Climax AUTOBOREWELDER BW3000 Operating Manual Download Page 26

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BW3000 Operating Manual

IGURE

2-2. BW3000

COMPONENTS

Summary of Contents for AUTOBOREWELDER BW3000

Page 1: ...BW3000 BW3000 AUTOBOREWELDER OPERATING MANUAL P N 52815 February 2019 Revision 7 ...

Page 2: ......

Page 3: ...ons about CLIMAX products or services please call CLIMAX or e mail info cpmt com For quick and accurate service please provide your representative with the following Your name Shipping address Telephone number Machine model Serial number if applicable Date of purchase CLIMAX World Headquarters 2712 East 2nd Street Newberg Oregon 97132 USA Telephone worldwide 1 503 538 2815 Toll free North America ...

Page 4: ...Page B BW3000 Operating Manual CLIMAX GLOBAL LOCATIONS ...

Page 5: ...ctory representative and return the part or repaired machine shipping pre paid to the factory CLIMAX will at its option either repair or replace the defective part and or correct any defect in the labor performed both at no charge and return the part or repaired machine shipping prepaid These warranties do not apply to the following Damage after the date of shipment not caused by defects in materi...

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Page 7: ...essories 24 2 2 3 BoreWelder accessories 24 2 2 4 Plate offset head protector inverted operation 25 2 3 CONTROLS 26 2 4 DIMENSIONS 28 2 5 SPECIFICATIONS 30 2 6 ITEMS REQUIRED BUT NOT SUPPLIED 31 3 SETUP 33 3 1 RECEIPT AND INSPECTION 33 3 2 LIFTING AND RIGGING 34 3 3 MACHINE ASSEMBLY 34 3 3 1 Mounting system when not using the boring bar interface 34 3 3 2 Attaching the BW3000 using the adjustable ...

Page 8: ...2 Stopping the weld 53 4 5 USING ARC INTERRUPT 53 4 6 USING AUTO SKIP 53 4 7 USING PIE MODE AND CARRIAGE RETURN 54 4 7 1 Pie mode 54 4 7 2 Carriage return 55 4 8 WELDING TIPS 56 4 8 1 Achieving the smoothest and least violent arc action 56 4 8 2 Avoiding wire flip by using a wire with a large cast 56 4 8 3 Cleaning glass inclusions from the bore 57 4 8 4 Providing appropriate axial movement each r...

Page 9: ...G 68 5 3 1 Common welding problems and their cures 71 5 3 2 Mechanical electrical troubleshooting 74 6 STORAGE AND SHIPPING 77 6 1 STORAGE 77 6 1 1 Short term storage 77 6 1 2 Long term storage 78 6 2 SHIPPING 78 6 3 DECOMMISSIONING 78 APPENDIX A ASSEMBLY DRAWINGS 79 APPENDIX B SCHEMATICS 123 ...

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Page 11: ...technique 42 3 9 X and Y axes 42 3 10 Swivel connector 43 3 11 Toggle switch in normal position 44 4 1 Function cycle 54 4 2 Conduit shape 57 4 3 Components for locking the head 60 5 1 Components for daily maintenance 63 5 2 Components for offset head adjustments 64 5 3 Knob rotation 64 5 4 Inserting the liner into the torch 68 5 5 Illustration of graping 74 6 1 Packaging arrangement 78 A 1 BW3000...

Page 12: ... mm and 6 152 mm assembly P N 82155 110 A 31 Extension torch 12 305 mm and 18 457 mm assembly P N 85213 111 A 32 Conduit wire feed assembly P N 78533 112 A 33 Shielding gas hose assembly P N 30774 113 A 34 Electrode stick holder assembly P N 36169 114 A 35 Power supply cable 14 pin plastic connectors assembly P N 72101 115 A 36 Power supply cable 6 pin plastic connectors assembly P N 72138 116 A 3...

Page 13: ...2 Spring washer alignment component identification 36 3 3 9 o clock alignment component identification 38 3 4 6 o clock alignment component identification 39 3 5 Available torches 40 3 6 X and Y axes identification 42 4 1 Rotation speed 49 4 2 Wire speed settings and amperage 0 035 diameter wire 49 4 3 Wire speed at startup with 0 035 diameter wire 50 4 4 Estimated step settings at a travel speed ...

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Page 15: ... to aid in setup operation and maintenance tasks Read this entire manual to familiarize yourself with the BW3000 before attempt ing to set it up or operate it 1 2 SAFETY ALERTS Pay careful attention to the safety alerts printed throughout this manual Safety alerts will call your attention to specific hazardous situations that may be encoun tered when operating this machine Examples of safety alert...

Page 16: ...ses risks to your safety Conduct a risk assessment Section 1 5 and Section 1 5 on page 4 of each job site before setting up and operating this machine Intended use Use this machine in accordance with the instructions and precautions in this manual Do not use this machine for any purpose other than its intended use as described in this manual Personal protective equipment This machine produces radi...

Page 17: ...ed while welding Keep combustibles or any other fire hazards well away from the work area For in shop use have a fire extinguisher readily available Moving parts Many CLIMAX machines have numerous exposed moving parts and interfaces that can cause severe impact pinching cutting and other injuries During machine operation Keep hands and tools away from moving parts Wear proper PPE for welding and a...

Page 18: ...e machine 1 5 RISK ASSESSMENT AND HAZARD MITIGATION Welding tools are specifically designed to perform precise metal joining and over lay operations Some welding tools are used in controlled environments such as factories and repair shops however portable welding tools are used in a wide vari ety of conditions A portable welding tool typically attaches directly to the work piece itself or to an ad...

Page 19: ...perator should con sider Use these checklists as part of your risk assessment TABLE 1 2 RISK ASSESSMENT CHECKLIST BEFORE SET UP Before Set up I took note of all the warning labels on the machine I removed or mitigated all identified risks such as tripping cutting crushing entanglement shearing or falling objects I considered the need for personnel safety including shielding from arc rays I read th...

Page 20: ...sent I examined the area surrounding the workpiece for flammable materials and removed them if possible I have an appropriate fire extinguisher nearby I have a fire extinguisher nearby I have assessed for additional risks unique to this application of the Portable Machine tool TABLE 1 3 RISK ASSESSMENT CHECKLIST AFTER SET UP After Set up ...

Page 21: ...relaxed state Centering Positioning the BoreWelder so that it s centered over the bore Complete centering is called centrality DIP Transfer See short arc ESO Electrical Stickout See Stickout HAZ Heat Affected Zone Leveling The process of aligning the axis of the BoreWelder to the axis of the bore to be welded MIG Welding Metal inert gas welding where the consumable metal electrode wire is mechanic...

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Page 23: ...1A TORCH 19 2 1 3 9 000 TORCH 19 2 1 4 CONSUMABLES 20 2 1 4 1 EZ FEED 0 AND 00 TIPS 20 2 1 4 2 HEAVY DUTY TIPS NOZZLES AND DIFFUSERS 20 2 1 5 CABLES AND CONDUITS 20 2 1 5 1 STICK ELECTRODE HOLDER 20 2 1 5 2 POSITIVE WELD CABLE 90 DEGREE CONNECTOR 21 2 1 5 3 2 3 4 5 10 AND 15 FEET CONDUITS 0 6 TO 68 6 M 21 2 1 5 4 NON CLIMAX FEEDER CONDUITS 21 2 2 ACCESSORIES 22 2 2 1 WIREFEEDER ACCESSORIES 23 2 2 ...

Page 24: ...sting the offset head In addition the BW3000 has an Auto Skip function that allows you to set up the BW3000 to not weld a portion of the bore such as a keyway or to weld only a por tion of the bore such as a worn section Principle components include Variable step control for extended weld coverage Auto Skip for designating weld only or skip only areas Auto Stop and Position Indicator Collar to set...

Page 25: ...nent 1 Shop style wirefeeder 2 Wirefeed conduit 3 Enclosed wirefeeder 4 Gas hose inert gas bottle and gas regulator not provided 5 Control box 6 Wirefeed control cable 7 BoreWelder control cable 8 BoreWelder 9 Power supply control cable 10 Weld negative 11 Weld positive 12 Adjustable base ...

Page 26: ...Page 12 BW3000 Operating Manual FIGURE 2 2 BW3000 COMPONENTS 2 3 4 5 5 7 8 9 10 11 12 13 14 15 16 17 18 20 19 21 2 6 1 3 ...

Page 27: ...operator sets the detent in the cams to correspond with the area of the bore to be skipped Also permits welding within the cam detent for repairing worn or out of round bores 6 Adjustable step collar allows the operator to change the location of the step 7 Step motor 8 Clamp hand knob 9 Locking collar supports the BoreWelder in the vertical axis when not clamped 10 Mounting rod supports the BoreWe...

Page 28: ...nd pre machining time Lower consumable and labor costs Elimination of re welding by skipping good sections of the bore Auto stop and position marker The Auto Stop function allows you to set a stop point so that the Bore Welder stops when the bore is complete The Position Marker recalls the last stop point Control box When a CLIMAX wire feeder is used the control box provides One central location f...

Page 29: ... potentiometers allow you to adjust rotation speed wire speed step size and weld voltage The control cables connect the control box to the BW3000 wirefeeder welding power supply and the 100 to 120V AC power 2 1 2 3 Wirefeeder The wirefeeder supports a standard 12 305 mm roll The four roll assembly and shielding gas solenoid are operated by the control box Wirefeeders may be enclosed Figure 2 4 or ...

Page 30: ...od to the bore being welded It s also used to help center the BoreWelder Locking collar The locking collar installed on the mounting rod prevents the BoreWelder from slid ing down the mounting rod when the bore axis is vertical 2 1 2 5 Torches The torches attach to the offset head assembly using the orientation fitting Torches are available to weld holes from 0 5 56 13 1422 mm in diameter Torch ex...

Page 31: ...e BW3000 comes equipped with a power supply control cable that interfaces the control box and the power supply The power cable 2 welding cable transmits welding current from the power sup ply to the BW3000 2 1 2 9 Carrying case The all weather case protects the BoreWelder while providing quick access to the equipment From the top tray remove the control box cables gas hose and isola tor pad From t...

Page 32: ...hen doing OD buildup restrict such buildup to about 10 254 mm from the end This torch can be ordered for 28 56 0 7 1 4 meter diameters Radial mounts equal to the radius of the bore should be fitted between the mounting rod and the BoreWelder The trammel torch requires a mounting rod extender The Trammel Torch is supplied with the following A standard torch adapter for fitting of BW3000 torches and...

Page 33: ...d be moved in or out on its arm until it balances the weight of the torch 2 1 3 7 Torch extension support kit The torch extension support kit is used to provide extension and torch support when the distance from the BoreWelder to the torch is far enough to make torch stability questionable and alignment difficult This accessory is advisable when torch extensions reach over 48 1 219 mm in the horiz...

Page 34: ...mum diameter ranges of the torches that they are fitted to as detailed in the torch ranges shown in Table 2 3 2 1 5 Cables and conduits 2 1 5 1 Stick electrode holder This cable plugs directly into the standard positive weld cable supplied with the BW3000 This cable allows very quick changeover from borewelding to stick welding As most modern power supplies have both CV and CC capability this atta...

Page 35: ...lications 2 1 5 4 Non CLIMAX feeder conduits Many different styles of conduits are available to attach the BoreWelder to wire feeders other than the CLIMAX feeder Most common brands of wirefeeders can be integrated with the CLIMAX BoreWelder These conduits change the stock BW3000 system in the following ways The weld current is transmitted through the conduit itself to a junction block at the Bore...

Page 36: ... Extended Range Torch 13 24 34473 Adapter Standard Torch to Trammel 36170 Counterbalance Kit 30756 Torch Extension Support Kit 33256 1A Torch 39723 000 Torch 39724 Consumables EZ Feed 0 and 00 Tips 35486 Heavy Duty Tips Nozzles and Diffusers Consult CLIMAX Wirefeeder accessories Push Pull Option 44992 Wire Straightener shop style wirefeeder only 35357 Mounting accessories Radial Mount 5 Inch 31411...

Page 37: ...ength or wires that are difficult to feed To use this option the main wirefeeder must be push pull capable The following picture shows a BoreWelder equipped with a push pull feeder FIGURE 2 9 PUSH PULL WIREFEEDER BoreWelder accessories Auto Skip Option factory installed 28000 Slow Rotation Pulley and Belt 32574 Fast Rotation Motor Consult CLIMAX Plate Offset Head Protector Inverted Operation Consu...

Page 38: ... needs radial clearance to rotate without hitting the mounting rod Two lengths are available 5 10 127 254 mm 2 2 2 2 Mounting rod extender The mounting rod extender is used with the mounting rod to extend its length This item is commonly used when using the face conical or trammel torch to provide axial clearance between the BoreWelder and the part 2 2 3 BoreWelder accessories 2 2 3 1 Slow rotatio...

Page 39: ...dle speed is triple the original speed The final output spindle speed allows welding of diam eters from 0 5 9 3 13 236 mm at a travel speed of 20 IPM TIP Installation requires partial disassembly and should be handled only by qualified personnel with instruction from CLIMAX to prevent damage to the BoreWelder 2 2 4 Plate offset head protector inverted operation This shield is designed to protect t...

Page 40: ...L 2 3 4 1 5 7 8 6 TABLE 2 6 CONTROL PANEL COMPONENT IDENTIFICATION Number Component 1 Arc interrupt formula 2 Remote arc interrupt 3 Burnback adjustment formula 4 Refer to the manual for more information on backburning 5 Arc voltmeter 6 Auto skip 7 Pie mode 8 Carriage return ...

Page 41: ...When AUTO SKIP is on the ARC INTERRUPT light is blue ARC INTERRUPT Briefly stop welding but maintain the motion of the BoreWelder Disable AUTO SKIP Note When AUTO SKIP is off the ARC INTERRUPT light is off EMERGENCY STOP Disconnect the mains power Not applicable Knobs STEP SIZE Sets the step size between 0 025 0 220 0 6 5 6 mm ROTATION SPEED Sets the rotation speed between 0 875 28 22 711 mm diame...

Page 42: ...g burnback will change the amount of time the power supply con tinues to feed current into the weld wire after the wire has stopped feeding 0 on the step dial is zero burnback which results in the wire stuck to the base material 10 is maximum burnback which results in the wire burning back into the welding tip 2 5 on the step dial is usually an optimal burnback setting TABLE 2 7 CONTROL PANEL DEFI...

Page 43: ...P N 52815 Rev 7 Page 29 FIGURE 2 12 BW3000 DIMENSIONS P N 85576 9 939IN 252 654MM 20 074IN 509 88MM 6 25 574IN 649 58MM 12 5 846IN 148 488MM ...

Page 44: ... 87 11 78 TABLE 2 8 SUB COMPONENT MASS Specification Description Welding process Metal inert gas MIG Wire diameter range 0 023 0 045 0 6 1 mm Buildup diameter ranges standard model Bore 0 88 27 22 686 mm Outside 0 88 14 22 356 mm Face 0 88 20 22 508 mm Unsupported torch reach in vertical axis 60 1 5 meter ...

Page 45: ... the use of ER 70S 6 Negative cable and C type clamp to connect the power supply to the work piece Stick electrode holder and stick welding rod Weld power supply CC CV 300 amperes Length of stroke 6 152 mm and 12 305 mm Step range 0 025 0 200 0 6 5 mm Maximum continuous welding current 175 A Welding power required Constant voltage CV 200 A minimum 100 duty cycle Control box power requirements 100 ...

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Page 47: ...L AND ROTATIONAL START POSITIONS 45 This section describes the setup and assembly procedures for the BW3000 BW3000 AutoBoreWelder 3 1 RECEIPT AND INSPECTION Your CLIMAX product was inspected and tested prior to shipment and packaged for normal shipment conditions CLIMAX does not guarantee the condition of your machine upon delivery When you receive your CLIMAX product perform the following receipt...

Page 48: ...MBLY 3 3 1 Mounting system when not using the boring bar interface A 1 2 13x3 bolt attaches the BW3000 adjustable base to the part being welded Do the following to use the mounting system 1 Weld the bolt to the part CLIMAX recommends stick welding which pro vides quick setup and reliable performance in rough environments The optional A 1086 stick electrode holder fits quickly into the A 1097 posit...

Page 49: ...ABLE BASE AND MOUNTING HARDWARE 2 3 4 1 5 7 8 9 10 6 11 12 13 TABLE 3 1 ADJUSTABLE BASE AND MOUNTING HARDWARE COMPONENT IDENTIFICATION Number Component 1 Mounting rod 2 Slider 3 Clamping knob type 2 4 Workpiece bore 5 Rear jack screw 6 Front jack screws 7 Center line 8 Mounting bolt 9 Base plate ...

Page 50: ...provided The spring washers maintain consistent pressure on the leveling screws while you adjust the parallelism by doing the following 1 Screw the mounting rod into the slider hole and tighten firmly Torque to 15 ft lbs 20 Nm 2 Install the locking collar P N 10140 8 203 mm from the top of the mounting rod This sets the height of the BoreWelder and prevents the equipment from inadvertently sliding...

Page 51: ... the control box flash three times and then only the red LED and the Arc Interrupt blue LED stay lit If the control cables aren t plugged in the LEDs continue to flash 3 3 4 Adjusting parallelism using the torch extension as a guide Do the following to adjust parallelism using the torch extension as a guide 1 Set the offset head assembly to zero offset by lining up the large hash mark on the side ...

Page 52: ...ars the bore surface at the 6 o clock or 12 o clock position see Figure 3 6 on page 39 Adjust the rear jack screw as needed to make the extension paral lel to the bore TABLE 3 3 9 O CLOCK ALIGNMENT COMPONENT IDENTIFICATION Number Component 1 Forward jack screws 2 Align at the 9 o clock and set the extension parallel to bore surface 2 1 ...

Page 53: ...nsion to the center of bore Estimate the center by eye or mea sure with a scale 2 Lock the BoreWelder to the radial mount by tightening the clamp knob on the BoreWelder 15 ft lbs 20 Nm maximum torque 3 Lightly tighten the radial mount clamp knob to the mounting rod 4 Remove the extension from the orientation fitting TABLE 3 4 6 O CLOCK ALIGNMENT COMPONENT IDENTIFICATION Number Component 1 Rear jac...

Page 54: ...ntation fitting and secure the torch in position with the 1 5 38 mm orientation nut as shown in Figure 3 7 TABLE 3 5 AVAILABLE TORCHES Torch used Bore sizes for torch with standard diffuser Bore sizes for torch with 52fn diffuser 00 0 875 1 75 22 44 mm 0 1 75 3 44 76 mm 1 2 75 5 5 70 140 mm 4 25 7 00 108 178 mm 2 4 5 7 5 114 191 mm 6 00 9 00 152 229 mm 3 6 9 152 229 mm 7 5 10 5 191 267 mm 4 8 11 2...

Page 55: ...s could damage the equipment The range of the torch changes depending on which side of the offset head the torch is oriented toward 3 Align the torch to the offset head dovetail travel Using the adjustment knob on the offset head shift the offset of the torch to adjust the diameter range If the torch doesn t fit the bore as shown in the figure turn the torch and orientation fitting clockwise 180 d...

Page 56: ...s pointing in the 6 o clock position when viewed from the top Do the following 1 Press the ROTATE JOG button or manually rotate the offset head to rotate the torch from the 6 o clock position Point A to the 12 o clock position Point B Make a mental note of the distance from the torch nozzle to the bore surface at these positions 2 Turn the adjustment screw on the adjustable base to center the torc...

Page 57: ...djustment is normally limited to one axis the Y or swing axis from the mounting rod Section 3 3 7 explain how to center on the Y axis In most cases the boring bar interface eliminates the need for parallelism adjust ment since the interface is trued to the boring bar and consequently the bore In situations where parallelism is inaccurate please refer to your boring bar manual for adjustment inform...

Page 58: ...traighten about 6 152 mm of wire at the end of the roll to prepare for feeding 7 If your wirefeeder is equipped with the push pull option place the toggle switch in the normal position see Figure 3 11 before you proceed with the following steps 8 Disengage the pressure rolls on the wire feeder by flipping the levers off the pres sure roll arm 9 Thread the wire into the feed mechanism inlet guide P...

Page 59: ...the end of the hole farthest from the Bore Welder Typically the wire is 1 16 1 8 1 6 3 2 mm from the end Welding always progresses toward the BoreWelder To set the rotation start position push and hold the ROTATION INITIALIZE button on the control box until the torch stops rotating This will be the rotation starting posi tion for the weld Starting here ensures a complete revolution of the torch be...

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Page 61: ...e BoreWelder Coarse 14 Adjust BoreWelder radial mount to move the attached extension to the center of the bore 15 Lock BoreWelder to radial mount 16 Lightly tighten radial mount clamp knob to the mounting rod 17 Remove the extension from the Orientation Fitting Install a Welding Torch 18 Attach torch extensions to BoreWelder Orientation Fitting secure torch with the 1 5 in 38 mm Orientation Nut 19...

Page 62: ...ating the BoreWelder Pre Weld Checklist Weld positive connected to BoreWelder and weld power supply Weld negative connected to part and weld power supply Rotation speed set ROTATION SPEED EXAMPLE 3 5 in diameter x 10 35 SPR 20 IPM Wire speed set WIRE SPEED EXAMPLE 6 sec of wire jog 19 in of wire in 10 min for 190 IPM Step set STEP SIZE NOTE If travel speed is 20 in min amperage step value in inche...

Page 63: ...ROM THE BORE 57 4 8 4 PROVIDING APPROPRIATE AXIAL MOVEMENT EACH REVOLUTION 57 4 9 WELDING IN THE HORIZONTAL AXIS 58 4 9 1 PROCEDURE FOR HORIZONTAL AXIS WELDING 58 4 9 2 OFFSET HEAD SETTINGS WHEN USING EXTENSIONS IN THE HORIZONTAL AXIS 60 4 1 PRE OPERATION CHECKS Do the following checks before operating the machine 1 Complete the risk assessment checklist in Table 1 3 on page 5 2 Check that the wor...

Page 64: ... to the success and speed of completion of a weld Estimating rotation speed SPR As a rule of thumb in a 1 diameter bore at 20 IPM travel speed the SPR is 10 seconds For every inch of bore diameter add 10 seconds to your SPR Example 3 5 diameter x 10 35 SPR 20 IPM Calculating rotation speed SPR exactly The diameter of the bore and the target travel speed IPM provide the information necessary to exa...

Page 65: ...ld ing Setting of wire speed to measure the IPM of wire set the WIRE SPEED dial to 2 for example depress the WIRE JOG button for 6 seconds and multiply that result by 10 Example 6 seconds of WIRE JOG feeds 19 of wire Multiply 19 by 10 to get 190 IPM of wire If you start welding at this dial setting your amperage will be approximately 120 amperes referencing Table 4 2 While the BoreWelder can use d...

Page 66: ...e step is set right To visually check whether the step is set correctly watch the leading edge of the weld process The intent is to have the weld bead lying directly in between the previous bead and the base metal If the step is too short lack of fusion to the base metal can result If the step is too long lack of fusion to the previous bead can result 4 2 3 Setting the arc voltage Understanding ar...

Page 67: ...control on the power supply to REMOTE where appli cable Setting arc voltage The CLIMAX control box interfaces with most power sup plies allowing remote control of voltage at all times If your power supply has digital readouts set the arc voltage to 18 5 volts as a startup value If your power supply has no digital readouts wait until the arc is struck and then adjust the voltage to between 17 19 vo...

Page 68: ...ep is attained when the weld is evenly placed between the previous bead and base metal Normally only adjustments to step wire speed and voltage are necessary to main tain the required weld deposits and feed necessary for successful borewelding WARNING Use the appropriate light shield when making any visual inspection Avoid both direct and indirect exposure to arc rays TABLE 4 6 PRE WELD CHECKLIST ...

Page 69: ...bore This function greatly increases productivity as it is possible to fix a worn section of the bore without excessive pre machining and subsequent borewelding to fill in the over bored area Program the skip area using two cam disks on the top of the BoreWelder Do the following if there are keyways to avoid or worn sections to weld 1 Check that the BoreWelder is centered and parallel to the bore ...

Page 70: ...p setting to Carriage Return hold down the FUNCTION key and press the WELD button twice To move from Carriage Return to Auto Skip hold down the FUNCTION key and press the WELD button once 4 7 1 Pie mode Pie mode is used to weld up worn areas of bore in the vertical axis and worn areas of horizontal axis bores when the worn area is on the top or the bottom of the bore The following procedure assume...

Page 71: ...e machining process 4 7 2 Carriage return Carriage Return is used to weld up a worn area of a bore in the horizontal axis when the worn section occurs on the uphill or downhill side of the bore The following procedure assumes you have just powered up the control and are in the Auto Skip mode Do the following to use Carriage Return 1 Set up the BoreWelder as described in Section 3 and in this secti...

Page 72: ...t condition in borewelding The spindle and torch of the BoreWelder rotate around a nonrotating wire Torque is applied to the wire by the rotating torch and is affected by a number of variables including but not limited to extension lengths stroke of machine conduit length conduit shape and configuration orientation of wirefeeder in relation to Bore Welder and the cast of the wire As the BoreWelder...

Page 73: ... larger glass clumps It is therefore a good practice to clean the glass from the bore after two layers have been applied 4 8 4 Providing appropriate axial movement each revolution During welding check that the STEP SIZE setting is providing appropriate axial movement during each revolution If the step is too great the bead will appear ropey and spaces may appear between the beads If the step is to...

Page 74: ... bead is not against a shoulder or a previous bead take special care to ensure that this first bead is smooth and even At the start a reduced current wire speed is advisable about 95 amps for 0 030 wire and 110 amps for 0 035 wire A normal to slightly fast rotational travel speed is appropriate to promote fast freezing It also is advisable to set the step to a lower value for the first step becaus...

Page 75: ...he causes for lack of fusion to the base material To be safe check that the step size is too large rather than too small Check that the rotation speed is fast enough to prevent the puddle from flowing ahead of the arc If the weld puddle flows ahead of the arc on the downhill the weld bead may not adhere to the base metal This is a common cause for lack of fusion on the downhill Travel speeds of 22...

Page 76: ... clamping screws should be tightened to no greater that 20 in lbs 2 Nm to lock the slide and body together FIGURE 4 3 COMPONENTS FOR LOCKING THE HEAD Consider using the torch extension support kit when reach extends past 4 feet 1 2 meters TABLE 4 8 LOCKING THE HEAD COMPONENT IDENTIFICATION Number Component 1 Body P N 10023 2 Two binder screws to set constant dovetail tension 3 Slide P N 10030 4 Tw...

Page 77: ...ND THEIR CURES 71 5 3 1 1 LACK OF FUSION TO THE BORE SURFACE 71 5 3 1 2 LACK OF FUSION TO THE PREVIOUS WELD BEAD OF THE SAME LAYER 71 5 3 1 3 WIRE FEEDING STOPS AND WIRE BURNS BACK TO TIP 71 5 3 1 4 WELD BEADS ARE ROPEY 71 5 3 1 5 TOO MUCH SPATTER 72 5 3 1 6 TORCH NOZZLE BECOMES TOO HOT 72 5 3 1 7 POROSITY IN THE WELD 72 5 3 1 8 STEEL WELD DEPOSIT IS TOO HARD TO MACHINE 73 5 3 1 9 WELD BREAKS CUTT...

Page 78: ...Remove debris oil and moisture from machine surfaces After each use Wipe down the quill and the mating surface of the offset head assem bly with a clean shop towel lightly sprayed with WD 40 Section 5 2 1 1 Periodically Inspect the following wirefeeder components for signs of wear Drive rolls Pressure rolls Geared drive roll adapters Axles Rubber isolator feet on a shop style wirefeeder Section 5 ...

Page 79: ...void spraying Anti Spatter on the quill tube Offset head After use use a clean shop towel lightly sprayed with lubricant such as WD 40 to clean the mating surface of the offset head assembly It s best to move the slide to its full extent of travel in both directions and clean the exposed area of the body dovetail face Orientation fitting and nut Check that the mating area of the orientation fittin...

Page 80: ... and also prevents shielding gas from escap ing The adjustment is made by tightening the two upper 10 32 socket head cap binder screws that secure the side plate Adjust the binder screws so that the head slides with moderate resistance External hand pressure is neces sary in addition to turning the knob to move the slide The tension of the offset head is correct when the slide can be moved only by...

Page 81: ...side of the case is clean and free of metallic objects Also check that the wire feed motor is secure in the frame of the wirefeeder Damage to the system can result if the wire feed motor is allowed to make contact with the frame of the wirefeeder 5 2 3 2 Wirefeeder adjustments The wire feed drive roll pressure has a wide range of acceptable settings However when the force transmitted to the wire e...

Page 82: ...ses CLIMAX recommends a wire feed setting well below this For mild steel 0 035 diameter wire set the feed roll pressure from 2 5 to 3 on the adjuster barrels TIP Welding wire varies in consistency so a feed roll pressure that was right for one wire may be too much for another wire With each new wire you may have to re adjust the feed roll pressure 5 2 4 Torches conduits and cables 5 2 4 1 Maintain...

Page 83: ...e prevents sharp liner ends from being exposed 5 2 4 4 Replacement of contact tips for torches 00 and 0 When replacing the contact tips of torches 00 and 0 check that the contact tip is positioned correctly in the nozzle The tip should not be centrally located axially Instead the tip should be secured so its exit end is closer to the end of the torch nozzle To determine the proper location and as ...

Page 84: ...environment with minimal maintenance However care should be taken to avoid direct contact with water weld spatter high heat and excessive impact The control box is provided with a cover to completely enclose the case when not in use and to partially protect the case when in use To clean the control overlay and buttons use a shop towel lightly sprayed with WD 40 CAUTION The control box enclosure is...

Page 85: ...on page 75 Porosity in the weld Protect shielding gas from contamination from bore surface by lowering gas flow preventing spatter buildup cleaning bore surface and or using stick welding on laminated sur faces Section 5 3 1 7 on page 72 Too much spatter Lower the arc voltage Section 5 3 1 5 on page 72 Step Machine does not step Check that the step is enabled Check that the STEP switch is working ...

Page 86: ...eed of the torch Deposit another weld layer on top of the hard layer to temper it Post heat the buildup after welding and allow to cool Section 5 3 1 8 on page 73 No arc no wire feed but rotates at dial speed Check that the control box is not in Pie Mode or Carriage Return Section 5 3 2 9 on page 76 No arc no wire feed but rotates at full speed Check that the AUTO SKIP switch is horizontally align...

Page 87: ...posited bead To prevent this problem direct the arc at the exact intersec tion of the previous bead and the bore surface 5 3 1 3 Wire feeding stops and wire burns back to tip This problem is also referred to as tip seizure and is usually caused by one of two reasons A mechanical blockage of debris at the cone entrance to the contact tip This debris jams between the wire and contact tip bore When t...

Page 88: ...c voltage that s too high Keep the voltage between 15 and 18 volts 5 3 1 7 Porosity in the weld Porosity is indicated by a sponge like appearance of the weld bead Porosity is commonly caused by two factors Lack or contamination of shielding gas and a contaminated bore surface Spatter buildup in the nozzle can restrict flow resulting in a lack of shielding gas A gas flow that s too high can cause a...

Page 89: ...vent hardening slow down the cooling rate To do so increase the preheat of the part and or decrease the rotational travel speed of the torch Fast travel speeds produce a rapid quench of the weld beads If hard weld beads are encountered you may be able to temper the hardened bead by welding another pass directly over it If the buildup is still too hard post heat to a temperature of about 1 100 F 59...

Page 90: ...electrical troubleshooting 5 3 2 1 Machine does not step The default setting on power up is step enabled Step can be turned on and off by pressing the FUNCTION key then RETRACT on the control box The STEP switch inside the BoreWelder head unit may not be working properly To check it hold ROTATION INITIALIZE and wait for the spindle to rotate and stop at the step point As an alternate means of chec...

Page 91: ...for continuity If you still have a problem contact CLIMAX 5 3 2 4 Wirefeeder does not feed wire First check the motor for continuity 20 ohms check the schematic in Appendix B Then check the cable for continuity check the schematic in Appendix B If you still have a problem contact CLIMAX 5 3 2 5 Nothing happens when the WELD button is pressed First check if the machine is completely retracted Press...

Page 92: ...rizontally aligned to cams that is the switch roller contacts both cams Check that the AUTO SKIP switch is radially engaging the cams properly that is the switch roller is actuated by the high spot on the cams 5 3 2 9 No arc no wire feed but rotates at dial speed Check that the control is not in Pie Mode or Carriage Return ...

Page 93: ...ain all liquids from the pneumatic conditioning unit Store the BW3000 AutoBoreWelder in its original shipping container Keep all packing materials for repackaging the machine 6 1 1 Short term storage Do the following for short term storage three months or less 1 Retract the tool head from the workpiece 2 Remove the tooling 3 Remove hoses 4 Remove the machine from the workpiece 5 Clean the machine ...

Page 94: ...rding to manufacturer instructions 3 Store the shipping container in an environment out of direct sunlight with temperature 70ºF 21ºC and humidity 50 6 2 SHIPPING The BW3000 AutoBoreWelder can be shipped in its original shipping container 6 3 DECOMMISSIONING To decommission the BW3000 AutoBoreWelder prior to disposal remove the drive assembly from the RDU and dispose of the drive assembly separate...

Page 95: ...SSEMBLY P N 28186 100 FIGURE A 21 8 203 MM FACE TORCH ASSEMBLY PARTS LIST P N 28186 101 FIGURE A 22 CONICAL SEAT TORCH ASSEMBLY P N 28020 102 FIGURE A 23 CONICAL SEAT TORCH ASSEMBLY PARTS LIST 1 P N 28020 103 FIGURE A 24 CONICAL SEAT TORCH ASSEMBLY PARTS LIST 2 P N 28020 104 FIGURE A 25 OD TRAMMEL TORCH ASSEMBLY P N 81384 105 FIGURE A 26 STANDARD TORCHES 2 12 ASSEMBLY P N 82215 106 FIGURE A 27 TOR...

Page 96: ...BW3000 ASSEMBLY 1 P N 85576 58 62 7 64 83 46 45 42 44 20 59 50 SEE DETAIL A 52 51 33 34 65 48 49 34 33 40 12 9 12 84 79 4 71 63 53 54 43 55 27 39 26 25 24 23 22 3 57 19 17 39 41 15 18 23 57 37 36 83 38 29 47 5 76 70 73 68 77 72 10 28 21 78 56 6 ...

Page 97: ...P N 52815 Rev 7 Page 81 FIGURE A 2 BW3000 ASSEMBLY 2 P N 85576 5 38 5 2 83 38 30 16 35 2 85 1 11 13 80 8 68 74 8 75 74 76 67 14 32 82 DETAIL A ...

Page 98: ...2 AWG FLEX A PRENE BLACK 36813 1 19 SWITCH STEP LIMIT 37407 1 20 BELT V SPINDLE DRIVE GOODYEAR 40179 1 21 WASHER SHIM 625 ID 875 OD 062 THK STEEL 40476 1 22 SPRING COMP 845 OD X 067 WIRE X 875 40477 2 23 BRG THRUST 40478 1 24 BUSHING INSULATOR POWER COUPLING 40479 1 25 COUPLING POWER UPPER 40480 1 26 PULLEY POWER COUPLING 40482 1 27 PULLEY ROTATION MOTOR STD 40558 1 28 SHROUD MOTOR ROTATION 40565 ...

Page 99: ...CONNECT DBL CRIMP MALE 22 18 AWG 250 X 032 RED 67048 2 60 NOT SHOWN CONNECTOR SOCKET DBL CRIMP 22 18 AWG 250 X 032 RED 67050 2 61 SHROUD PUSH PULL MODEL Z CLIMAX 67077 1 62 WASHER ISOLATING POWER COUPLING 67168 1 63 SPACER MOUNT PULL FEEDER 67201 2 64 QUILL 6 IN STROKE QUILL 12 IN STROKE 67221 67224 1 65 TOP PLATE ASSY BW3000 68385 1 66 NUT 10 32 STDN ZINC PLATED 10837 1 67 SCREW 10 32 X 3 8 BHSCS...

Page 100: ...NDLE 33955 1 5 FITTING TORCH ORIENTATION 40283 1 6 NUT TORCH ORIENTATION FITTING 40284 1 7 PLATE OFFSET HEAD SIDE 40578 1 8 RACK OFFSET HEAD 40579 1 9 CHART SPINDLE OFFSET HEAD ASSEMBLY CHART 1 10 LINER BOREWELDER SPINDLE 065 ID X 188 OD 67162 CHART 11 AVAILABLE CONFIGURATIONS PART NO DESCRIPTION P N 64162 LENGTH ITEM 10 P N 54273 SPINDLE OFFSET HEAD ASSEMBLY 6 INCH STROKE 17 0 in 62466 62468 SPIN...

Page 101: ...IT 37407 1 2 SCREW 4 40 X 3 8 BHSCS 58482 4 3 CONNECTOR RECEPTACLE 22 16 NICKEL PLATED 58483 1 4 SCREW 4 40 X 3 4 BHSCS 62487 2 5 BRACKET COVER SUB FRAME METAL CONNECTORS 62506 1 6 COVER SWITCH AUTO SKIP MODEL Z 62509 1 7 SHROUD AUTO SKIP PUSH PULL MODEL Z CLIMAX 67077 1 8 SPACER MOUNT PULL FEEDER 67201 2 9 LABEL CLIMAX LOGO 1 5 X 5 5 70226 1 13 13 3 4 1 2 7 5 6 9 8 ...

Page 102: ...ASTIC FLANGE 33988 1 2 SWITCH STEP LIMIT 37407 1 3 SCREW 4 40 X 3 8 BHSCS 58482 4 4 SCREW 4 40 X 3 4 BHSCS 62487 2 5 BRACKET COVER SUB FRAME PLASTIC CONNECTORS 62507 1 6 BEZEL BW3000 62508 1 7 COVER SWITCH AUTO SKIP MODEL Z 62509 1 8 SHROUD AUTO SKIP PUSH PULL MODEL Z CLIMAX 67077 1 9 SPACER MOUNT PULL FEEDER 67201 2 10 LABEL CLIMAX LOGO 1 5 X 5 5 70226 1 15 15 7 4 1 2 3 8 5 6 10 9 ...

Page 103: ...P N QTY ITEM SCREW 1 4 20 X 1 4 SSSHDP 15595 1 1 CLAMP RADIAL MOUNT 40586 1 2 KNOB CLAMPING 40591 1 3 BODY MOUNT RADIAL SEE CHART CHART 1 4 1 4 2 3 AVAILABLE CONFIGURATIONS PART NO DESCRIPTION ITEM 4 P N 28208 MOUNT RADIAL 5 IN RADIUS 125 MM 67227 35006 MOUNT RADIAL 10 IN RADIUS 250MM 67287 ...

Page 104: ...10849 1 1 WASHER 1 2 FLTW SAE 11779 2 2 PIN DOWEL 1 4 DIA X 1 2 20166 2 3 BASE ADJUSTABLE 35933 1 4 WASHER SPRING BELLEVILLE 1 2 ID X 1 OD X 073 37975 4 5 SCREW 1 2 13 X 2 HHHCS GRADE 8 39179 1 6 SCREW 1 2 13 X 3 SQHSSCP 39461 3 7 KNOB CLAMPING 40591 2 8 SLIDER BASE ADJUST 66972 1 9 SCREW ADJUSTMENT 66973 1 10 3 6 4 1 5 7 10 9 2 8 ...

Page 105: ...P N 52815 Rev 7 Page 89 This page intentionally left blank ...

Page 106: ...ge 90 BW3000 Operating Manual FIGURE A 10 SHOP STYLE WIREFEEDER ASSEMBLY P N 82207 36 34 34 9 29 43 42 19 8 11 7 6 21 22 17 3 28 22 39 27 4 1 30 10 35 15 18 8 2 26 12 31 33 40 25 23 38 26 14 13 34 5 34 36 ...

Page 107: ...45 WIRE 62505 1 7 in 18 LABEL WARNING 63504 1 19 NOT SHOWN TUBING 1 4 ID 3 8 OD PVC CLEAR 67031 8 5 in 20 SCREW 5 16 18 X 1 HHCS BLK OX 67034 2 21 WASHER 5 16 FLTW SAE BLK OX 67037 4 22 FITTING CONDUIT FEEDER BW3000 67039 1 23 NOT SHOWN CONNECTOR PIN DBL CRIMP 22 18 AWG 250 X 032 RED 67048 2 24 THUMBSCREW 1 4 20 X 3 4 NO SHOULDER 67059 1 25 CLAMP HOSE 3 8 DIA DBL PINCH STEEL 67064 2 26 FEED MECHAN...

Page 108: ... SCREW 5 16 18 X 1 HHCS BLK OX 67034 1 2 BODY WIRE STRAIGHTENER WELDED 67275 1 3 GUIDE WIRE STRAIGHTENER 67276 1 4 KNOB THREADED ROD ASSY 67278 1 5 BRG BALL 8MM ID X 22MM OD X 497 W SEALS DEEP GROOVE 67279 1 6 NOT SHOWN MANUAL INSTRUCTION SHEET WIRE STRAIGHTENER SHOP STYLE WIRE FEEDER 71322 1 7 NUT 1 4 20 JAMN BLK OX 71568 1 8 NUT 5 16 18 STDN BLK OX 71570 1 9 2 3 6 9 5 3 8 4 1 ...

Page 109: ... OXIDE 11315 20 2 SCREW 10 32 X 1 2 BHSCS 11673 12 3 SCREW 10 32 x 5 8 BHSCS 11674 4 4 SCREW 1 2 13 X 1 SHCS 15307 1 5 SUPPORT WIRE REEL 46555 1 6 CASE PELICAN ENCLOSED W FEED BOX NO LOGO NO CUSTOM FOAM 67302 1 7 WIRE FEED ENCLOSED PANEL BOX 67315 1 8 WIRE FEED ENCLOSED TOP SUPPORT 67316 1 9 WIRE FEED ENCLOSED SPOOL FRAME 67317 1 10 5 1 2 2 3 2 1 3 10 3 2 7 8 9 6 2 4 ...

Page 110: ...READY 24 VDC ASSEMBLY P N 82174 35 1 7 24 12 20 13 21 11 29 34 26 2 8 24 3 33 17 23 28 19 25 5 16 14 15 31 30 9 AVAILABLE ASSEMBLIES PART No WIRE FEEDER ENCLOSED METAL CONNECTORS PUSH PULL READY 24 VDC 66946 WIRE FEEDER ENCLOSED PLASTIC CONNECTORS PUSH PULL READY 24 VDC 44993 ...

Page 111: ...0 X 3 8 BHSCS 58482 8 15 METAL CONNECTOR SOCKET RECEPTACLE 14 5 PLASTIC CONNECTOR SOCKET RECEPTACLE SIZE 13 58486 67163 1 16 LINER STAINLESS STEEL 065 ID X 144 OD FOR 023 045 WIRE 62505 1 25 in 17 FITTING CONDUIT FEEDER SHORT 63213 1 18 LABEL WARNING 63504 1 19 SOLENOID BODY 24V 65473 1 20 BALL 5 32 302 SS GRADE 100 65474 1 21 NOT SHOWN TUBING 1 4 ID 3 8 OD PVC CLEAR 67031 8 5 in 22 THUMBSCREW 1 4...

Page 112: ...EED SYSTEM ASSEMBLY P N 82097 AVAILABLE ASSEMBLIES PART No FEED SYSTEM TOP MOUNT METAL CONNECTORS PUSH PULL 24 VDC 64288 FEED SYSTEM TOP MOUNT PLASTIC CONNECTORS PUSH PULL 24VDC 44992 10 19 20 2 6 x4 12 5 x4 8 10 4 15 1 14 16 10 3 10 7 18 9 17 11 ...

Page 113: ...NIPPLE 1 8 NPTM X 1 8 NPTM X 3 4 BRASS 67006 1 9 WASHER 5 16 FLTW SAE BLK OX 67037 4 10 CONNECTOR SOCKET DBL CRIMP 22 18 AWG 250 X 032 RED 67050 2 11 CONNECTOR PLUG 11 4 PLASTIC CONNECTOR RECEPTACLE 14 5 NICKEL PLATED 67063 58481 1 12 CONNECTOR PIN CRIMP CONTACT 18 16 AWG 67155 2 13 ADAPTER INLET PULL FEEDER 67199 1 14 PLATE MOUNTING PULL FEEDER 67200 1 15 WIRE FEEDER TOP MOUNT 1 ROLL 67210 1 16 S...

Page 114: ... BW3000 Operating Manual FIGURE A 18 COMPACT 6 152 MM FACE TORCH ASSEMBLY P N 48013 1 25 36 12 16 29 12 17 19 6 37 38 28 5 18 12 40 11 7 21 15 24 32 10 31 9 8 8 10 13 3 4 22 34 30 33 14 26 2 12 20 23 35 40 11 ...

Page 115: ... 8 12 LH ACME 67036 1 16 BLOCK HUB FACE TORCH 67139 1 17 BLOCK TRAVELING 67140 1 18 HUB FACE TORCH 67145 1 19 GEAR BEVEL MODIFIED 67148 1 20 GEAR BEVEL PINION 67149 1 21 SPACER TORCH ROD END 257 ID X 500 OD X 10 67150 1 22 ASSY ROD TORQUE RESTRAINT 67153 1 23 SPACER GEAR FACE TORCH 093 THICK 67154 1 24 WASHER SHIM 313 ID 438 OD 010 THK 67175 1 25 LEADSCREW SHORT 3 8 12 ACME LH 67182 1 26 NOT SHOWN...

Page 116: ...W3000 Operating Manual FIGURE A 20 8 203 MM FACE TORCH ASSEMBLY P N 28186 26 16 5 38 15 25 15 37 18 36 1 13 31 9 4 20 41 10 20 40 42 21 15 11 30 8 3 29 27 28 35 32 24 40 34 12 6 41 14 2 19 22 20 23 33 42 7 39 17 ...

Page 117: ...9 1 18 NUT FACE TORCH 3 8 12 LH ACME 67036 1 19 FTG HOSE END 1 4 HOSE TO 1 8 NPTF 67058 3 20 LEADSCREW FACE TORCH 3 8 12 LH ACME 67073 1 21 BLOCK HUB FACE TORCH 67139 1 22 BLOCK TRAVELING 67140 1 23 ROD ROUND GUIDE 8 25 LONG RADIAL TORCH 67141 1 24 CHART GUIDE BAR SQUARE 67142 1 25 LEADSCREW RADIAL TORCH 3 8 16 LH X 5 25 67144 1 26 HUB FACE TORCH 67145 1 27 GEAR BEVEL MODIFIED 67148 1 28 GEAR BEVE...

Page 118: ...l FIGURE A 22 CONICAL SEAT TORCH ASSEMBLY P N 28020 18 53 16 52 19 47 6 35 37 34 2 21 20 45 29 5 13 26 31 41 32 30 33 19 36 38 30 43 40 42 8 24 25 23 1 12 19 7 39 3 39 10 46 44 17 16 52 4 27 15 48 49 50 7 27 14 9 28 11 52 22 48 49 50 ...

Page 119: ...D 19236 1 10 SPACER STEP DRIVE 36625 1 11 BLOCK END FACE TORCH 48870 1 12 LINER STAINLESS STEEL 065 ID X 144 OD FOR 023 045 WIRE 62505 90in 13 ROD TORCH HEAD 64059 1 14 TORCH TRAMMEL NOZZLE STYLE 2 64060 1 15 HOSE CLAMP WIRE 1 2 ID STYLE SELF CINCHING 64062 2 16 HOSE AIR 1 4 ID X 1 2 OD X 72 64063 72in 17 SCREW 3 8 16 X 1 4 SSSFP 64064 1 18 SCREW 10 32 X 3 16 SSSFP 66971 6 19 SCREW 1 4 20 X 1 2 PH...

Page 120: ...K LEFT SIDE 67257 1 36 PLATE RIGHT HUB SIDE 67259 1 37 PLATE LEFT HUB SLIDE 67261 1 38 BRACKET SEAT TORCH TUBE 67266 2 39 SCREW 3 8 16 RH LEAD 67269 1 40 SPACER GEAR FACE TORCH 010 THICK 67289 3 41 ROD SEAT TORCH GUIDE 68154 1 42 GUIDE SEAT TORCH SQUARE 68157 1 43 RADIUS ASSEMBLY FACE 68991 1 44 TUBE TOMMY 8 INCH CONICAL SEAT TORCH 68997 1 45 SCREW 3 8 16 X 1 2 SPHMS 18 8 STAINLESS 69316 1 46 SCRE...

Page 121: ... 112 10 ROD TORCH HEAD 64059 1 11 TORCH TRAMMEL NOZZLE STYLE 2 64060 1 12 HOSE CLAMP WIRE 1 2 ID STYLE SELF CINCHING 64062 2 13 HOSE AIR 1 4 ID X 1 2 OD PER INCH 28 DIA TRAMMEL 56 DIA TRAMMEL 64063 42 60 92 14 SCREW 3 8 16 X 1 4 SSSFP 64064 1 15 HOLDER TRAMMEL TORCH NOZZLE 67004 1 16 SPACER TORCH ROD END 257 ID X 500 OD X 10 67150 1 17 BAR 2 IN EXTENDER TORCH HEAD 67151 1 18 DIFFUSER WELDING 69778...

Page 122: ...T SHOWN LINER TORCH 9 065 in ID X 144 in OD NOT SHOWN LINER TORCH 10 065 in ID X 144 in OD NOT SHOWN LINER TORCH 11 065 in ID X 144 in OD NOT SHOWN LINER TORCH 12 065 in ID X 144 in OD 62505 62505 62505 62505 62505 62505 62505 62505 62505 62505 62505 6 0 in 6 0 in 9 6 in 10 8 in 12 0 in 14 4 in 16 8 in 18 0 in 19 2 in 20 4 in 22 8 in 5 4 3 2 1 AVAILABLE ASSEMBLIES PART No TORCH 2 114 190mm OR 4 5 ...

Page 123: ...107 FIGURE A 27 TORCH 1A ASSEMBLY P N 39723 PARTS LIST DESCRIPTION P N QTY ITEM SCREW 8 32 X 3 16 SSSCP 10841 1 1 NOT SHOWN LINER 065IN ID X 144IN OD 62505 6IN 2 TIP WELDING 035 9mm 69865 1 3 NOZZLE WELDING 69866 1 4 1 3 4 ...

Page 124: ...H HEAD 61389 1 6 NOT SHOWN LINER STAINLESS STEEL 065 ID X 144 OD FOR 023 045 WIRE 62505 120 in 7 ROD TORCH HEAD 64059 1 8 TORCH TRAMMEL NOZZLE STYLE 2 64060 1 9 HOSE 1 4 ID X 1 2 OD 64063 102 in 10 SCREW 3 8 16 X 1 4 SSSFP 64064 1 11 FTG HOSE END 1 4 HOSE TO 1 8 NPTF 67058 2 12 HUB TELESCOPE 13 24 TORCH 68998 1 13 DIFFUSER WELDING 69778 1 14 TIP WELDING 035 9mm 69865 1 15 NOZZLE WELDING 69866 1 16...

Page 125: ...X 144 OD 62505 25 5 IN 4 HUB BEARING CLEARANCE TORCH 6 TO 12 RANGE 64058 1 5 ROD TORCH HEAD 64059 1 6 TORCH TRAMMEL NOZZLE STYLE 2 64060 1 7 HOSE CLAMP WIRE 1 2 ID STYLE SELF CINCHING 64062 2 8 HOSE AIR 1 4 ID X 1 2 OD 64063 18 5 IN 9 SCREW 3 8 16 X 1 4 SSSFP 64064 1 10 FTG HOSE END 1 4 HOSE TO 1 8 NPTF 67058 2 11 DIFFUSER WELDING 69778 1 12 TIP WELDING 035 9mm 69865 1 13 NOZZLE WELDING 69866 1 14...

Page 126: ...ND 6 152 MM ASSEMBLY P N 82155 PARTS LIST DESCRIPTION P N QTY ITEM SCREW 8 32 X 3 16 SSSCP 10841 2 1 LINER STAINLESS STEEL 065 ID X 144 OD FOR 023 045 WIRE 62505 3IN 6IN 2 AVAILABLE CONFIGURATIONS PART NO DESCRIPTION 29038 EXTENSION TORCH 3IN 29039 EXTENSION TORCH 6IN 1 2 ...

Page 127: ...ASSEMBLY P N 85213 PARTS LIST DESCRIPTION P N QTY ITEM SCREW 8 32 X 3 16 SSSCP 10841 2 1 LINER STAINLESS STEEL 065 ID X 144 OD FOR 023 045 WIRE 62505 12IN 18IN 2 AVAILABLE CONFIGURATIONS PART NO DESCRIPTION 29040 EXTENSION TORCH 12IN 305MM 29065 EXTENSION TORCH 18IN 457MM 1 2 1 ...

Page 128: ...ONDUIT FEEDER END BW3000 86832 1 10 O RING 3 32 X 1 16 ID X 1 4 OD BUNA N DASH 102 86835 2 11 SCREW WITH WIRE ORIFICE SEAL CONDUIT 86836 1 12 WASHER 25 OD 068 ID x 025 THK 86847 1 13 A 2 1 6 8 4 3 4 7 9 5 AVAILABLE CONFIGURATIONS PART NO DESCRIPTION P N 35011 P N 40550 P N 62505 31894 CONDUIT WIRE FEED 2FT 0 6M LONG 22 24 27 31895 CONDUIT WIRE FEED 3FT 0 9M LONG 34 36 39 35574 CONDUIT WIRE FEED 4F...

Page 129: ...HOWN WIRE TIE MEDIUM 14 X 8 13243 1 1 NUT SIZE B INERT GAS 48939 1 2 HOSE 1 4 ID X 1 2 OD 64063 240 in 3 CLAMP HOSE 1 2 DIA DBL PINCH STEEL 67007 2 4 FTG NIPPLE INERT GAS B SIZE 1 4 HOSE 67033 1 5 FTG HOSE END 1 4 HOSE TO 1 4 NPTF 67065 1 6 FTG QUICK COUPLER 1 4B 1 4 NPTF FEMALE AIR ARO STYLE 72570 1 7 3 7 4 4 5 2 6 ...

Page 130: ...al FIGURE A 34 ELECTRODE STICK HOLDER ASSEMBLY P N 36169 PARTS LIST DESCRIPTION P N QTY ITEM INSERT WELDING CABLE CLAMP 36812 2 1 CABLE POWER COUPLING 36813 72 in 2 CONNECTOR POWER MALE 67159 1 3 HOLDER ELECTRODE 67235 1 4 2 1 3 1 4 ...

Page 131: ... 22 AWG 67169 5 7 RUBBER BUSHING FOR MS3057A CABLE CLAMP 312 ID 67214 2 8 CONNECTOR V300 14 PIN KEY 67298 1 9 TUBING HEAT SHRINK 75 ID 2 1 SHRINK RATIO CLEAR 1 5 LONG 70657 1 10 CORD TYPE SOOW 18 AWG 5 COND 600V 325 OD UNSHIELDED GRAY JACKET 83988 CHART 11 AVAILABLE CONFIGURATION PART NO DESCRIPTION P N 83988 QTY 32042 CABLE ASSY POWER SUPPLY LINCOLN 14 PIN PLASTIC CONNECTORS 25 FT 301 44232 CABLE...

Page 132: ...NNECTOR CABLE CLAMP MS3057A SIZE 18 67138 1 4 TERMINAL PIN 18 16 AWG 67155 7 5 RUBBER BUSHING FOR MS3057A CABLE CLAMP 312 ID 67214 1 6 CONN PLUG 6 PIN 70259 1 7 TUBING HEAT SHRINK 5 ID 2 1 SHRINK RATIO CLEAR 70655 1 8 CORD TYPE SOOW 18 AWG 5 COND 600V 325 OD UNSHIELDED GRAY JACKET 83988 CHART 9 5 4 7 6 9 8 2 1 3 AVAILABLE CONFIGURATION PART No DESCRIPTION P N 83988 QTY 55327 CABLE ASSY POWER SUPPL...

Page 133: ...IMP CONTACT MALE 24 20 AWG MULTIMATE 53102 6 2 CONNECTOR PLUG 17 14 PLASTIC 58576 1 3 CABLE CLAMP LARGE SIZE 11 67060 1 4 NOT SHOWN WIRE 20 AWG RED CU STRAND TYPE MTW 67123 2 5 CONNECTOR PLUG 4 PIN REVERSE MALE FEMALE SIZE 11 67160 1 6 CABLE POWER 2 CONDUCTOR 18 AWG 300 VAC RUBBER JACKET BLACK 67280 300 7 TUBING HEAT SHRINK 5 ID 2 1 SHRINK RATIO CLEAR 70655 5 8 2 3 1 8 7 4 6 2 ...

Page 134: ... BW3000 Operating Manual FIGURE A 38 BW3000 CONTROLLER PLASTIC METAL CONNECTORS ASSEMBLY P N 87304 27 56 x16 19 x16 7 x4 16 15 x4 26 15 x4 40 28 25 23 x4 32 29 31 30 28 14 26 17 10 52 28 x4 41 15 x4 18 9 x4 35 ...

Page 135: ...15 Rev 7 Page 119 FIGURE A 39 BW3000 CONTROLLER METAL CONNECTORS ASSEMBLY P N 87304 47 2 2 47 2 47 12 5 4 8 2 47 58 40 11 60 60 11 x2 11 x2 60 5 33 24 20 12 6 28 6 24 20 53 46 x4 39 38 29 36 35 42 22 59 13 37 ...

Page 136: ...58482 SCREW 4 40 X 3 8 BHSCS 16 1 58484 58580 CONNECTOR RECEPTACLE 22 14 NICKEL PLATED RECEPTACLE FLANGED 14 PIN AMP THERMOPLASTIC HOUSING 17 1 58485 58580 CONECTOR RECEPTACLE 14 7 ZINC PLATED RECEPTACLE FLANGED 14 PIN AMP THERMOPLASTIC HOUSING 18 1 58486 CONNECTOR RECEPTACLE 14 5 METAL 19 16 62944 SCREW 6 32 X 5 8 BHSCS 20 2 63525 DRIVE MOTOR CONTROL 115 230VAC 21 1 66917 NOT SHOWN CORD POWER 5 1...

Page 137: ...OLE 5 X 20MM FUSE 230V ONLY 46 4 73758 NUT 4 40 NYLON INSERT LOCKNUT ZINC PLATED 47 8 73763 NUT 8 32 NYLON INSERT LOCKNUT HEX ZINC PLATED 48 1 73773 NOT SHOWN DRAWER FUSE 2 POLE W SHORTING BAR 5 X 20MM FUSE 49 2 73776 NOT SHOWN WIRE TIE 20 5 LONG 50 2 IN 73786 NOT SHOWN FOAM STRIP 75W X 5 SQFT URETHANE ADHESIVE BACKED PLASTIC ONLY 51 1 73878 NOT SHOWN CORD POWER CEE 7 7 230V 90 DEG C13 RIGHT 8 FT ...

Page 138: ... X 144 OD X 16 FT FOR 023 045 WIRE 1 52815 MANUAL INSTRUCTION MODEL BW3000 BOREWELDER 1 63846 WRENCH SPANNER 2 INCH 1 63847 WRENCH SPANNER 1 5 INCH 1 63848 WRENCH SPANNER 1 2 7 8 INCH MODEL Z 1 66947 KIT CONSUMABLE PACKAGE BW3000 035 9MM TIPS KB 1 67082 GLOVES WELDING CLIMAX BRANDED SIZE LARGE 1 67313 WELD SAMPLE 2 750 ID X 3 500 OD X 2 000 KB 1 67337 LUBRICANT 3 OZ WD 40 1 69866 NOZZLE WELDING AL...

Page 139: ...3 WIRE FEEDER WITH PLASTIC CONNECTORS SCHEMATIC P N 87415 126 FIGURE B 4 POWER SUPPLY INTERFACE CABLE WITH PLASTIC CONNECTOR SCHEMATIC P N 87419 127 FIGURE B 5 POWER SUPPLY INTERFACE CABLE SCHEMATIC WITH PLASTIC CONNECTOR P N 87421 128 FIGURE B 6 METAL CONNECTORS SYSTEM LAYOUT P N 70186 1 129 FIGURE B 7 METAL CONNECTORS LADDER SCHEMATIC P N 70186 2 130 FIGURE B 8 CHART CONTROLLER WITH METAL CONNEC...

Page 140: ...Page 124 BW3000 Operating Manual FIGURE B 1 BOREWELDER WITH METAL OR PLASTIC CONNECTORS SCHEMATIC P N 87413 ...

Page 141: ...P N 52815 Rev 7 Page 125 FIGURE B 2 WIRE FEEDER WITH METAL CONNECTORS SCHEMATIC P N 87414 ...

Page 142: ...Page 126 BW3000 Operating Manual FIGURE B 3 WIRE FEEDER WITH PLASTIC CONNECTORS SCHEMATIC P N 87415 ...

Page 143: ...P N 52815 Rev 7 Page 127 FIGURE B 4 POWER SUPPLY INTERFACE CABLE WITH PLASTIC CONNECTOR SCHEMATIC P N 87419 ...

Page 144: ...Page 128 BW3000 Operating Manual FIGURE B 5 POWER SUPPLY INTERFACE CABLE SCHEMATIC WITH PLASTIC CONNECTOR P N 87421 ...

Page 145: ...P N 52815 Rev 7 Page 129 FIGURE B 6 METAL CONNECTORS SYSTEM LAYOUT P N 70186 1 ...

Page 146: ...Page 130 BW3000 Operating Manual FIGURE B 7 METAL CONNECTORS LADDER SCHEMATIC P N 70186 2 ...

Page 147: ...P N 52815 Rev 7 Page 131 FIGURE B 8 CHART CONTROLLER WITH METAL CONNECTORS P N 70186 3 ...

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