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Climax BW5000 Operating Manual

Autoborewelder
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BW5000
AUTOBOREWELDER
OPERATION MANUAL
BW5000 AutoBoreWelder
P/N 68191
May 2019
Revision 4

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

  • Page 3: Table Of Contents

    Introduction ..........................7 Product Features ........................11 Specifications ..........................12 Major Assemblies ........................14 Receiving the Machine ......................18 Setup of the BW5000 ........................20 Operation of BW5000........................38 Optional Equipment – Description and Use ................41 Maintenance and Adjustments ....................43 Configuration Line Drawings .....................46 Shipping and Storage........................53 Recommended Spare Parts ......................54...
  • Page 4 This page is intentionally left blank Page ii BW5000 Operating Manual...

  • Page 5: Safety Precautions

    The primary challenge for most on-site maintenance is that repairs are often done under difficult conditions. Climax Portable Machining and Welding Systems, Inc. leads the way in promoting the safe use of portable machine tools. Safety is a joint effort. As the operator of this machine, you are expected to do your part by scrutinizing the job site and closely following the operating procedures outlined in this manual, your own company rules, and local regulations.
  • Page 6 Most of the machine components are heavy and WARNING LABELS must be moved or lifted with approved rigging and Warning labels are already attached to your practices. Climax accepts no responsibility for the machine. Contact Climax immediately selection of lifting equipment.
  • Page 7 Safety Sign and Symbol Guidelines The purpose of product safety signs and symbols is to increase the level of awareness to possible dangers. Safety alert symbols indicate DANGER, WARNING or CAUTION. These symbols may be used in conjunction with other symbols or pictographs. Failure to obey safety warnings can result in serious injury or death.
  • Page 8 Due to the unique nature of portable machining applications, identifying one or more hazards that must be addressed is typical. When performing the on-site risk assessment, it is important to consider the Portable Machine Tool and the workpiece as a whole. Page 4 BW5000 Operating Manual...
  • Page 9 Risk assessment checklist Use these checklists as part of your on-site risk assessment and include any additional considerations that may pertain to your specific application. 1. R ABLE ISK ASSESSMENT CHECKLIST BEFORE SET Before Set-up I took note of all the warning labels on the machine. ...
  • Page 10 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.

  • Page 11: Introduction

    12 feet (3.75 M). Substantial input from field research and our own technical staff has resulted in the BW5000 which combines ease of use, durability, and high deposition rates in a highly refined product.
  • Page 12 Product Description & Basic Operation The BW5000 is an automated welding device that consists of a rotating and axially stepping MIG torch system in conjunction with a rotatable power coupling and slip ring system to build up the surface of part.
  • Page 13 Safety The BW5000 welding machine is designed for safety and ease of use in mind. As with operation of any machinery, safe operation depends mainly upon the operator. The BW5000 requires thoughtful, careful operation to produce optimum results and safety. This manual is an important prerequisite in operating the BW5000 safely and effectively.
  • Page 14 To obtain additional details on safety precautions, we highly recommend “Safety in Welding and Cutting”, American National Standard ANSI Z49.1 Page 10 BW5000 Operating Manual...

  • Page 15: Product Features

    The BW5000 brass body torch enables longer run times and longer consumable life, increasing production and decreasing downtime. Wire Feed System The BW5000 Wire Feed system allows feeding of a wide range of exotic alloys. The modular wire feeder allows multiple configurations, and is reversible for maximum capability. Wire / Torch Stickout Adjustment...

  • Page 16: Specifications

    Specifications BW5000 bore/ face range: 2 to 12 feet diameter (609.6 to 3657.6 mm) Max. outside diameter: 10 feet diameter (3048 mm) Stroke: 10, 20, 30, 40, 50 inches (254, 508, 762, 1016, 1270 mm) Weight (head unit): 170 lbs. (77.1 kg)
  • Page 17 Figure 1 Major Assemblies P/N 68191, Rev. 4 Page 13...

  • Page 18: Major Assemblies

    Step motor and Auxiliary motor current travel from the AMP connectors on the stationary side of the Head, through a series of brushes in the head body, and are terminated at an AMP quick disconnect fitting in the side of the Line Bar coupling at the lower part of the BW5000 head. Line Bar The Line Bar installs into the line bar coupling on the head assembly by means of a taper fitting.
  • Page 19 Aux Step unit is electrically isolated from the Aux Stepping Unit chassis, and subsequently from the rest of the BW5000. This feature prevents weld current from being shunted to ground through the chassis of the BW5000.
  • Page 20 Torch Support Rods. Gas Hose The Gas Hose connects the output of the shielding gas regulator to the Head of the BW5000 via a quick connect fitting. The Gas Hose is 20’ long (P/N A1018). (508 mm)
  • Page 21 The power supply must be of the constant voltage (CV) type (the type suitable for MIG welding), and it should have remote voltage control capabilities As mentioned above, the BW5000 comes equipped with a power supply control cable. Consult our Technical Department for information regarding cables not mentioned in this manual.

  • Page 22: Receiving The Machine

    Receiving the Machine The machine was run tested and thoroughly inspected before leaving the factory. When leaving the factory, the machine is packaged well for the demands of normal transportation. Climax cannot, however, guarantee the condition upon arrival of the machine.
  • Page 23 The containers are designed to be lifted only with the provided lifting points and with the container fully closed. Do Not lift with the container covers removed. Surfaces subject to corrosion were sprayed with a rust preventative prior to shipment (and possibly wrapped in oil impregnated paper). The user should exercise caution while handling the components provided since they may be greasy and/or slippery.

  • Page 24: Setup Of The Bw5000

    AutoBoreWelder. Any swaying movements must be eliminated by cross bracing. Lifting the Head To lift the BW5000 head, screw the lifting eye into the threaded hole in the spindle located at the top of the BW5000 Head Assembly. The Eye should be screwed into the threaded hole until the eye shoulder bottoms out on the spindle, and then tightened.
  • Page 25 Position of BW5000 on Rails Set the BW5000 down on the rails with two leveling screws on one rail, and the third screw on the second rail. The AutoBoreWelder should be positioned so that the Mounting Plate Assembly / Spindle is approximately central to the bore to be welded—within 1 inch (203.2 mm).
  • Page 26 Plate / Line Bar Assembly, ensure that the lifting components are adequately rated and securely attached to the lifting eye. Coarse Alignment of the BW5000 Head Axis to the Bore Axis Consistent BoreWelding depends on the proper alignment of the AutoBoreWelder to the bore to be welded.
  • Page 27 Centering the BW5000 Line Bar to the Bore Centrality is obtained by utilizing the X-Y table at the top of the BW5000 mounting plate. A tape measure can be used to measure from the Line Bar to the side of the Bore, in quadrants that are aligned to the X-Y table on the BW5000 mounting plate.
  • Page 28 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. Light oil should be used sparingly to protect the shaft and sliding mechanism.
  • Page 29 (stickout). This unit installed between 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 Torch Adjuster, the benefits generally outweigh the setup time requirements.
  • Page 30 BW5000. If the setup of the BW5000 prevents a straight line from the Wire Reel to the Wire feeder inlet, it is possible to install a PULL conduit from the Wire Reel to the Wire feeder inlet. Consult Climax for details on this option.
  • Page 31 Install other end into torch, and secure nut by hand only. Avoid 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 inch section of 1/4 inch (6.35 mm) rubber hose from the wire feeder nipple at the...
  • Page 32 BW5000 Power Coupling. Insert the female end of the weld cable into the male quick couple at the base of the red shroud of the BW5000 head assembly. Attach the other end to the positive lead of the power supply.
  • Page 33 Figure 8 General Schematic Powering up Control The power switch is located adjacent to the AC power inlet. To power up control, flip rocker switch to the ON position. 1 depressed is on, 0 depressed is off. The control will take 5 seconds to power up, indicated by illumination of the red AUTO SKIP LED.
  • Page 34 Control Functions The functions of the Climax 160 Control are shown in FIG 9 Check all functions of the Control for operation. Insure that there are no obstructions to any of the moving parts of the BW5000. • ROTATION (verify operation of Rotation drive) •...
  • Page 35 Final Centering For rapid and final centering of the BW5000, utilize ROT JOG to move the spindle assembly and all attached components through the 4 quadrants that relate to the X and Y adjustment table on the BW5000 base plate.
  • Page 36 EXAMPLE: At 20 IPM travel speed, the torch takes 3 seconds to travel 1 linear inch. This is a preferred method for quickly roughing in the rotation speed. For more accuracy in this timing method, increase the length to 5 inches, and make the necessary changes to the time constant. Page 32 BW5000 Operating Manual...
  • Page 37 Figure 11 Seconds Per Rotation and Travel Speed Constants P/N 68191, Rev. 4 Page 33...
  • Page 38 To estimate step, (@ 20 IPM travel speed), current is nearly equal to step in thousandths of an inch. To cycle step while not welding, utilize keystroke FUNCTION-ROT INIT. To reverse step direction, utilize keystroke FUNCTION-RETRACT. To shut Step off, utilize keystroke FUNCTION-EXTEND. Figure 13 Step Location Page 34 BW5000 Operating Manual...
  • Page 39 The skip area is programmed 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. Rotate to the beginning of the “interrupt”, or weld...
  • Page 40 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 press WELD twice (to cycle from Auto Skip to Carriage Return). Page 36 BW5000 Operating Manual...
  • Page 41 4. Set the rotation direction to the preferred weld direction for your application by holding down the FUNCTION key and pressing the ROTATE button to toggle the rotation direction. 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.

  • Page 42: Operation Of Bw5000

    • Verify that gas hose from power coupling to Wire feeder is connected and free of kinks and obstructions. • Verify Weld Power Supply is on and set correctly. • Check Positive and Negative weld connections at Welder, BW5000, and part to be welded. • Verify connection of positive weld cable from Power Coupling to Torch.
  • Page 43 Arc Interrupt The Arc interrupt function is utilized to stop the welding process manually (while maintaining rotation and step function). This is a momentary type switch, therefore the operator needs to hold it down to maintain the interrupted arc. This function can be activated remotely by the Remote Arc Interrupt Cable. Welding Pointers RUNTIME: The length of time that the AutoBoreWelder will weld continuously is largely dependent on the spatter buildup in the welding nozzle.
  • Page 44 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 verifying stroke clearance after initial setup is complete.

  • Page 45: Optional Equipment - Description And Use

    This torch may be advantageous for certain outside diameter buildups as well as small bore applications.. Line Bars The BW5000 can be fitted with different length line bars, 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 Rods and Aux slide guide rods.
  • Page 46 Line Bar. Welding in the horizontal axis limits the maximum current that can be run with the BW5000, as the vertical up weld bead is limited to approximately 180 amperes maximum current. Travel speeds must be at or near 22 IPM and the voltage a shorting transfer.

  • Page 47: Maintenance And Adjustments

    Every 500 hours, the Rotating Power Coupling underneath the Base plate of the BW5000 should be lubricated. The grease cup located on the Brass power coupling is delivered from the factory fully charged, (mostly unscrewed).
  • Page 48 If the chain is loose, it is possible that the chain will climb off the sprocket, causing damage to the motor or other components. If there is any backlash noted in the drive system of the BW5000, the chain must be tightened. To tighten drive chain, remove the red shroud from the head of the BW5000.
  • Page 49 3. Undo the motor lead connections in the space revealed when the Motor shroud is removed 4. Remove the two Allen Head cap screws which fasten the steel plate the main block. (Bubble #2 Fig 18) Do not remove the steel plate from the step motor. 5.

  • Page 50: Configuration Line Drawings

    Configuration Line Drawings The following pages detail 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 application drawings do not cover your specific application, contact Climax Technical Support.
  • Page 51 P/N 68191, Rev. 4 Page 47...
  • Page 52 Page 48 BW5000 Operating Manual...
  • Page 53 P/N 68191, Rev. 4 Page 49...
  • Page 54 Page 50 BW5000 Operating Manual...
  • Page 55 BW5000 Small Bore Torch Welding P/N 68191, Rev. 4 Page 51...
  • Page 56 BW5000 Torch Offset / Centerline Page 52 BW5000 Operating Manual...

  • Page 57: Shipping And Storage

    • Store the machine in the crates provided. • Place desiccant bags or vapor wrap around the machine to absorb moisture. Climax advises changing the desiccant bags in the storage crate every 18 months. Ideal Long-Term Storage Conditions Ideal long-term storage conditions are cool and dry indoors (50°F and 20% relative humidity).

  • Page 58: Recommended Spare Parts

    33999 WRENCH HEX SET .050 - 3/8 BONDHUS BALL END (KB) 65895 GREASE CONDUCTIVE ELECTRICAL JOINT 1 OZ 67082 GLOVES WELDING CLIMAX BRANDED SIZE LARGE 67162 LINER STAINLESS STEEL .065 ID X .188 OD (STOCKED IN INCHES) 67337 LUBRICANT 3 OZ WD-40 67453 FEED ROLL V-GROOVE .045/.062...

  • Page 59: Exploded Views And Parts Lists

    The following diagrams and parts lists are for your reference purposes only. The machine Limited Warranty is void if the machine has been tampered with by anyone who has not been authorized in writing by Climax Portable Machining and Welding Systems, Inc. to perform service on the machine.
  • Page 60 16. 71988 – KIT SMALL BORE TORCH 12 - 24 IN ID BW5000 17. 71989 – KIT RADIAL RODS BW5000 RANGE 24 - 120 ID / 24 - 96 OD 18. 71990 – KIT RADIAL RODS BW5000 RANGE 24 - 144 ID / 24 - 120 OD 19.
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  • Page 93 P/N 68191, Rev. 4 Page 89...
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  • Page 118: Schematics

    Schematics Page 114 BW5000 Operating Manual...

  • Page 121: Quick Reference Charts

    Quick Reference Charts P/N 68191, Rev. 4 Page 117...
  • Page 122 BW5000 Copyright © 2019 Climax Portable Machining & Welding Systems, Inc. Page 118 Part No. 68191 climaxportable.com...

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