CARRIAGE 2-30 IPM (38-750 mm/min) Tool Kit SPEED WEAVER II Weaver Swivel Mount Cable Anchor Assembly
BUG-1912 ROL-O WEAVING KIT (240/50-60/1) BUG-1914 ROL-O WEAVING KIT (42/50-60/1)
Net Weight of Kit: Shipping Weight of Kit: 40 lbs. (18.2 kg kg) 50 lbs. (22.7 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 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 USA ROM 1:16 A DIVISION OF WELD TOOLING CORPORATION Weld Tooling Corp. Litho in U.S.A. LIT-SPWV-BRO-1108
SPRINKLER FABRICATION EQUIPMENT
FABRICATE SPRINKLER PIPE quickly and easily with Cypress Welding Equipments complete line of SPRINKLER FABRICATION MACHINES. This easy to use equipment increases production and quality with reduced costs.

A Subsidiary of Weld Tooling Corporation
P.O BOX 690168, HOUSTON, TEXAS 77269 Telephone: 1-281-469-0746 Fax: 1-281-469-9354 http://wwwcypressweld.com
SPRINKLER FABRICATION EQUIPMENT CB-1P (CBO-1020) AIR PLASMA MACHINE

Cut from 3/4" to 12" (19 mm to 300 mm) diameter holes in pipe up to 3/8" (9.5 mm) wall thickness, utilizing the Air Plasma process. The CB-1P (CBO-1020) AIR PLASMA MACHINE allows you to cut precise, clean holes in 5 to 15 seconds with no distortion of the pipe. The machine may be operated continuously in either direction without hose or power cable wrap-up. The machine is equipped with machine torch, power source control cables, PM drive motor and variable speed control for rotation, horizontal and vertical adjustment. It has switches for manual rotation without cutting as well as automatic rotation with cutting.
TECHNICAL DATA
Rating: Input Voltage: Cutting Diameter: Rotation Speed: 60% Duty Cycle 220 VAC Single Phase 3/4" - 12" O.D. (19 - 300 mm) 20 - 400 ipm (500 - 10,000 mm/min) Rise and Fall Cam: Piercing Capability: Cutting Capability: Height: Net Weight: 5" (125 mm) 3/8" (9.5 mm) 1/2" (12 mm) 29" (737 mm) 98 lbs. (44 kg)
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.
2

CWO-4530 MODEL 151 CARRIAGE May be used only with CW-5 CIRCLE WELDERS. The carriage, which is mounted on a standard monorail, is used to move the welder along a length of pipe. Carriage Net Weight: 72 lbs. (32.7 kg)
CWO-4540 MODEL 151P CARRIAGE This carriage, which is mounted on a standard monorail, is used with the CB-1P AIR PLASMA MACHINE. A winch holds the machine and prevents the machine from falling into the hole when the slug drops. This carriage may also be used with CW-5 CIRCLE WELDERS. Carriage Net Weight: 82 lbs. (37.2 kg)
CWO-4550 MODEL 151M CARRIAGE May be used with either the CW-5 CIRCLE WELDER or the CB-1P AIR PLASMA MACHINE. The primary use is with machines on bridge crane type setups, to allow the operator to raise or lower the machine whild reaching over a number of pieces of pipe. The carriage may also be used on standard monorails. Carriage Net Weight: 92 lbs. (41.7 kg)
SPRINKLER FABRICATION EQUIPMENT SE-4P (SEO-4520) PROGRAMMABLE SADDLE & ELBOW CUTTER
The SE-4P programmable machine will cut saddles, laterals, miters, offsets (hillsides) and elbows using a micro-processor and handheld terminal. Oxyfuel or Plasma may be used. Cutting diameter 1" - 12" (25300 mm). (Maximum length of pipe to be cut, 18" [450 mm]). Maximum rotation speed is 3.7 rpm, which is 47 ipm (1160 mm/min) on 4" (100 mm) O.D.s.
TECHNICAL DATA
Cutting Diameter: Rotation Speed: 1-12" O.D. (25 - 300 mm) 0.2-3.7 rpm (47 ipm) (1160 mm/min) Net Weight: Dimensions: Input Power: 200 lbs. (91 kg) 38"L x 15.25"W x 22.25"H 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 ADAPTOR

Used to center the welder in the coupling. The adaptor holds the coupling in place, eliminating the need for tacking. The adaptor is for coupling sizes: 1/2", 3/4", 1", 1-1/4", 1-1/2", 2", 2-1/2", 3", 3-1/2", 4".
SPRINKLER FABRICATION EQUIPMENT CW-5 (CWO-1500 FOR MIG AND FLUX CORED WELDING
The CW-5 (CWO-1500) CIRCLE WELDER is designed for single pass or multipass welding of couplings on sprinkler pipe, utilizing MIG or the Flux Cored process, with gas shielding. The machine is equipped with its own wire feeder, welding control, drive motor, speed control for rotation, horizontal and vertical adjusting racks, rise and fall cam, gun and cable assembly, burnback control, 50 feet (15 m) of control cable, and wire reel adaptor for 30 lb. (14 kg) spools. Welding control has wire feed speed (amperage control), cold wire inch, wire direction and weld switches.
TECHNICAL DATA
Amperage: Input Voltage: Voltage: Wire Sizes: Rotation Speed: 0-300 AMPS 115 VAC 0-50 VAC .035-.062" (.8-1.6 mm) 3-130 ipm (75-3300 mm/min. Cam Range: Welding Diameter: Shielding Gas: Height: Net Weight: 5" (125 mm) 1-12" (25-300 mm) Solenoid Control 29" (737 mm) 135 lbs. (61 kg)
TYPICAL SETUP FOR SPRINKLER FABRICATION
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Dual Sided Fillet Welder Doubles Production.

The Programmable Stiffener Welder will weld both sides of a stiffener at the same time.
The Programmable Stiffener Welder is a self-contained, dual head welding travel carriage with integrated wire feeders and spool mounts. It will produce continuous or programmable intermittent fillet welds on stiffeners with heights of 4" to 18" (102-457mm) and widths of 4" to 12" (102-305mm). The unit is self propelled and runs directly on the stiffener. Spring loaded floating torch holders compensate and maintain torch standoff with variations of work piece fit-up. The machine can be used with solid or cored welding wire.
STIFFENER WELDER
The Programmable Stiffener Welder can accommodate 10, 30 or 60 pound wire reel spools and features 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 of weld length and travel speed, skip length, reverse drive crater fill, pre-weld and post-weld gas purge times.
14.00" (356mm) 18.00" (457mm)
35.00" (889mm)
47.00" (1194mm)
24.00" (610mm)
Technical Data:
Programmable Weld/Skip Travel Speed: 0"-36" ipm (0-900mm/min) Programmable Reverse Drive Crater Fill: 0"-1" (0-25mm)
Soft Touch Programming Center With Digital Readout
Voltage Control (A) Wire Speed Control (A) Wire Jog (A) Feeder On/Off (A) Solenoid Purge Main Weld Cycle Start Travel Jog
Voltage Control (B) Wire Speed Control (B) Wire Jog (B) Feeder On/Off (B) Solenoid Purge Main Weld Cycle Stop
Programmable Pre-Weld/ Post Weld Gas Purge: 0-10 seconds Stiffener Size Range: 4"-18" High (102-457mm) 4"-12" Wide (102-305mm)

2 Weld Tooling Corp.
3001 WEST CARSON STREET LIT- SW-BRO-0404
PITTSBURGH, PA USA 15204-1899 Litho in U.S.A.
ROM 1:16
Automate two heavy duty wire feeders at the same time!

The Stiffener Welder will weld "I", "T", and "L" stiffeners on one or both sides at the same time.
The STIFFENER WELDER from BUG-O SYSTEMS is a self-contained, dual head welder. It will produce continuous or intermittent fillet welds on stiffeners with flange widths up to 12" (0-300 mm) and heights of 3"-16" (75-400 mm). The unit is self-propelled and tracks on the stiffener. The floating gun holders are spring loaded and have dual wheels to ride over tacks. Three ready to use models are available: MIG, Flux-Core or Sub-Arc. A bare machine is also available for those who wish to mount their own feeders. PATENTS WORLDWIDE
STIFFENER WELDER
Operation:
The Stiffener Welder is rolled into position on one end of the beam or stiffener to be welded. The guide wheels are set on each side of the beam to insure that the machine will follow the web of the beam/stiffener as it is being welded. The spring loaded gunholder assemblies are racked into position and the welding guns are centered in the joint to be welded. All controls for the machine are located on the control panel on the front of the machine. To skip weld, turn the Skip/Continuous switch to the Skip Mode. Set the Skip Length dial to determine how long the machine will travel without welding. Next, set the weld length dial to determine how long the machine will travel while welding. (To do this, make a chalk mark on the work piece and time the machine as it travels). Travel distance is determined by the length of time the dials are set for and the speed the machine is traveling while it welds or skips. For continuous welding, turn the Skip/Continuous switch to the Continuous position. Then start the machine by turning on the Carriage Travel switch and set the speed of the machine as it welds. A timer is provided for Puddle Buildup and Crater Fill. (See below)
Control Box:
Power Switch Wire Feed Switches Skip/Continuous Switch Carriage Travel Switch Puddle Buildup and Crater Fill Skip Length (The amount of time the machine travels without welding) G. Weld Length (The amount of time the machine welds; skip mode only) H. Digital Readout (Of Travel Speed) J. Carriage Travel Speed Knob A. B. C. D. E. F.
TO LEFT WIRE FEEDER
POWER CORD TO DRIVE UNIT
TO RIGHT WIRE FEEDER
H F E A
J G D
K C B
Gunholder Assembly:
The Stiffener Welder has two Spring Loaded Gunholder Assemblies which keep the welding torches aligned while the unit is running. Two "V" wheels ride over tack welds and keep the welding guns centered.
STIFFENER WELDER
Technical Data:
38.625 (981 mm) 19.000 (483 mm)
39.625 (1006 mm)
16.625 (422 mm) 17.500 (445 mm)
Direction of Travel
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 Controls:
19.250 (489 mm)
Travel Speed: 3-44 ipm (75-1100 mm/min) [Digital speed readout of carriage speed - inches or cms]
Wire feed: manual or automatic [cold wire feed for set up]. Independent control for left and right. Crater travel forward/off/reverse. Continuous or intermittent welds: Weld length timer: 1-30 seconds Skip length timer: 1-30 seconds
BUG-3190 Stiffener Welder Without Feeder 120 VAC Includes:

1 1 1 1 1 1 1 1 1 1 BUG-3219 BUG-3220 BUG-3230 BUG-3240 BUG-3250 BUG-3335-L BUG-3335-R BUG-3270 BUG-3275 BUG-3280 Chain Assembly Carriage Assembly Drive Assembly Drive Support Cable Anchor Assembly H.D. Corner Follower LH H.D. Corner Follower RH Spool Bracket Motor/Control Mounting Control Box 120 VAC 131 lbs. (60 kg) 226 lbs. (103 kg)
Net Weight: Shipping Weight:
BUG-3192
Same as above except 240 VAC. B
C
3
STIFFENER WELDER
BUG-3200-_____* Stiffener Welder Flux Core 120 VAC/50-60/1
Includes: 1 Stiffener Welder with Feeders 2 Gun and Cable Assemblies 1 Spare Parts Kit 2 Reel Assemblies BUG-3202-___* Same as above except 240 VAC Net Weight of Kit: Shipping Weight of Kit: * Wire sizes available: 264 lbs. (120 kg) [without wire] 360 lbs. (163 kg) [without wire] .068, 5/64, 3/32, 7/64, and .120"
BUG-3180-_____* Stiffener Welder MIG 120 VAC/50-60/1

Includes: 1 Stiffener Welder with Feeders 2 Gun and Cable Assemblies 1 Spare Parts Kit 2 Reel Assemblies BUG-3182-___* Same as above except 240 VAC 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/50-60/1

Includes: 1 Stiffener Welder with Feeders 2 Gun and Cable Assemblies 2 Flux Hoppers 2 Nozzle Assemblies 1 Spare Parts Kit 2 Clamps 2 Adaptor Bracket Assemblies 2 Reel Assemblies BUG-3172-___* Same as above except 240 VAC 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 A DIVISION OF WELD TOOLING CORPORATION Weld Tooling Corp. ROM 1:16
PITTSBURGH, PA USA 15204-1899 Litho in U.S.A. LIT- SWL-BRO-0305
Bug-O Sub-Arc Tractor

Heavy Duty for Welding Fillet and Butt Joints.
The Bug-O Systems Submerged-Arc Tractor is outfitted with all of the necessary equipment for performing submerged-arc welding for fillet and butt joints. The integrated wire-feeder and torch provide racking for cross-seam and vertical 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-feed control unit, providing a seamless interface to the complete welding process. Heavy duty wire feed equipment is included 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.
3001 WEST CARSON STREET PITTSBURGH, PENNSYLVANIA USA 15204-1899 PHONE: 1- 800-245-3186 http://www.bugo.com TELEFAX: 1- 412-331- 0383
Bug-o Sub-Arc Tractor

Controls:
HDT-1086 Control Box
Weld Current Analog Read-Out Control Power/ Emergency Stop Digital Speed Read-Out Speed Control Knob Current Control Knob Voltage Control Knob
Dimensions:
HDT-1300
Travel Selection Switch Wire Feed Inch Up & Down
34.41" (874.01 mm)
42.82" max. (1087.63 mm)
Cycle Start Weld Voltage Analog Read-Out
Cycle Stop
27.44" (696.98 mm)
Travel Direction Switch
HDT-1000
42.22" (1072.4 mm)
13.54" (343.92 mm) 40.47" (1027.94 mm) 24.89" (632.10 mm)
14.02" (356.12 mm) 23.53" (597.75 mm) 47.42" (1204.42 mm)
Net Weight: 255 lbs. (116 kg)

A QUALITY PRODUCT FROM BUG-O SYSTEMS 3001 WEST CARSON STREET PITTSBURGH, PA USA 15204-1899 A DIVISION OF WELD TOOLING CORPORATION Weld Tooling Corp. ROM 1:16 Litho. in U.S.A. LIT-SAT-BRO-1107
Supports & Accessories

The TOOL POSITIONING SYSTEM is a compact and rigid system which can be used to hold a wide variety of cutting torches, welding guns and other handheld tools. It consists of black anodized 7/8" (22.2mm) square aluminum bars with 16-pitch machined racks and ways, right angle clamps, machined rackholders and torchholders.
MDS-1040 Machined Rack Welding Group

A. B. C. D. E. BUG-1796 BUG-1853 MDS-1031 BUG-5455 BUG-5462 Machined Rack 14" (355.6mm) Machined Rack 7-1/2" (190.5mm) 3.5" (88.9mm) Rackholder Gun Mounting Group Right Angle Clamp A B D C E
MDS-1050 Machined Rack Cutting Group

A. C. E. F. BUG-1796 MDS-1031 BUG-5462 BUG-5188 Machined Rack 14" (355.6mm) 3.5" (88.9mm) Rackholder Right Angle Clamp Torchholder Assembly
C E
A F
MDS-1075 Dual Torch Welding Group

Includes: (2) H. MDS-1040 Machine Rack Group (1) I. MDS-1045 Double Rackholder Mount
MDS-1090 Dual Torch Cutting Group

Includes: (2) G. MDS-1050 Machined Rack Cutting Group (1) I. MDS-1045 Double Rackholder Mount
H H I
G I
280 TECHNOLOGY DRIVE CANONSBURG, PENNSYLVANIA USA 15317-9564 PHONE: 1- 800-245-3186 http://www.bugo.com FAX: 1- 412- 331- 0383
Supports & Accessories - Panograph

BUG-O SYSTEM'S CUTTING AND WELDING PANOGRAPHS are spring loaded torch holders that automatically compensate for surface variations. They are designed to carry a cutting torch or welding gun along an irregular or wavy surface to maintain torch to work distance.
PAN-1000 Panograph Torch Floater

J. PAN-1071 Panograph Rackholder K. PAN-1015 Rack 22 5/8" (574.68mm) L. PAN-1010 Panograph with Torchholder J L K
PAN-1008 Welding Panograph

J. PAN-1071 Panograph Rackholder K. PAN-1015 Rack 22 5/8" (574.68mm) M. PAN-1007 Panograph with fits-all clamp J M K
PAN-1072 Double Torch Panograph

N. PAN-1070 Panograph Mounting Double Torch O. PAN-1000 Panograph Torch Floater N
Supports & Accessories - Seam Tracking

PAN-2145-L, R Mechanical Corner Follower
A. B. C. D. E. F. BUG-1796 BUG-1853 MDS-1031 UNI-1036 BUG-5462 PAN-2140-L or -R Machined Rack 14'' (355.60mm) Machined Rack 7.5'' (190.5mm) 3.5'' (88.90mm) Rackholder Rackrider Right Angle Clamp Adjustable Corner Follower B E D A F C Used for tracking a fillet weld, the CORNER FOLLOWER using a spring loaded V-wheel keeps a welding torch centered in the corner of the joint and maintains correct torch to work distance. The Corner Follower is available in Right hand or Left hand configurations.
PAN-2160 Mechanical Seam Follower

A. B. C. D. E. BUG-1796 BUG-5451 BUG-5462 BUG-9180-10 PAN-2100 Machined Rack 14'' (355.60mm) 3.5'' (88.90mm) Rackholder Right Angle Clamps Rod 10'' (254mm) Seam Tracker B D Used for tracking a V grooved butt joint, the SEAM FOLLOWER features 2 axis of adjustment determined by a follower wheel which rides in the joint. It will provide up to 2'' (50.8mm) of compensation up and down as well as left and right for fit up variations. C
Supports & Accessories - Accessories

MDS-1085 4-pin Weld Contact Cable 15' (457.2cm) BUG-9485 2-Pin Connector BUG-9180_ 7/8" (22.2mm) Diameter Rod (Specify Length) BUG-9865 Stepping Module 120VAC
BUG-2660 Fits-All Clamp
BUG-2708 Clamp with 7/8" (22.2mm) Rod
BUG-2915 Torchholder Assembly
BUG-5188 Torchholder Assembly w/7/8" (22.2mm) Rod
CON-1020 Swivel Clamp Assembly
MDS-1031 3.5" (88.90mm) Rackholder
UNI-1036 Rackrider with Post
BUG-2407 Post AssemblyVertical
BUG-5451 3.5" (88.90mm) Rackholder
BUG-5295 Rod Mount Assembly
BUG-2594-10 Taper Glides Package of 10
BUG-5930 Low Profile Cable Anchor Assembly
BUG-5485 Contactor/Cable Anchor
BUG-2975 Cable Mounting Assembly
UNI-1035 Outrigger Arm
CIR-1010-_ Twin Hose Assembly
MUG-1119-36 Triple Hose Assembly

18. 18" (457.2mm) 32. 32" (812.8mm)
GOF-3025 2-Hose Quick-Acting Manifold
BUG-9898 3-Hose Quick-Acting Manifold
BUG-2597 (Specify Length) Machined Rack with rounded 7/8" (22.2mm) end
BUG-2597-8 BUG-2597-15 BUG-2597-22 BUG-2597-27 BUG-2597-30 BUG-2597-36 BUG-2597-39 BUG-2597-42 BUG-2597-48 BUG-2597-54 BUG-2597-60 BUG-2597-72
8" 15" 22" 27" 30" 36" 39" 42" 48" 54" 60" 72"
(203.2mm) (381mm) (558.8mm) (685.8mm) (762mm) (914.4mm) (990.6mm) (1066.8mm) (1219.2mm) (1371.6mm) (1524mm) (1828.8mm)
BUG-5462 Right Angle Clamp Assembly [for 7/8" (22.2mm) Rods]

7/8" (22.2mm) 7/8" (22.2mm)
BUG-3232 Dropping Bar
7/8" (22.2mm) 7/8" (22.2mm)
A QUALITY PRODUCT FROM BUG-O SYSTEMS 280 TECHNOLOGY DRIVE CANONSBURG, PA USA 15317-9564 ROM 1:16 Litho in U.S.A. LIT-SA-BRO-0208 A DIVISION OF WELD TOOLING CORPORATION Weld Tooling Corp.
SUPER-FLEX
WELD OR CUT DIFFERENT DIAMETERS WITH ONE PIECE OF EQUIPMENT!

The SUPER-FLEX RAIL AND CARRIAGE SYSTEM consists of an all position positive rack and pinion drive unit mounted on a SUPER-FLEX rail. The rail conforms to any shape with a radius of 24" (600 mm) or larger and is easily mounted directly on the workpiece. The SUPER-FLEX rail can be used on compound curvatures and can be twisted 10 degrees per 24" (600 mm) of length. Powerful permanent magnets or vacuum cups clamp the rail onto the work surface, fixture or jig. SUPER-FLEX rails can be bolted together for unlimited lengths. SUPER-FLEX rails are made of stainless steel for long life and rugged durability. Several sections of rail, bolted together can be used for a wide range of diameters, shapes and sizes. Standard BUG-O accessories may be used for torch mounting, positioning, and weld weaving applications.
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
SUPER-FLEX
COMPONENTS: Carriages: SFX-1200-F Super-Flex Drive Carriage SFX-1255 Super-Flex Weaver Mount Rail: Magnets: SFX-1160 SFX-1120 SFX-1140 Super-Flex Rail 5' (1.5 m) Magnet Bar With Release Magnet Bar - Swivel With Release Spacer Bar
BUG-2915 GOF-3025 BUG-5451 BUG-9198
BUG-5455
Spacer Bar: SFX-1130
PAN-1033 PAN-1015
BUG-5025
SFX-1200-F BUG-5025 BUG-5300
BUG-1540
SFX-1255
SFX-1120
SFX-1130
ACCESSORIES:
BUG-5451 BUG-1540 BUG-5455 BUG-2915 BUG-5025 BUG-5300 BUG-9198 BUG-9898 2 Rackholder 3.5" (89 mm) Cable Anchor Assembly Gun Mounting Group Torchholder Assembly Angle Mount Speed Weaver II 120 VAC Right Angle Rack 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) Rack PAN-1033 Rod Clamp SFX-1255 Weaver Mount for Super-Flex
SUPER-FLEX
The Super-Flex Rail and Carriage System provides fast easy setup and can be used almost anywhere!
SFX-1160 SUPER-FLEX RAIL: is designed to be 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)
7.25" (184 mm)
USE WITH SUPER-FLEX RAIL ONLY
7.25" (184 mm)
4" (102 mm)
4" (102 mm)
9.00" (229 mm)
SFX-1160 Super-Flex Rail

8.25" (210 mm)
MAGNETS: Two types of magnets are available for use with SUPERFLEX RAILS the SFX-1120 magnet bar with release, or the SFX-1140 magnet bar swivel with release. Both magnets have the same holding capacity. We normally suggest using the SFX-1120 but, the choice is yours specify the magnet bars you want. A minimun of four magnets and four spacer bars (SFX-1130), should be used on each SFX-1160 Super-Flex rail. FOR HORIZONTAL APPLICATIONS, use eight magnets and eight spacer bars.
5.5" (140 mm) 8" (203 mm) 8" (203 mm) 5.5" (140 mm)
2" (51 mm)
2" (51 mm)
1.5" (38 mm)
SFX-1120 Magnet Bar, Fixed
SFX-1130 Spacer Bar
Net Weight: Shipping Weight: Net Weight: Shipping Weight:
SFX-1120/1140 SFX-1120/1140 SFX-1130 SFX-1130
2.25 lbs (1.02 kg) 4 lbs (1.81 kg) 0.25 lbs (0.11 kg) 1 lb (0.45 kg)
TECHNICAL DATA:
Models: SFX-1200-F Super-Flex Drive Carriage 120/50-60/1 SFX-1202-F Super-Flex Drive Carriage 240/50-60/1 SFX-1204-F Super-Flex Drive Carriage 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-F 14 lbs (6.4 kg) Trailer Carriage: Model: Load: Capacity: SFX-1250 Super-Flex Trailer 30 lbs (15 kg)
Mounting Surface: 6"L x 7"W (152 mm x 178 mm) 3
SUPER-FLEX
Super-Flex Flame Cutting Kits
SFX-1000 Includes: 1 SFX-1200-F Super-Flex Carriage Includes: 1 BUG-9444 Tool Kit 2 SFX-1160 8 SFX-1140 8 SFX-1130 1 BUG-5451 1 PAN-1015 1 PAN-1033 1 BUG-2915 1 GOF-3025 1 CIR-1010-3 2 BUG-5025 Super-Flex Laminated Rail 5' (1.5 m) Magnet Bar, Swivel Spacer Bar Rackholder 3.5" (89 mm) Rack 22-5/8" (574 mm) Rod Clamp Torchholder Assembly 2-Hose Q.A. Manifold Twin Hose Assembly 32" (812 mm) Angle Mount SFX-1000-1 Includes: 1 SFX-1200-F Super-Flex Carriage Includes: 1 BUG-9444 Tool Kit 2 SFX-1160 8 8 1 1 1 1 1 1 SFX-1120 SFX-1130 BUG-5451 PAN-1015 PAN-1033 BUG-2915 GOF-3025 CIR-1010-3 Super-Flex Laminated Rail 5' (1.5 m) Magnet Bar, Fixed Spacer Bar Rackholder 3.5" (89 mm) Rack 22-5/8" (574 mm) Rod Clamp Torchholder Assembly 2-Hose Q.A. Manifold Twin Hose Assembly 32" (812 mm) Angle Mount
2 BUG-5025
SFX-1002 Same as above except 240 VAC SFX-1004 Same as above except 42 VAC
SFX-1002-1 Same as above except 240 VAC SFX-1004-1 Same as above except 42 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-1010 Includes: 1 SFX-1200-F Super-Flex Carriage Includes: 1 BUG-9444 Tool Kit 2 SFX-1160 8 8 1 2 1 SFX-1140 SFX-1130 BUG-5440 BUG-5025 BUG-1540 Super-Flex Laminated Rail 5' (1.5 m) Magnet Bar, Swivel Spacer Bar Machined Rack Welding Grp. Angle Mount Cable Anchor Assembly
SFX-1010-1 Includes: 1 SFX-1200-F Super-Flex Carriage Includes: 1 BUG-9444 Tool Kit 2 SFX-1160 8 SFX-1120 8 SFX-1130 1 BUG-5440 2 BUG-5025 1 BUG-1540 Super-Flex Laminated Rail 5' (1.5 m) Magnet Bar, Fixed Spacer Bar Machined Rack Welding Grp. Angle Mount 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-1020 Includes: 1 SFX-1200-F Super-Flex Carriage Includes: 1 BUG-9444 Tool Kit 1 BUG-5300 1 SFX-1255 2 SFX-1160 8 SFX-1140 8 SFX-1130 1 BUG-1540 Speed Weaver II Super-Flex Weaver Mount Super-Flex Laminated Rail 5' (1.5 m) Magnet Bar, Swivel Spacer Bar Cable Anchor Assembly
SFX-1020-1 Includes: 1 SFX-1200-F Super-Flex Carriage Includes: 1 BUG-9444 Tool Kit 1 BUG-5300 1 SFX-1255 2 SFX-1160 8 SFX-1120 8 SFX-1130 1 BUG-1540 Speed Weaver II Super-Flex Weaver Mount Super-Flex Laminated Rail 5' (1.5 m) Magnet Bar, Fixed Spacer Bar 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 VACUUM CUP SUPPORTS FOR 120 VAC AND 220 VAC CONSULT FACTORY.

Weld Tooling Corp.
L IT- SFX-BRO-1098
Return to Index
TANK FABRICATION
Automated Solutions for Your Tank Fabrication Project.
Bug-o Systems
www.bugo.com
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 Drive
Bug-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 Winch
The 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.

Rotating Flux Dam and Welding Head
The 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 Storage
The 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 Features
A 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.

Girth Welder Control Panel
Travel Ready Indicator Input Power Indicator Power Switch Interior Lighting Switch 110 VAC / 220 VAC Flux Recovery Vacuum On/Off Switch
LCD Speed Display Speed Adjustment Knob Maximum Weld Speed Indicator Weld Speed Indicator Left-Stop-Right Travel Direction Switch
Model BGW-1000 Single Side Weld BGW-2000 Double Side Weld BGW-1000-LNG Single Side Weld BGW-1000-D Single Side Weld
Application
Tank Diameter
Welding Thickness
Travel Speed
Min. - Max. Shell Plate Height 6'-10' (1.8 - 3.0 m)
Wire 3/32'' (2.4mm) 1/8'' (3.2mm)
Approx. Weight 2,094 lbs. 950 kg 3,968 lbs. 1800 kg 1,984 lbs. 900 kg 2,425 lbs 1100 kg
Conventional Storage Tanks
Min. 15' (4.5m)
5/16''-1 9/16'' (8-40mm)
Double Shell Cryogenic Storage Tanks Top Down Constructed Storage Tanks
4-114 ipm (100-2900 mm/min) 7'-13' (2-4 m)
2 x 1/16" (2 x 1.6mm)
6'-10' (Tinytwin Arc) (1.8-3.0m)

Girth Welder Application Photos
MDS WEAVER AND VERTICAL WELDER

Modular Drive System
The 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 Welder
The 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.
BUG-GY AND BUG-GY-VERT

Buggy
The 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 AFW-3002 120 Volt 240 Volt
For more detailed information please see our Bug-gy Brochure.
Bug-gy-vert
The 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 (includes battery and charger) VFW-3000 220 Volt (includes battery and charger) 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.
7
GO-FER III
Go-fer III
The straight line Go-fer III can be used to cut, bevel and weld the floor plates. The Go-fers low cost and high reliability make it a great fit for many tank fabrication applications including repair work. GOF-3250 GOF-3252 120 Volt 240 Volt
For more detailed information please see our Go-fer III Brochure.
BUG-O SYSTEMS
Automated Solutions Since 1948.
Six Advantages of Automating Your Welding and Cutting Applications:

1) Increase Production 2) Increase Quality 3) Reduce Material Handling 4) Reduce Distortion 5) Improve Workers' Environment 6) Adapts to Your Application
PITTSBURGH, PA USA 15317-9564 LIT-TANK-BRO-0408 Litho in U.S.A.
BUG-O SYSTEMS
A QUALITY PRODUCT FROM BUG-O SYSTEMS 280 TECHNOLOGY DRIVE A DIVISION OF WELD TOOLING CORPORATION ROM 1:16 Weld Tooling Corp.
TAR-GIT 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
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) Scale
Net Weight: 1 lb. (0.45 kg)
Shipping Weight:
2 lbs. (0.91 kg)
C TAR-1100 SCALE
A QUALITY PRODUCT FROM BUG-O SYSTEMS 280 TECHNOLOGY DRIVE CANONSBURG, PA 15317-9564 USA A DIVISION OF WELD TOOLING CORPORATION Weld Tooling Corp. ROM 1:16 Litho in U.S.A. LIT-TAR-BRO-0908
Bug-O Systems Machine Cutting Torches

Versatile torches for your cutting application.
Positive Pressure "E" Type Torches for Oxy-Acetylene and Alternate Fuels
Part No. BUG-1271 BUG-1274 BUG-1275 Style 2 Hose & Rack 3 Hose & Rack 3 Hose & Rack Barrel 10'' (254 mm) 10'' (254 mm) 18'' (457 mm) Weight 3.3 lbs. (1.50 kg) 3.3 lbs. (1.50 kg) 4.2 lbs. (1.91 kg)
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 Torches for Oxy-Propane and Natural Gas
Part No. BUG-4071 Style 2 Hose & Rack Barrel 10'' (254 mm) Weight 3.3 lbs. (1.50 kg)
Bug-O's Machine cutting torches are designed to handle all types of machine cutting applications. The torches can provide up to 15'' (381 mm) cutting capacity. Two hose and three hose torches are available for all fuel gases at pressures 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.
280 TECHNOLOGY DRIVE CANONSBURG, PENNSYLVANIA 15317-9564 PHONE: 1- 412-331-1776 http://www.bugo.com FAX: 1- 412- 331- 0383
USA
Cutting Tips and Accessories

Oxy-Acetylene Tips
Part No. BUG-1270-000 BUG-1270-00 BUG-1270-0 BUG-1270-1 BUG-1270-2 BUG-1270-3 BUG-1270-4 Tip Size 000 00 0 1 2 3 4 Plate Thickness Light Gauge to 3/16 3/16-3/8 3/8-5/8 5/8-1 1-2 2-3 3-6 Oxygen PSIG 15-20 20-25 35-40 35-40 40-45 45-50 50-75 Fuel Gas PSIG 5-15 5-15 5-15 5-15 5-15 5-15 10-15 Orifice Drill Size #68 #64 #60 #56 #52 #48 #42
* For tips to cut 6'' to 15'', please consult factory.

Part No. BUG-4070-000 BUG-4070-00 BUG-4070-0 BUG-4070-1 BUG-4070-2 BUG-4070-3 BUG-4070-4 BUG-4070-5 BUG-4070-6 Tip Size 000 00 0 1 2 3 4 5 6 Plate Thickness Light Gauge to 3/16 3/16-3/8 3/8-5/8 5/8-1 1-2 2-3 3-6 6-8 8-12 Oxygen PSIG 15-30 20-30 30-40 35-50 40-55 45-60 50-75 65-80 70-90 Fuel Gas PSIG 5-15 5-15 5-15 5-15 5-15 5-15 5-15 5-15 5-15 Orifice Drill Size #68 #64 #60 #56 #52 #42 #42 #35 #30
Adjustable Tip Adapter BUG-1289

Adjust tip to any angle without moving the torches. Tips not included.
Machined Rack Cutting Group MDS-1050

A. B. C. D. BUG-1796 MDS-1031 BUG-5462 BUG-5188 Machined Rack 14'' (355.6 mm) 3.5'' (88.9 mm) Rackholder Right Angle Clamp Torchholder Assembly
Beveling Head BUG-1290

Increases speed of quality bevel cuts. Preheat tip swivels for either left or right travel. Equipped with a heating tip. Use with natural gas or propane tips (not included).
B C
Adjustable Twin Tip Holder BUG-1291

For making two cuts simultaneously with one torch. Adjusts from 1 1/2'' (38.10 mm) to 12'' (304.8 mm) width. Tips not included. A D
Twin Hose Assembly CIR-1010

Specify Length When Ordering
Triple Hose Assembly MUG-1119

Specify Length When Ordering
2-Hose Quick-Acting Manifold GOF-3025
3-Hose Quick-Acting Manifold BUG-9898
A QUALITY PRODUCT FROM BUG-O SYSTEMS 280 TECHNOLOGY DRIVE CANONSBURG, PA 15317-9564 USA A DIVISION OF WELD TOOLING CORPORATION Weld Tooling Corp. ROM 1:16 Litho in U.S.A. LIT-TORCH-BRO-0708
Trac-Bug
Straight Line Track Burning Machine.
Produce machined quality cuts and bevels with Oxy-Fuel or Plasma.
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.
Trac-Bug
The 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. Technical Specifications: Travel Speed: 4-72 ipm (100-1800 mm/min)
*Does not include track or torch.
TRB-1500 Trac-Bug Plasma* Includes Bug-5485 plasma contactor and cable support.
Net Weight: 33 lbs. (15 kg)
Shipping Weight: 38 lbs. (17 kg)

Trac-Bug Plasma TRB-1500 110 VAC TRB-1502 240 VAC TRB-1504 42 VAC
Trac-Bug Oxy-Fuel TRB-1000 110 VAC TRB-1002 240 VAC TRB-1004 42 VAC
12.00'' (305 mm) 18.38'' (467 mm) 12.00'' (305 mm) 17.25'' (439 mm) 7.25'' (185 mm) 6.00'' (152 mm) 18.00'' (470 mm)
9.00'' (229 mm)
8.00'' (204 mm)
6.00'' (152 mm) 7.25'' (185 mm)
TRB-1250 72" (183 cm) Track.

7.00'' (178 mm) 6.00'' (152 mm)
.313'' (8 mm)
72.00'' (1828 mm)

280 TECHNOLOGY DRIVE
Weld Tooling Corp.
ROM 1:16
CANONSBURG, PA 15317-9564 USA Litho in U.S.A. LIT- TRB-BRO-0908
Reliable Low Cost Motion Control.
The Ultimate Welding And Cutting System!
The UNI-BUG II...
up to 2" (50 mm) thick. Weighs only 14 lbs. (6.5 kg). Can go from a straight to a 6" (152 mm) radius inside or out.
Runs directly on workpieces
BUG-O SYSTEMS
Powerful Solutions For Welding And Cutting Automation. www.bugo.com
THE UNIVERSAL BUG-O II

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.
UNI-BUG II
(Torch holding devices not shown for clarity, see back page).
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.
Typical UNI-BUG II applications.
Straightline burning.
Fillet welding.
Coaming welding.
Beam splitting.
Irregular shape burning and welding.
Circle burning and welding.
THE UNIVERSAL BUG-O II

Technical Data:
Power Requirement: UNI-1000 UNI-1002 UNI-1004 Dimensions: Speed Range: Maximum Stiffener Size: Net Weight: Shipping Weight: 120 VAC/50-60/1 240 VAC/50-60/1 42 VAC/50-60/1
10.50'' (267 mm)
Dimensions:
7.62'' (194 mm) 6.25'' (159 mm) 5.75'' (146 mm)
8.00" L x 7.62" W x 10.50" H (203 x 194 x 267 mm) 4 ipm to 75 ipm (102 to 1905 mm/min) 2" (50.8 mm) 14 lbs. (6.35 kg) 16 lbs. (7.26 kg)
6.00'' (152 mm)
2.00'' (51 mm) 2.00'' (51 mm)
6.25'' - 9.0'' (159-229 mm)
8.00'' (203 mm)
Kits:
NOTE: Minimum work height is 2" (50.8 mm). (4" [101.6 mm] when welding). Minimum work height with corner follower is 5" (127 mm).
BUG-1780 Rigid Rail is available for straight line applications, 40" (1 m) long, includes two ON/OFF magnets.
UNI-1100 UNI-BUG II Welding Kit UNI-1102 UNI-BUG II Welding Kit UNI-1104 UNI-BUG II Welding Kit Net Weight: Shipping Weight: 19 lbs. (8.62 kg) 21 lbs. (9.53 kg)
120 VAC 240 VAC 42 VAC
UNI-1200 UNI-BUG II Cutting Group UNI-1202 UNI-BUG II Cutting Group UNI-1204 UNI-BUG II Cutting Group Net Weight: Shipping Weight: 20 lbs. (9.07 kg) 22 lbs. (10.0 kg) Cutting Group UNI-BUG II
120 VAC 240 VAC 42 VAC
Includes: (1) BUG-1855 (1) UNI-100_
Welding Group UNI-BUG II
Includes: (1) BUG-1875 (1) UNI-100_
A QUALITY PRODUCT FROM BUG-O SYSTEMS 280 TECHNOLOGY DRIVE CANONSBURG, PA 15317-9564 USA A DIVISION OF WELD TOOLING CORPORATION Weld Tooling Corp. Litho in U.S.A. LIT- UBII-BRO-0608 ROM 1:16
PROGRAMMABLE UNI-BUG III StItch WELdER
Produce uniform high quality welds with the:
thE UNI-BUG III StItch WELdER

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.
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, 2504 The 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).
UNI-2600, 2602, 2604 The 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.

UNI-2700, 2702, 2704 The 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, 2804 The 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).

UNI-2900, 2902, 2904 The 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).
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: Minimum Stiffener height: Net Weight: Shipping Weight: 75 ipm (1905 mm/min)
dimensions:
11.50'' (292 mm) 7.00'' (178 mm)
2.00'' (51 mm)
2'' (50.8 mm) 27 lb. (12.2 kg) 36.5 lb. (16.6 kg)
2.00'' (51 mm) 6.25'' (159 mm) 7''-9'' (178-229 mm) 8.00'' (203 mm)
Welding & cutting Automation Since 1948.

www.bugo.com 1-412-331-1776 A QUALITY PRODUCT FROM BUG-O SYSTEMS 280 TECHNOLOGY DRIVE CANONSBURG, PA 15317-9564 A DIVISION OF WELD TOOLING CORPORATION Weld Tooling Corp. ROM 1:16 Litho in U.S.A. LIt-UBIII-BRO-0608
BUG-O SYStEMS
BUG-O-MATIC UNIVERSAL BUG-O-MATIC

Flexible, compact Drive and Oscillator combination for welding in all positions.
The UNIVERSAL BUG-O-MATIC is a compact unit which combines a powerful drive and precision oscillator all in one housing. The unit is lightweight and can easily be handled by one operator. The machine works in all positions and can be used for vertical and overhead welds. By simply changing the carriage, the unit can work on rigid rail, semi-flex rail, hi-flex rail or complete ring rails. The opening mechanism of the carriage allows the unit to be released or installed anywhere on the rail.
UNIVERSAL BUG-O-MATIC
While welding, adjustments can be made to the travel speed, amplitude and oscillation speed as well as dwell left and dwell right. While the machine is welding, the torch can be guided by a separate steering knob. Closed loop feedback and dynamic braking allow the Bug-O-Matic to make precise starts, stops and travel at a constant speed.
Technical Data: Input Voltage: Travel Speed: Oscillation Speed: Vertical Load Capacity: Dwell Left/Right: Amplitude: Arc Position Control: Net Weight: BUG-5700 120 VAC 50/60Hz 3-65 ipm (70 1670 mm/min.) 4-98 ipm (100 2500 mm/min.) 31 lbs. (14 kg.) 0-3 Seconds .078-1.37" (2-50 mm) Steering 2" right & left 23 lbs. (10.5 kg.)
7.2" 184 mm
Dimensions
J F E
5.5" 143 mm 9.5" 241 mm
Pendant Control Functions:
G H B C
D A
A. B. C. D. E. F. G. H. J.
Pattern Selector Switch Carriage Travel Switch Carriage Speed Dwell Right Dwell Left Weave Speed Amplitude Weld Contact Steering, Right & Left
Carriages
For Rigid and Semi-Flex rail. For Ring Rail. For Hi-Flex rails.
MPD-1065 4-wheel carriage. Releasable, can be installed or released in any position anywhere on the rail.
BUG-5910 Ring Rail Carriage. 4 wheels can be adjusted to the required ring diameter. Releasable.
FMD-1100 Hi-Flex Carriage. Runs on high flexible SS-Rails as shown below. Releasable. FMD-1050 Hi-Flex Rail Length = 5' (1.5 m) R - Minimum Radius 30" (1,000 mm)
The above shown carriages can be used on the rails shown below: ARR-1080 L = 8' (2.4 m) HD-Rigid Aluminum Rail ARR-1085 L = 4' (1.2 m) HD-Rigid Aluminum Rail AFR-3000 L = 8' (2.4 m) Semi-Flex Aluminum Rail Magnet Bars and Vacuum Bars ARM-2325 Magnet w/Release ARM-2425 Magnet w/Release ARV-1080/1085 Vacuum System ARM-2120 RE-Magnet w/Release FMD-2325 Magnet w/Release FMD-1220/1230 Vacuum System Ring Rails BRR-1210-20 BRR-1210-27 BRR-1210-34 BRR-1210-41 BRR-1210-48 Diameter (20" 500 mm) (27" 680 mm) (34" 860 mm) (41" 1040 mm) (48" 1220 mm)
ARM-2380 Support Bar with Screw Feet ARM-2480 Support Bar with Screw Magnet Feet


LIT-UBM-BRO-1001
Weld Tooling Corp.
Non Metallic Weld Backings For Full Penetration Welding.

Weld More Efficiently. Achieve Full Penetration Welding From One Side And Eliminate Gouging, Backgrinding And Material Handling.
Front View
One-sided welding with Bug-O Systems MDS Travel Carriage.
Back View
Front and back view of a single sided weld.
BUG-O SYSTEMS weld backings are non metallic, non hygroscopic, neutral, and unlike metal backing bars, do not become part of the finished weld. When properly positioned and attached to the back side of a weld joint, your welds can be free of defects eliminating rework and cleanup associated with poor root welds. One-sided one-pass and one-sided muti-pass welds are possible with BUG-O SYSTEMS weld backings. Our backings support molten weld metal over a wide range of welding heats resulting in uniform back beads of finished quality.
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
Non Metallic Weld Backings For Full Penetration Welding.
CSM-1001 CSM-1006
24" 609.6mm 3" 25.4mm
0.05" 1.27mm
0.50" 12.7mm
0.27" 6.86mm
24" 609.6mm 3" 25.4mm
0.04" 1.02mm
0.70" 17.78mm
0.25" 6.35mm
0.90" 22.86mm
1.03" 26.16mm
CSM-1002
CSM-1007
24" 609.6mm 3" 25.4mm
0.04" 1.02mm
0.43" 10.92mm
0.26" 6.60mm
24" 609.6mm 3" 25.4mm
0.51" 12.95mm
0.61" 15.49mm
0.93" 23.62mm
CSM-1003
CSM-1008
23.62" 600mm 2.24" 57mm
0.31" 8mm
24" 609.6mm 3" 25.4mm
0.61" 15.49mm 0.52" 13.21mm
CSM-1004
CSM-1009
23.62" 600mm 2.24" 57mm
.39" 10mm
24" 609.6mm 3" 25.4mm
0.70" 17.78mm 0.46" 11.68mm
CSM-1010
0.04"
BUG-O SYSTEMS
24" 1.02mm 609.6mm 3.5" 88.9mm
0.44" 11.18mm 0.32" 8.13mm 1.23" 31.24mm
3001 WEST CARSON STREET PITTSBURGH, PENNSYLVANIA USA 15204-1899 Weld Tooling Corp. ROM 1:16 Litho in U.S.A. LIT-CSM-BRO-0905
Other configurations are available. Please consult factory for more information.

BUG-O Welding and Cutting

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BUG-O Welding and Cutting

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Affordable Automation for Welding, Cutting and Semi-Automatic Processes

AUTOMATIC HEIGHT CONTROL

A DIVISION OF WELD TOOLING CORPORATION

AUTOMATIC HEIGHT CONTROL

Vertical Travel: Load Capacity: Net Weight: Dimensions: Control Box:

Reduces Material Handling, Cut Beams, Channels And Angles In Place.

BEAM BUG III

Affordable Track Cutting and Welding Systems. www.bugo.com

BEAM BUG III

8. 9. 10. 11. 12.

BEAM BUG III

10.50" (267 mm)

ONLY ONE RAIL SETTING REQUIRED

BEAM BUG III

Welding and Cutting Solutions Since 1948.

A DIVISION OF WELD TOOLING CORPORATION

PORTABLE PLATE BEVELING MACHINE

PBM-2100 Pipe Adaptor (optional)

PBM-2051 Cutting Insert (12 required)

Welding & Cutting Automation Since 1948.

BUG-GY Fillet Welder AFW-3000

The BUG-GY can follow any outside edge.

BUG-GY Fillet Welder AFW-3000

Optional Sub Arc Gun.

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

BUG-GY Fillet Welder AFW-3000

Shipping Weight: 34 lbs. (15.5 kg)

15" (381 mm)

15" (381 mm)

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

BUG-GY-VERT Controls With Oscillator.

Torch Holder Start

Oscillator Dwell Left

H01134-001-01-02 14.4 volt rechargeable battery.

1.250" (32 mm) .50" (13 mm)

8.125" 206 mm 13.188"/16.688" 335/424 mm

8.188" 208 mm 16.250" 413 mm

Welding and Cutting Solutions Since 1948.

280 TECHNOLOGY DRIVE Weld Tooling Corp. LIT- BUG-GY-VERT-BRO-0208

CANONSBURG, PA USA 15317-9564 Litho in U.S.A. ROM 1:16

Bug-O Gantry / Side Beam Automatic Welding Systems

Bug-O Gantry / Side Beam Automatic Welding Systems

Side Beam Welding System

Mechanical torch tracking devices maintain proper torch position.

PITTSBURGH, PA USA 15204-1899 Litho in U.S.A. LIT- BRO-BG-0405

UNI-BUG Bulb Flat Welder

Affordable Automation for Welding, Cutting and Semi-Automatic Processes

A DIVISION OF WELD TOOLING CORPORATION

UNI-BUG Bulb Flat Welder

For 140 to 280 mm.

Shipping Weight: 31 lbs. (14 kg)

UNI-BUG Bulb Flat Welder

* Spacer Block For 280 to 430 mm.

Dimensions shown without torch mounts

5.75 (146 mm)

10.50 (267 mm) 6.00 (152 mm)

Special assembly note:

2.00 (51 mm)

4.6 (117 mm)

Tool Positioning Assembly On Bulb Flat Welder

A QUALITY PRODUCT FROM BUG-O SYSTEMS

3001 WEST CARSON STREET

Weld Tooling Corp.