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INSTRUCTIONS
PARTS MANUAL
CIRCLE WELDER
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.
280 TECHNOLOGY DRIVE
PHONE: 412-331-1776
AND
CWP-7
Bug-O Systems is guided by honesty, integrity and
ethics in service to our customers and in all we do.
A DIVISION OF WELD TOOLING CORPORATION
CANONSBURG, PENNSYLVANIA 15317-9564 USA
http://www.bugo.com
LIT-CWP-7-IPM-0218
FAX: 412- 331- 0383
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Related Manuals for BUG-O CWP-7
Summary of Contents for BUG-O CWP-7
- Page 1 Whenever you request replacement parts or information on this equipment, always supply the information you have recorded above. LIT-CWP-7-IPM-0218 Bug-O Systems is guided by honesty, integrity and ethics in service to our customers and in all we do. A DIVISION OF WELD TOOLING CORPORATION...
- Page 2 SAFETY PROTECT YOURSELF AND OTHERS FROM SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS. EQUIPMENT DAMAGE ELECTRIC SHOCK can kill. POSSIBLE. 1) The equipment is not waterproof. Using the unit in a wet environment may result in serious injury.
- Page 3 HIGH FREQUENCY WARNINGS SPECIAL PRECAUTIONS ARE REQUIRED WHEN USING PLASMA, TIG OR ANY WELDING PROCESS THAT USES HIGH FREQUENCY TO STRIKE AN ARC. WARNING: HIGH FREQUENCY CAN EFFECT MACHINE OPERATION AND THEREFORE, WELD QUALITY. Read the precautions below before installing and using the equipment. PRECAUTIONS: 1) Some plasma or welding cables are strong sources of high frequency interference.
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Page 4: Table Of Contents
17..CWP-1700 CWP-7 Circle Welder / Exploded View 18..CWP-1700 CWP-7 Circle Welder / Parts List 19..CWP-1700 CWP-7 Circle Welder / Wiring Diagram / Electrical Component Chart 20..CWO-3495 CW-7 Collector / Exploded View / Parts List 21..CWO-3139 Universal Power Cable / Exploded View / Parts List 21.. - Page 5 INTRODUCTION The CWP-7 Circle Welder is designed for welding of nozzles into vessels or domed heads utilizing SUB- ARC, MIG or FLUX CORED PROCESS, with gas shielding. The CWP-7 mounts on a 3-Jaw Chuck welding diameter 6" to 24" O.D.
- Page 6 WELD STARTING POSITION Proper positioning of the electrode is crucial to a successful weld. The CWP-7 rotates in a clockwise direction. Depending on the job, whether on-center or hillside, or the process, the optimum starting point of the weld may vary.
- Page 7 8. Depress the green START button to begin the weld program. 9. Turn on the FLUX RECOVERY VACUUM Switch to the ON position. 10. The CWP-7 will automatically stop at the end of the weld program. WARNING: When using an open arc process, it is necessary...
- Page 8 CWP-1570 CONTROL PANEL The CWP-1570 control panel, (shown below), controls all aspects of the CWP-7 machine and the weld and provides real time displays for Rotation Speed, Volts, and Current. The panel is divided into three major sections - Rotation Controls, Keypad and Wire Feeder Controls.
- Page 9 CWP-1570 CONTROL PANEL, CONT’D. ROTATION CONTROLS The rotation controls are located on the left portion of the control panel (Items 1-11 on page 8). Use these controls to maneuver the electrode to the starting position, to start or interrupt the weld and to control the rotation speed.
- Page 10 When entering data, use the diameter of the cylinder along whose intersection the cut has been made. Usually this will be the inside diameter of the nozzle or the outside diameter of the pipe it fits on. This will also allow for any bevel, if necessary.
- Page 11 CWP-1570 CONTROL PANEL - OPEN BOX / EXPLODED VIEW...
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Page 12: Cwp-1570 Control Panel - Open Box / Parts List
CWP-1570 CONTROL PANEL - OPEN BOX / PARTS LIST ITEM QTY PART NO. DESCRIPTION ITEM QTY PART NO. DESCRIPTION CWP-1571 Enclosure, hinged BUG-9909 Panel Connector, 6T-M CWP-1573 Legend Plate, Rotation BUG-6028 Terminal Block, Kulka CWP-1572 Legend Plate, Wire Feed FAS-0115 Screw, Pan Hd, 6-32 x 1/2 ARM-2279 Toggle Switch... - Page 13 CWP-1570-WD CONTROL PANEL / WIRING DIAGRAM (1 OF 3)
- Page 14 CWP-1570-WD CONTROL PANEL / WIRING DIAGRAM (2 OF 3)
- Page 15 CWP-1570-WD CONTROL PANEL / WIRING DIAGRAM (3 OF 3)
- Page 16 TECHNICAL DATA Amperage: 0-500 amps Input Voltage: 115 VAC Voltage: 0-50 VAC Wire Sizes: .035-3/32" (.8-2.4 mm) Rotation Speed: .2-2.2 rpm Welding Diameter: 6"-24" (150-600 mm) Shielding Gas: Solenoid Control (MIG only) Height: 38" (965.2 mm) Net Weight: 250 lbs. (113.6 kg) Shipping Weight: 380 lbs.
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Page 17: Cwp-1700 Cwp-7 Circle Welder / Exploded View
CWP-1700 CWP-7 CIRCLE WELDER / EXPLODED VIEW * Shown with optional flux recovery system... -
Page 18: Cwp-1700 Cwp-7 Circle Welder / Parts List
CWP-1700 CWP-7 CIRCLE WELDER / PARTS LIST ITEM PART NO. DESCRIPTION CBP-1640 Motorized Racking System CWO-1690 Large Horizontal Racker CWO-2005 Wire Feed Guard CWP-1570 Dual Control Box CWO-3063 Brush Holder & Support Assembly CWO-3194 CW-7 Housing Assembly CWO-3204 Slide Bar Mounting Assembly... - Page 19 CWP-1700 CWP-7 CIRCLE WELDER / WIRING DIAGRAM ELECTRICAL COMPONENT CHART ITEM DESCRIPTION PART NO.
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Page 20: Cwo-3495 Cw-7 Collector / Exploded View / Parts List
CWO-3495 CW-7 COLLECTOR / EXPLODED VIEW / PARTS LIST ITEM PART NO. DESCRIPTION CWO-3127 Brass Ring 4.250" Dia x .188 Thk CWO-5741 Brass Ring 4.250" Dia x 3.000 Thk CWO-5744 Micarta Spacer CWO-5747 Micarta Spacer w/Notch CWO-5748 Micarta Sleeve .500" Dia x 3.750" Lg CWO-5806 Micarta Sleeve .500"... -
Page 21: Cwo-3139 Universal Power Cable / Exploded View / Parts List
CWO-3139 UNIVERSAL POWER CABLE / EXPLODED VIEW / PARTS LIST CWO-3139-M MILLER POWER CABLE / EXPLODED VIEW / PARTS LIST... -
Page 22: Cwo-1690 Horizontal Racker / Exploded View / Parts List
CWO-1690 HORIZONTAL RACKER / EXPLODED VIEW / PARTS LIST ITEM PART NO. DESCRIPTION BUG-2032 Knob, Black CWO-1671 Racker Shield CWO-1678 Racker Plate CWO-1679 Pinion 11T CWO-1680 W2 Fixed Leg & Wheel Assembly CWO-1681 W2 Adj. Leg & Wheel Assembly CWO-1687 Mount Plate (Large Racker) CWO-4326 Fixed Leg &... -
Page 23: Cwo-2005 Wire Feeder Guard / Exploded View / Parts List
CWO-2005 WIRE FEEDER GUARD / EXPLODED VIEW / PARTS LIST ITEM PART NO. DESCRIPTION BUG-3209 Hinge 3/4" x 2" Lg CWO-2008 Plastic Guard FAS-0535 Soc Hd Cap 10-24 x 1/2" HDW-1001 Steel Hair Pin Zinc Plated BUG-3197 Binding Post, #8-32 x 3/16 Lg BUG-3198 Binding Post Screw, #8-32 x 3/16 Lg... -
Page 24: Cwo-3496 Shaft Assembly / Exploded View / Parts List
CWO-3496 SHAFT ASSEMBLY / EXPLODED VIEW / PARTS LIST ITEM PART NO. DESCRIPTION BUG-9096 Outlet Bushing, Oxygen CWO-4049 O-Ring, Oxygen, Fuel CWO-5778 Shaft CW-7AG / CW-7ABG CWO-3498 WIRE REEL MOUNT ASSEMBLY / EXPLODED VIEW / PARTS LIST ITEM PART NO. DESCRIPTION BUG-3293 Reel, 60 lbs. -
Page 25: Cwo-3063 Large Brush Holder And Support / Exploded View / Parts List
CWO-3063 LARGE BRUSH HOLDER AND SUPPORT / EXPLODED VIEW / PARTS LIST ITEM PART NO. DESCRIPTION CWO-4036 Large Brush Holder Support CWO-4339 Attachment Bar CWO-3263 Large Brush Holder CWO-3264 Spring Clip CWO-4337 Large Brush 1-1/2" x 3/4" x 2" CWO-5548 Micarta Spacer CWO-5549 Micarta Bushing... -
Page 26: Cwo-3361 P.m. Motor Assembly #147 / Exploded View / Parts List
CWO-3361 P.M. MOTOR ASSEMBLY #147 / EXPLODED VIEW / PARTS LIST ITEM PART NO. DESCRIPTION CWO-4067 P.M. Motor 1072 CWO-4147 P.M. Motor Bracket #970 CWO-5767 Gear, P.M. Motor FAS-0454 Set Scr 1/4-20 x 3/8" TER-WTE-1508 #8 Fork Blue 14RB-8FL-T&B CWE-1530 SMALL BRUSH HOLDER ASSEMBLY / EXPLODED VIEW / PARTS LIST ITEM PART NO. - Page 27 CWP-7 GUN ASSEMBLIES (MIG/FLUX-CORED) CWO-1560-A #5 .035 GUN ASSEMBLY MIG/FLUX .035 WIRE SIZE CWO-8027 15H-35 CONTACT TIP CWO-8034 25CT-75 NOZZLE CWO-8035 35CT NOZZLE INSULATOR CWO-8036 55 SW GAS DIFFUSER CWO-8039 45-3545-15 CABLE LINER CWO-8524 50394 500 AMP CABLE CWO-1560-B #5 .045 GUN ASSEMBLY MIG/FLUX .045 WIRE SIZE...
- Page 28 CWP-7 GUN ASSEMBLIES (SUB ARC) CWO-1700-A #5 .035 GUN ASSEMBLY SUB ARC .035 WIRE SIZE CWO-8027 15H-35 CONTACT TIP CWO-8036 55 SW GAS DIFFUSER CWO-8039 45-3545-15 CABLE LINER CWO-8054 25-SA NOZZLE FLUX CONE CWO-8524 50394 500 AMP CABLE CWO-1700-B #5 .045 GUN ASSEMBLY SUB ARC .045 WIRE SIZE...
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Page 29: Cw-7 Drive Roll Kits
CW-7 DRIVE ROLL KITS PART NO. DESCRIPTION CWO-7026-.035 DRIVE ROLL KIT .035 (0.9mm) SOLID WIRE CWO-7026-.035C DRIVE ROLL KIT .035 (0.9mm) CORED WIRE CWO-7026-.052 DRIVE ROLL KIT .045-.052 (1.0-1.3mm) SOLID WIRE CWO-7026-.052C DRIVE ROLL KIT .045-.052 (1.0-1.3mm) CORED WIRE CWO-7026-1/16 DRIVE ROLL KIT 1/16 (1.6mm) SOLID/CORED WIRE CWO-7026-3/32 DRIVE ROLL KIT .068-3/32 (1.7-2.4mm) SOLID/CORED WIRE... -
Page 30: Cwo-3700-_ Subarc Gun Assembly / Exploded View / Parts List
CWO-3700-_ SUBARC GUN ASSEMBLY / EXPLODED VIEW / PARTS LIST ITEM PART NO. DESCRIPTION CWO-3698 Adaptor-LN7 CWO-1817 Bulk Head Connector QCB CWO-3697 QCC 72" (1829 mm) Liner CWO-3695-1/2 Adaptor K231 1/2" CWO-3670-72 Weld Cable 4/0 Assembly 72" (1829 mm) Lg CWO-3690-1/16 Sub-Arc Nozzle 1/16"... -
Page 31: Gun & Cable Assembly / Exploded View / Parts List
#5 GUN AND CABLE ASSEMBLY / EXPLODED VIEW / PARTS LIST PARTS LIST WIRE SIZE ITEM QTY PART NO. DESCRIPTION .035 .045 .052 1/16 5/64 3/32 CWO-8024 15H-52 Contact tip CWO-8027 15H-35 Contact Tip CWO-8028 15H-45 Contact Tip CWO-8029 15H-116 Contact Tip CWO-8031 15H-564 Contact Tip CWO-8032... -
Page 32: Jaw Expandable Chucks
3-JAW EXPANDABLE CHUCKS 3-Jaw Expandable Chucks Mounts and automatically centers the Circle Welder on nozzles with or without flanges. As shown below. PART NO. FOR NOZZLE I.D.’S WEIGHT CWO-3660 2"-10" (51mm-254mm) 69.3 lbs. (31.3 kg) CWO-3660 CWO-3661 8"-16" (204-405 mm) 36 lbs. -
Page 33: Optional Motorized Racking Equipment / Cwo-1690-Mh / Exploded View / Parts List
OPTIONAL MOTORIZED RACKING EQUIPMENT / CWO-1690-MH / EXPLODED VIEW / PARTS LIST ITEM PART NO. DESCRIPTION BUG-1550 Gear Motor (150:1) CWO-1680 W2 Fixed Leg & Wheel CWO-1681 W2 Adj. Leg & Wheel CWO-1687 Mount Plt Large Racker CWO-1693 Racker Motor MT Plt CWO-1694 Stand-Off CWO-4326... -
Page 34: Optional Horizontal Motorized Racking / Cwp-3351 / Exploded View / Parts List
OPTIONAL HORIZONTAL MOTORIZED RACKING / CWP-3351 / EXPLODED VIEW / PARTS LIST 13,11 ITEM PART NO. DESCRIPTION CWP-3355 Hvy Duty Rack 150:1 No Mounting Bracket CWO-5933 Jaw Coupling 3/8" & 5/8" Bores With Spider CWO-5565 5/8" Pillow Block CWP-3354 Screw for Mtrzd Hrz Hvy Duty Rack CWP-3353 Mtrzd Hrz Slide Hvy Duty Rack CWP-3362... -
Page 35: Optional Motorized Racking Equipment / Prs-1100 / Exploded View / Wiring Diagram
OPTIONAL MOTORIZED RACKING EQUIPMENT / PRS-1100 / EXPLODED VIEW / WIRING DIAGRAM... -
Page 36: Optional Motorized Racking Equipment / Prs-1100 / Parts List
OPTIONAL MOTORIZED RACKING EQUIPMENT / PRS-1100 / PARTS LIST ITEM COMPONENT ITEM DESCRIPTION 120VAC 240VAC 42VAC Input End Panel PRS-1111 .7 Amp Circuit Breaker BUG-2923 .5 Amp Circuit Breaker BUG-2952 2 Amp Circuit Breaker BUG-2933 BUG-2924 “Reset Seal, Transparent” BUG-5001 Transformer 115VAC Transformer 240VAC BUG-5002... -
Page 37: Optional Motorized Racking Equipment / Cwp-3363 / Exploded View / Parts List
OPTIONAL MOTORIZED RACKING EQUIPMENT / CWP-3363 / EXPLODED VIEW / PARTS LIST ITEM PART NO. DESCRIPTION CWO-1687 Plate CWO-4326 Wheel & Leg Assembly, Fixed CWO-4327 Wheel & Leg Assembly, Adjustable OPTIONAL MOTORIZED RACKING EQUIPMENT / PRS-1075 / EXPLODED VIEW / PARTS LIST... -
Page 38: Preventive Maintenance / Cwp-7 Circle Welder
AFTER DAILY USE: Refer to CWP-7 Exploded View Parts List. (Pg. 11) Racking System Item #1: Inspect gear rack, hardened ways and wheels (remove all dirt, grease, weld spatter and rust). Check hardened ways for nicks and replace if necessary. - Page 39 EVERY TWELVE MONTHS: Refer to CWP-7 Exploded View Parts List. (Pg. 11) 1-1/2" Bearing With Fasteners Item #26: Do not grease the bearing, it is greased for life by the manufacturer. If the grease fitting has not been removed and plugged we suggest that you do so now.
- Page 40 PREVENTIVE MAINTENANCE / CWP-7 CIRCLE WELDER Refer to CWP-7 Electrical Component Chart. (Pg. 13) CW-7 Collector Item #11: The collector ring should be sanded once a year. If the collector ring is pitted too badly it should be replaced. Inspect all wires coming out of the collector ring for cut or missing insulation. All wires should be fastened to the center shaft with a nylon cable tie.
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Page 41: Warranty
BE SURE to mention the MODEL and SERIAL numbers. *Bug-O System’s warranty applies to Bug-O components only. Where other brands of power sources, wire feeders or sub components are a part of Bug-O Equipment, please refer to that specific Manufacturer’s manual for warranty specifications...
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