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Climax BW1000 Operating Manual

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

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

  • Page 3: Table Of Contents

    Table of Contents LABELING GUIDELINES ..................................1 SAFETY ......................................2 .............................. 2 RECAUTIONS AND ULES FOR PERATION ..............................2 DDITIONAL ELDING AFETY RECAUTIONS SAFETY PRECAUTIONS: GENERAL HAZARDS............................3 ..............................4 ISK ASSESSMENT AND HAZARD MITIGATION ..................................5 ISK ASSESSMENT CHECKLIST LIMITED WARRANTY ..................................
  • Page 4 TEEL WELD DEPOSIT TOO HARD TO MACHINE " " : ........................... 30 GRAPING WHEN WELDING IN THE HORIZONTAL AXIS : ......................30 EAD ROPY VOLTAGE HARD TO CONTROL UNABLE TO CLEAR STUBBING EXPLODED VIEW DRAWINGS AND PARTS LISTS ..........................31 Page ii BW1000 Operating Manual...

  • Page 5: Labeling Guidelines

    Labeling Guidelines The purpose of product safety signs and labels 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.

  • Page 6: Safety

    Safety Precautions and Rules for Safe Operation • The BW1000 is designed for safety and ease of use. As with the operation of any machinery, safety depends on the operator. • It is most important that the operators read and understand the specific instructions for set-up and operation of the BW1000 found in the operator's guide as well as the following safety information.

  • Page 7: Safety Precautions: General Hazards

    Obey all warnings and warning labels. Failure to follow instructions or heed warnings could result in injury, or even be fatal. 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 instructions in this operating manual.

  • Page 8: Risk Assessment And Hazard Mitigation

    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 BW1000 Operating Manual...

  • Page 9: Risk Assessment Checklist

    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: Limited Warranty

    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: Bortech Limited Warranty

    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 to repair or replace any components or parts of the BW1000 that are determined by Bortech to be defective.

  • Page 12: Ce Data

    Issued by: Climax Portable Machining and Welding Systems Date of Issue: (Original Dated) Type of Equipment: Automated Bore Welding Equipment Brand Name: Climax Portable Machining and Welding Systems BoreWelder Model Number: BW1000 Serial Numbers: (See Machine) Audible Noise Levels: ➢ Surface sound pressure level (in dBA) 70 dBA ➢...
  • Page 13 P/N 40831, Rev. 4 Page 9...

  • Page 14: Safety

    • Dust, dirt, and/or sand may cause machine to cease, posing risk to operator. • Grease and/or oil may cease in cold weather, posing risk to operator. • Do not operate with substance outside of specifications. • Do not operate without proper ear protection. Page 10 BW1000 Operating Manual...

  • Page 15: Operation

    Operation The BW1000 is an automated welding device that uses a rotating and helically retracting spindle/torch, which must be coupled with a MIG Wire-feeder to deposit Weld on the surface of a bore or pin. The rate of axial feed per revolution is fixed. Torch selection, and/or adjustments to the swivel head accommodate differences in bore diameter.

  • Page 16: Specifications

    Maximum Continuous Welding 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 (short arc/. 035 wire) 16 to 17.5 volts Component Weight - 17 lbs.

  • Page 17: Power Supply Compatibility

    The BW1000 works well with numerous wire-feeders. It is imperative however that a Constant Voltage MIG Process is utilized. Power supplies with a rating of 175 amps are sufficient for the BW1000. The power supply must be of the constant voltage (CV) type (suitable for MIG welding).

  • Page 18: Major Assemblies

    The BW1000 provides the circular and axial motion required to accomplish bore build up. It also provides for the passage of weld current, welding wire, and shielding gas to the welding torch. BW1000 rotational speed and direction is controlled at the rear face of the machine.

  • Page 19: Optional Equipment

    3.98”. This mount is the correct distance for most 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.

  • Page 20: Quick Set-Up Procedure

    (See Use of Swivel Head for details on this part.) 5. Rotate Feed Knob to move spindle to the extended position 6. Slide the BW1000 along the Mounting Rod to bring the torch end to the bore end. 7. Lock the Radial Mount to the Mounting Rod 8.

  • Page 21: Using .035" Wire

    Using .035" wire 100amps @ 16v = 170ipm (inches per minute) 125amps @ 16½v = 240ipm 150amps @ 17v = 280ipm 1. To begin welding, flip Rotation switch to Retract/Weld and then depress the Weld Trigger switch into the ON position. Small changes to Voltage on power supply may be required to stabilize the weld process.

  • Page 22: Setting Rotation Speed

    3. Ensure that the voltage of your power supply is not greater than 18-volts and set wire speed to 250 inches/minute (with .035 wire this is approximately 130 amps, or 4.2 lb per hour. In MIG welding, the wire speed bears a direct relationship to the weld current. Page 18 BW1000 Operating Manual...

  • Page 23: Operation

    1. Weld a ½”-13 mounting bolt of suitable length to a position approximately 11 inches from the center of the bore to be welded. (If a greater distance from the BW1000 mounting rod is required, use radial mount (28208). This will change the bolt setting to between 11 and 14 inches).
  • Page 24 7. The BW1000 should be positioned along the mounting rod so that the axial torch travel will reach both extremes of the welding that is to be done in the bore. Slide the BW1000 along the mounting rod as necessary to position the stroke.

  • Page 25: Use Of Accessories

    These Torches have "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 with the torch detached. Push the wire through the torch with pliers, and then re-attach the torch to the Swivel Head.

  • Page 26: Use As Follows

    Use as follows: Attach the Radial Mount to the Mounting Rod (vertical axis also use 40320 locking collar) by slipping the open end over the rod, and tightening the nut. The BW1000 can then be installed into Radial Mount. Page 22...

  • Page 27: Maintenance

    If the liner is being installed in a portion of the BW1000 accessories where it forms a curve, it is important to preload the liner. That is, press the liner into the torch or conduit until the liner is felt to be contacting the outer wall of the bend in the torch or conduit.

  • Page 28: Operator Training

    Operator Training Initiation procedure: When first using the BW1000, begin by working with mild steel prior to attempting work with any other alloys. ER70S-6 or ER70S-2 wires are recommended. 1. Use a wire with a large arc or “cast.” Cut about 6 feet from the roll of wire and toss it on the floor.

  • Page 29: Welding Pointers

    Welding Pointers Wire and Gas The BW1000 is designed for solid steel wire using the MIG welding process. The length of time that the Borewelder can be used continuously is dependent mostly on spatter build up in the welding nozzle. Therefore, a main objective when deciding what kind of wire, gas and power supply to use is usually to select a combination that produces the smoothest and least violent arc action.

  • Page 30: Welding In The Horizontal Axis

    The following discussion provides insight for developing skills for work in the horizontal. Some practical suggestions are listed below. Lower and overhead positions of the bore present no problem for the BW1000. When the torch is welding vertical-up, the weld of course has a tendency to run downward. With controls set correctly, the solidifying weld-metal forms a shelf that supports the molten metal so vertical-up is done almost as easily as flat.
  • Page 31 P/N 40831, Rev. 4 Page 27...

  • Page 32: Welding Problems And Troubleshooting

    The usual cause for too much spatter can be that the arc voltage is too high. The arc should have an even sound that is not violent. A setting of 15½ to 18 volts is normal. Above 18 volts, Page 28 BW1000 Operating Manual...
  • Page 33 CFH is recommended. If the weld is not shielded from the atmosphere, the oxygen and nitrogen will react with the weld metal, causing porosity. ➢ Dirty bore surface. Although the BW1000 usually handles these problems well, excessive oil or other organic compounds could cause porosity. These may be on the surface or imbedded in crevices or grease holes.
  • Page 34 During the remainder of the buildup operation, graping should not be experienced within the current limits of the BW1000. If graping is experienced during the remainder of the buildup operation, the weld current probably is too high or the travel speed is too slow. The bead becomes so large that its weight overcomes the surface tension that otherwise would hold it in place and the bead spills.
  • Page 35 Exploded View Drawings and Parts Lists Please contact Climax if you have any questions about parts, service or operation. P/N 40831, Rev. 4 Page 31...
  • Page 36 Balloon No. Description Climax P/N 6-32x.375 BtnHd Cap Scr 38151 CLIMAX MODEL SERIAL TAG 65366 WARNING LABEL 63504 COVER, SHROUD 63487 6-32x.250 BtnHd Cap Scr 63497 SHROUD, DOZER- CE WG, BLUE 63489 POWER INLET MODULE 63491 FUSE, GLASS 64264 SWITCH...
  • Page 37 Balloon No. Description Climax P/N SCR,8-32X.375 BTNHD CAP 11359 SCR Motor Control115/230vac 63525 SCR, 10-32X.375 BTNHD CAP 62483 Bracket Dozer CE, BISON Motor 64254 Motor Gearbox Assembly 61210 5/16-18x.31Soc Set Scr- CP 62497 Motor Block,Double 63520 SOC ND CAP SCR 10-32 x .75...
  • Page 38 Page 34 BW1000 Operating Manual...
  • 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 Seconds Per Rotation @ 18 IPM = Bore Dia. x 10.4 VERT. BORE AXIS Seconds Per Rotation @ 20 IPM = Bore Dia. x 9.4 Seconds Per Rotation @ 22 IPM = Bore Dia. x 8.5 HORZ BORE AXIS Page 40 BW1000 Operating Manual...

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