Climax BW1000 Operating Manual Download Page 1

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P/N 40831
May 2019
Revision 4

BW1000

WELDING MACHINE

OPERATING MANUAL

ORIGINAL INSTRUCTIONS

CE only applies to the

entire machine when

P/N 40831 is included

Summary of Contents for BW1000

Page 1: ...P N 40831 May 2019 Revision 4 BW1000 WELDING MACHINE OPERATING MANUAL ORIGINAL INSTRUCTIONS CE only applies to the entire machine when P N 40831 is included...

Page 2: ......

Page 3: ...ICATIONS 12 BUILDUP DIAMETER RANGES 12 POWER SUPPLY COMPATIBILITY 13 MAJOR ASSEMBLIES 14 OPTIONAL EQUIPMENT 15 ADJUSTABLE BASE 15 RADIAL MOUNT 15 EXTENSION 15 TRAMMEL TORCH 15 HEADLESS SUPPORT KIT 15...

Page 4: ...ND WIRE BURNS BACK TO TIP 28 WELD BEADS ARE ROPY 28 TOO MUCH SPATTER 28 POROSITY IN WELD 29 STEEL WELD DEPOSIT TOO HARD TO MACHINE 29 WELD GRAPING WHEN WELDING IN THE HORIZONTAL AXIS 30 BEAD ROPY VOLT...

Page 5: ...s to reduce the risk of hazards and serious injury DANGER Indicates a hazardous situation that could be fatal or cause serious injury WARNING Indicates a potentially hazardous situation that could be...

Page 6: ...rks and flame Other personnel in the area need to be protected from the arc rays by a screen and or a warning not to watch or otherwise expose themselves to the rays or to any hot spatter Practice goo...

Page 7: ...al Proper care is your responsibility Contact Climax immediately for replacement of damaged or lost manuals or safety decals 1 800 333 8311 INTENDED USE Only use the machine according to the instructi...

Page 8: ...nclude lathes and milling machines and are typically found in a machine shop They are mounted in a fixed location during operation and are considered to be a complete self contained machine Stationary...

Page 9: ...taken precautions to keep workers away from the identified fall path I considered how this machine operates and the best placement for the controls cabling and the operator I evaluated and mitigated a...

Page 10: ...factory 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...

Page 11: ...tten authorization Equipment is owned by the original purchaser It shall be the warrantee s responsibility to prove compliance with the above conditions of warranty enforcement Bortech has the option...

Page 12: ...Portable Machining and Welding Systems BoreWelder Model Number BW1000 Serial Numbers See Machine Audible Noise Levels Surface sound pressure level in dBA 70 dBA Sound power level in dBA 84 dBA Sound...

Page 13: ...P N 40831 Rev 4 Page 9...

Page 14: ...features may result in operator or bystander harm Grease and or oil native to machinery may result in allergic reaction to operator Smoke from welding metals may be harmful if inhaled Gas bottle need...

Page 15: ...et up the operator is required to Align the Borewelder to the bore using either the appropriate interface tooling for Boring bar to be used or the Bortech Adjustable base Determine the proper torch bo...

Page 16: ...ding Current 140 amps Welding Power Required Constant Voltage CV BW1000 Power 220v 50 60Hz VAC 120v model also available Contactor Control Provided via remote switch Typical Voltage Operating Range sh...

Page 17: ...ge CV type suitable for MIG welding Only licensed electricians should perform attachment of the power supply control cable trigger or contactor control to the wire feeder This should be done only afte...

Page 18: ...at the rear face of the machine Conduit Assembly Provides passage of welding current welding wire and shielding gas to the BW1000 Includes Wire feed Control Cable for actuation of trigger circuit cont...

Page 19: ...t Boring bar interfaces that designed for the CLIMAX BW3000 The BW1000 is a center mount system enabling Climax Boring Bars to interface kits more effectively than previous designs The radial mount re...

Page 20: ...interface i e the swing axis from mounting rod 11 Set the torch nozzle to bore clearance from 1 8 to 1 4 inch 12 Connect BW1000 end of Wirefeeder Conduit to the Brass Power Coupling and secure setscr...

Page 21: ...hanges to Voltage on power supply may be required to stabilize the weld process 16 to 18 volts is typical borewelding voltage range 2 Visual confirmation that the Spindle axial feed rate matches weld...

Page 22: ...late the time per revolution multiply the diameter of the bore by one of the three IPM constants below to get Seconds per Rotation Seconds Per Rotation 18 IPM Bore Dia x 10 4 VERT BORE AXIS Seconds Pe...

Page 23: ...stments are being made Install the radial mount onto the mounting rod and then the BW1000 into the Radial Mount 5 Attaching extensions to the BW1000 and reaching through the hole to be welded facilita...

Page 24: ...sion in the downhill section For accurate results time the spindle rotation Multiply the diameter of the bore by one of the three inches minute constants to obtain the seconds revolution Seconds Rev 1...

Page 25: ...ve live copper nozzles making clearance between the nozzle and the bore particularly important Though not usually required it may be necessary to feed the wire through the BW1000 and Swivel Assembly w...

Page 26: ...ity of the Support Body with the bore is obtained attach the Extension Support Rod to an appropriate foundation as described above Radial Mount This accessory is used to extend the reach of the BW1000...

Page 27: ...necessary to oil the needle bearings that support the spindle Factory lubrication is low viscosity oil in sparing quantities Replacing Liners NOTE Liners and related parts in the BW1000 seldom requir...

Page 28: ...to hold the piece in a centered position This way the operator gets needed practice at this task If this is done it won t be long before the operator is able to center the machine in less than 1 or 2...

Page 29: ...d one on top of another the glass from the lower level re melts and is added to the new glass forming larger clumps Therefore it is good practice to clean the glass from the bore after each successive...

Page 30: ...tal Gouged out metal will flow and form globules or grapes or in less severe cases it may form a humped bead This also produces undercutting at the edge of the weld bead Increasing the Rotational spee...

Page 31: ...P N 40831 Rev 4 Page 27...

Page 32: ...and may improve the welding Changing the liners is usually not necessary in cases of wire stoppage Sometimes the liner right at the torch nozzle overheats and should be replaced Generally liners will...

Page 33: ...ful not to short Borewelder components to the piece being welded Steel weld deposit too hard to machine Assuming the wire is a mild steel wire such as 70s series the ability to harden must be coming f...

Page 34: ...hat its weight overcomes the surface tension that otherwise would hold it in place and the bead spills It also is possible for graping to occur if the step is too great or too little In these cases th...

Page 35: ...P N 40831 Rev 4 Page 31 Exploded View Drawings and Parts Lists Please contact Climax if you have any questions about parts service or operation...

Page 36: ...BEL 1 63504 4 COVER SHROUD 1 63487 5 6 32x 250 BtnHd Cap Scr 4 63497 6 SHROUD DOZER CE WG BLUE 1 63489 7 POWER INLET MODULE 1 63491 8 FUSE GLASS 2 64264 9 SWITCH 1 42753 10 KNOB 1 61266 11 THREADING N...

Page 37: ...er Worm Gear 1 63514 20 Handknob spindle drive 1 63515 21 Spring Washer Handknob Spindle Drive 1 63516 22 Nut Nylock 3 8 24 1 63517 23 10 32x1 5 Soc Hd Cap Scr 1 10936 24 Base Plate CE WG 1 64259 25 1...

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Page 39: ...P N 40831 Rev 4 Page 35...

Page 40: ...Page 36 BW1000 Operating Manual...

Page 41: ...P N 40831 Rev 4 Page 37...

Page 42: ...Page 38 BW1000 Operating Manual...

Page 43: ...P N 40831 Rev 4 Page 39...

Page 44: ...per minute IPM In Vertical borewelder axis welding travel speed can be decreased In the Horizontal borewelder axis welding travel speed should be increased to prevent lack of fusion on the downhill s...

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