Climax BW5000 Operating Manual Download Page 78

Page: 78 / 124

Page 74

BW5000 Operating Manual

Summary of Contents for BW5000

Page 1: ...P N 68191 May 2019 Revision 4 BW5000 AUTOBOREWELDER OPERATION MANUAL BW5000 AutoBoreWelder...

Page 2: ......

Page 3: ...and Adjustments 43 Configuration Line Drawings 46 Shipping and Storage 53 Recommended Spare Parts 54 Exploded Views and Parts Lists 55 Schematics 114 Quick Reference Charts 117 W WA AR RN NI IN NG G...

Page 4: ...Page ii BW5000 Operating Manual This page is intentionally left blank...

Page 5: ...operating this machinery ROTATING MACHINERY Rotating machinery can seriously injure an operator Lock out all power sources before you interact with the machine KEEP YOUR WORK AREA CLEAN AND TIDY Keep...

Page 6: ...ity of the machine The operator must ensure there are no other persons in danger from the machine METAL FRAGMENT HAZARD The machine produces metallic fragments during normal operation You should wear...

Page 7: ...and serious injury D DA AN NG GE ER R Indicates a hazardous situation that could be fatal or cause serious injury W WA AR RN NI IN NG G Indicates a potentially hazardous situation that could be fatal...

Page 8: ...y attach directly to the workpiece itself or to an adjacent structure and achieve their rigidity from the structure to which it is attached The design intent is that the Portable Machine Tool and the...

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: ...ed qualifying the equipment operators to the applicable codes and standards Assuring the availability of power and gases at the point of utilization Determining the equipment layout and sequencing for...

Page 12: ...above by a customer supplied frame which suspends the BW5000 over the parts providing a solid platform to make necessary parallelism and centering adjustments of the BW5000 axis to the part axis Diff...

Page 13: ...ressure etc 6 Read all instructions for the power supply unit you have chosen to use with the BW5000 7 Should you have any questions please call our Technical Service Department at 1 603 358 4030 C CA...

Page 14: ...th regard to potentially dangerous electrical shock Do not ever contact electrically live parts Your hands can be insulated with dry hole free leather gloves When working in any damp areas or on metal...

Page 15: ...eld metals and parameters Heavy Duty Torch System The BW5000 brass body torch enables longer run times and longer consumable life increasing production and decreasing downtime Wire Feed System The BW5...

Page 16: ...m Stroke 10 20 30 40 50 inches 254 508 762 1016 1270 mm Weight head unit 170 lbs 77 1 kg Current Capacity 350 amperes 100 duty cycle Step Range 070 to 325 1 78 to 8 26 mm Torch Adjustment 3 inches of...

Page 17: ...P N 68191 Rev 4 Page 13 Figure 1 Major Assemblies...

Page 18: ...ial Rod This clamping arrangement allows for the coarse diameter adjustment by movement of the radial rod in the clamp perpendicular to the line bar The secondary function of this part is an electrica...

Page 19: ...d inlet guide then toggling the switch on the Junction Box Shielding gas enters the wire feed conduit fitting from the Rotatable Power Coupling via the Gas Hose The Portable Wire feeder can be install...

Page 20: ...nnect the rotating AMP connector on the Line Bar Coupling to the Wire feeder Step Mechanism and Auxiliary Mechanism Weld Power Supply Cables Miller 14 Pin P N A1062 Lincoln 14 Pin P N A1088 Control to...

Page 21: ...y should only be completed by a licensed electrician and only after a thorough appreciation of the theory of operation of the power supply has been gained by studying this manual and appropriate power...

Page 22: ...00 333 8311 concerning damaged or missing components Unpacking Instructions When unpacking the machine take care not to drop or damage the components Use lifting eyes or slings to lift the components...

Page 23: ...ey may be greasy and or slippery W WA AR RN NI IN NG G Do not exceed the rated load limit on the Below The Hook lifting device Do not use the Below The Hook device for lifting loads that are not speci...

Page 24: ...609 6 mm above the part face This will give rotational clearance for the BW5000 while also allowing access to the bore The support rails should be securely anchored stable and capable of supporting th...

Page 25: ...r in place are unscrewed far enough so they do not protrude into the taper area Use a 1 4 inch 6 35 mm Allen wrench to turn these screws Remove the Safety Pin 4 that is chained to the Line Bar Couplin...

Page 26: ...it is challenging to measure parallelism as the Line Bar does not extend into the Bore In these cases it may be advisable to wait to do the parallelism adjustments until after the Radial rod and Aux...

Page 27: ...nadvertently Attach the AMP connector on the heavy black coil cord to the AMP connector on the Line Bar Coupling 3 Figure 5 Installing Radial Rod Retrieve the appropriate Radial Rod for the job 1 Choo...

Page 28: ...with Aux Step unit and torch parts before end of limit travel is reached Proper rigging and subsequent stroke check before welding is advisable to prevent damage to the BW5000 C CA AU UT TI IO ON N L...

Page 29: ...the Step Assembly and the Torch The Torch Adjuster is installed in such a way that its travel direction is perpendicular to the bore surface While it is possible to utilize the BW5000 without the Torc...

Page 30: ...may be advantageous to place the Wire feeder on the Radial Rod and place the Wire Reel on the Line Bar To increase the capability and flexibility of the Wire feed system on the BW5000 the inlet guide...

Page 31: ...void using a long conduit whenever possible creating smooth curves to aid in unrestricted wire feeding Contact Climax for special length conduits if needed Attaching Wire Feeder Gas Hose Attach the 40...

Page 32: ...hen welding begins electrically connect the part being welded to the BW5000 stand in order to get weld negative to register at the control voltmeter Attaching Control Cables Control to Head and Weldin...

Page 33: ...is off The control will take 5 seconds to power up indicated by illumination of the red AUTO SKIP LED If the RED LED does not illuminate make sure the E stop mushroom head is in its upper position tw...

Page 34: ...of the moving parts of the BW5000 ROTATION verify operation of Rotation drive ROT INIT verify operation and location of step switch RETRACT verify operation of Step Drive EXTEND verify operation of S...

Page 35: ...assembly 180 opposite to the 12 o clock quadrant and note the distance from the torch to the part Adjust the Y axis one half the difference of the distance between the two points Centering within 1 8...

Page 36: ...the Seconds per Inch of Diameter For example welding at 16 IPM travel speed with a Bore size of 57 inches take the Seconds Per inch of diameter value 11 7 x 57 666 seconds or 11 minutes per rotation A...

Page 37: ...P N 68191 Rev 4 Page 33 Figure 11 Seconds Per Rotation and Travel Speed Constants...

Page 38: ...cific Wire speed value Example 6 seconds of wire jog equals 32 inches of wire passed 32 x 10 320 IPM 812 8 mm x 10 812 8 cm Per Minute See Figure 12 below for approximate amperage values Step Adjustme...

Page 39: ...ammed using two cam disks on the top of the AutoBoreWelder described below 1 Make sure the BW5000 AutoBoreWelder is centered and parallel to the bore 2 Rotate the torch by pressing the ROTATE button R...

Page 40: ...e To use Pie Mode 1 Set up the AutoBoreWelder as described previously 2 Set the Auto Skip cams as if you were going to skip the worn section 3 While you are not welding hold down the FUNCTION key and...

Page 41: ...5 Resume welding as you would for normal BoreWelding The AutoBoreWelder welds in the rotation direction inside the worn area until it reaches the end of the set cam limit It then stops welding and re...

Page 42: ...p is set Verify Voltage is set Verify ROT INIT position is set Verify axial position is set Verify wire is at tip and wire feeder pressure rolls are closed Starting and Stopping the Weld Process To st...

Page 43: ...tments need to be made step adjustments are made in advance of the coming step point then wire speed adjustments made during or after the step point In this way all adjustments happen directly at the...

Page 44: ...y 4 Extend torch to starting point at end of weld and resume welding Limit Switch System Aux Step Mechanism It is important to prevent collision of the step mechanism into any parts of the BW5000 by v...

Page 45: ...rs 12 36 72 and 96 304 8 762 1828 8 and 2438 4 mm Various Configurations The BW5000 can be arranged to weld faces bores and outside diameters with simple changes to the configuration of the Radial Rod...

Page 46: ...rst set up and aligned to the bore using a dummy line bar After this is complete AutoBoreWelder line bar is placed in the Horizontal Mounting assembly the weld head installed and provisions made for s...

Page 47: ...ings Long Term Maintenance Every 15 hours of service blow out the conduit liner with a shot of compressed air to maintain a clean liner Replace Liner when necessary Every 200 hours Inspect feed rolls...

Page 48: ...tension the chain I IM MP PO OR RT TA AN NT T The rotation motor sprocket must be level with and in the same plane as the driven spindle sprocket A 6 inch machinist scale is helpful in verifying this...

Page 49: ...late from the step motor 5 Slide the step motor off of the main block P N 20202 6 Remove the main block from the Aux Slide Guide Rod Perform intended maintenance and clean the main block slide bore Be...

Page 50: ...the different basic configurations of the BW5000 The drawings are suggestions and it should be kept in mind that the BW5000 can be assembled in different ways to complete an application If the applic...

Page 51: ...P N 68191 Rev 4 Page 47 BW5000 Face Welding...

Page 52: ...Page 48 BW5000 Operating Manual BW5000 Outside Diameter Welding...

Page 53: ...P N 68191 Rev 4 Page 49 BW5000 Inside Diameter Conical Welding...

Page 54: ...Page 50 BW5000 Operating Manual BW5000 Outside Diameter Conical Welding...

Page 55: ...P N 68191 Rev 4 Page 51 BW5000 Small Bore Torch Welding...

Page 56: ...Page 52 BW5000 Operating Manual BW5000 Torch Offset Centerline...

Page 57: ...preventative material to unpainted surfaces WD 40 for short term storage LPS 3 for long term storage to prevent corrosion Store the machine in the crates provided Place desiccant bags or vapor wrap a...

Page 58: ...2 GLOVES WELDING CLIMAX BRANDED SIZE LARGE 1 67162 LINER STAINLESS STEEL 065 ID X 188 OD STOCKED IN INCHES 240 67337 LUBRICANT 3 OZ WD 40 1 67453 FEED ROLL V GROOVE 045 062 2 67461 WRENCH HEX 5 16 LON...

Page 59: ...24V 6 70105 ADJUSTER AUX TORCH 7 70106 STEPPING UNIT AUX W O AUX SLIDE GUIDE ROD 8 70107 BAR HOLDER MOUNT FIXED PLACE 9 70112 ASSY COIL CORD 10 70108 ASSY CABLE CONTROL 25 306 P 11 70109 CABLE WELD PO...

Page 60: ...LINCOLN MULTI WELD 6 PIN PLASTIC CONNECTORS 25 FT 8 69916 CABLE ASSY POWER SUPPLY ESAB 350MPI 14 PIN PLASTIC CONNECTORS 25 FT 9 69918 CABLE ASSY POWER SUPPLY MILLER DELTAWELD 5 PIN PLASTIC CONNECTORS...

Page 61: ......

Page 62: ...Page 58 BW5000 Operating Manual...

Page 63: ......

Page 64: ...Page 60 BW5000 Operating Manual...

Page 65: ......

Page 66: ...Page 62 BW5000 Operating Manual...

Page 67: ......

Page 68: ...Page 64 BW5000 Operating Manual...

Page 69: ......

Page 70: ...Page 66 BW5000 Operating Manual...

Page 71: ......

Page 72: ...Page 68 BW5000 Operating Manual...

Page 73: ......

Page 74: ...Page 70 BW5000 Operating Manual...

Page 75: ......

Page 76: ...Page 72 BW5000 Operating Manual...

Page 77: ......

Page 78: ...Page 74 BW5000 Operating Manual...

Page 79: ......

Page 80: ...Page 76 BW5000 Operating Manual...

Page 81: ......

Page 82: ...Page 78 BW5000 Operating Manual...

Page 83: ......

Page 84: ...Page 80 BW5000 Operating Manual...

Page 85: ......

Page 86: ...Page 82 BW5000 Operating Manual...

Page 87: ......

Page 88: ...Page 84 BW5000 Operating Manual...

Page 89: ......

Page 90: ...Page 86 BW5000 Operating Manual...

Page 91: ......

Page 92: ......

Page 93: ...P N 68191 Rev 4 Page 89...

Page 94: ......

Page 95: ...P N 68191 Rev 4 Page 91...

Page 96: ......

Page 97: ...P N 68191 Rev 4 Page 93...

Page 98: ......

Page 99: ...P N 68191 Rev 4 Page 95...

Page 100: ......

Page 101: ...P N 68191 Rev 4 Page 97...

Page 102: ......

Page 103: ...P N 68191 Rev 4 Page 99...

Page 104: ......

Page 105: ...P N 68191 Rev 4 Page 101...

Page 106: ......

Page 107: ...P N 68191 Rev 4 Page 103...

Page 108: ......

Page 109: ...P N 68191 Rev 4 Page 105...

Page 110: ......

Page 111: ...P N 68191 Rev 4 Page 107...

Page 112: ......

Page 113: ...P N 68191 Rev 4 Page 109...

Page 114: ......

Page 115: ...P N 68191 Rev 4 Page 111...

Page 116: ......

Page 117: ...P N 68191 Rev 4 Page 113...

Page 118: ...Page 114 BW5000 Operating Manual Schematics...

Page 119: ......

Page 120: ......

Page 121: ...P N 68191 Rev 4 Page 117 Quick Reference Charts...

Page 123: ......

Page 124: ......

Search results

Summary of Contents for BW5000

Reviews:

Related manuals for BW5000

Brands by name

Popular brands

Climax BW5000, Operating Manual

Search results

Summary of Contents for BW5000

Reviews:

Related manuals for BW5000

Brands by name

Popular brands