Table of Contents
Advertisement
Quick Links
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.
Bug-O Systems is committed to empowering our customers by providing operator
controlled mechanized solutions for their welding, cutting and custom applications.
280 TECHNOLOGY DRIVE
PHONE: 412-331-1776
AND
CW-7
A DIVISION OF WELD TOOLING CORPORATION
CANONSBURG, PENNSYLVANIA 15317-9564 USA
https://www.bugo.com
LIT-CW-7-IPM-0524
FAX: 412- 331- 0383
Advertisement
Table of Contents
Subscribe to Our Youtube Channel
Related Manuals for Bug-O Systems CW-7
Summary of Contents for Bug-O Systems CW-7
- Page 1 Whenever you request replacement parts or information on this equipment, always supply the information you have recorded above. LIT-CW-7-IPM-0524 Bug-O Systems is committed to empowering our customers by providing operator controlled mechanized solutions for their welding, cutting and custom applications. 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.
-
Page 4: Table Of Contents
30 ..CWO-3690-_ K231 Subarc Gun Assembly / Exploded View / Parts List 31 ..CWO-3700-_ Subarc Gun Assembly / Exploded View / Parts List 31 ..CWO-3490 CW-7 Flux Hopper Assembly / Exploded View / Parts List 32 ..#5 Gun & Cable Assembly / Exploded View / Parts List 33 .. - Page 5 INTRODUCTION The CW-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 CW-7 mounts on a 3-Jaw Chuck welding diameter 6" to 50" O.D.
- Page 6 3-2=1 The cam setting is 1. WHEEL ADJUSTMENT The CW-7 Racking System CWO-1665 and the Large Vertical Racker CWO- 1690 are equipped with adjustable wheels. Always check these components for proper wheel adjustment before using the machine. The wheels need adjustment if you can cock or wiggle the components out of alignment.
-
Page 7: Cwo-3332 Wire Feeder Controls
CWO-3332 WIRE FEEDER CONTROLS WIRE FEED SPEED WIRE DIRECTION MANUAL / AUTOMATIC PREFLOW POSTFLOW PURGE - UP BURNBACK COLD INCH - DOWN WIRE FEED SPEED CONTROL: This control sets the feed speed of the wire feeder. Turn the knob to the left for slower speeds and to the right for higher speeds. -
Page 8: Cwo-6210 Rotation Controls
CWO-6210 ROTATION CONTROLS Digital Readout Speed Control Travel Direction Pilot Light On/Off Switch DIGITAL READOUT: Displays reference number only. SPEED CONTROL: Controls the speed in which the machine travels. The depicted lines 0 to 100 should not be construed as inches per minute of travel. They should be considered as reference points only. TRAVEL DIRECTION: Controls the direction in which the machine will travel. -
Page 9: Technical Data / Dimensions
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 Cam Range: 0"-7" (0-175 mm) Welding Diameter: 6"-24" (150-600 mm) Shielding Gas: Solenoid Control Height: 34" (864 mm) Net Weight: 250 lbs. -
Page 10: Cwo-1700 Cw-7 Circle Welder / Exploded View
CWO-1700 CW-7 CIRCLE WELDER / EXPLODED VIEW... -
Page 11: Cwo-1700 Cw-7 Circle Welder / Parts List
CWO-1700 CW-7 CIRCLE WELDER / PARTS LIST ITEM PART NO. DESCRIPTION CWO-1665 CW-7 Racking System CWO-1690 Large Horizontal Racker CWO-2005 Wire Feed Guard CWO-3027 Meter Kit Assembly CWO-3063-2 Brush Holder & Support Assembly CWO-3194 CW-7 Housing Assembly CWO-3204 Slide Bar Mounting Assembly CWO-3205-11 7"... -
Page 12: Cw-7 Circle Welder / Wiring Diagram
CW-7 CIRCLE WELDER / WIRING DIAGRAM... -
Page 13: Cw-7 Circle Welder / Wiring Diagram / Electrical Component Chart
CW-7 CIRCLE WELDER / WIRING DIAGRAM / ELECTRICAL COMPONENT CHART ELECTRICAL COMPONENT CHART ITEM DESCRIPTION PART NO. Meter Kit Assembly CWO-3027 Brush Holder & Support Assembly CWO-3063-2 Power Cable CWO-3139* GMA Pigtail CWO-3331 GMA Wire Feed Control CWO-3332 P.M. Motor Assembly... -
Page 14: 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 15: 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 16: Cwo-1665 Cw-7 Racking System / Exploded View / Parts List
CWO-1665 CW-7 RACKING SYSTEM / EXPLODED VIEW / PARTS LIST ITEM PART NO. DESCRIPTION ABR-1060 V-Guide Ways 33" CWO-1675 Vertical Racker CWO-1695 Attachment Block CWO-3023-1 Torch Angle Adjuster 16" CWO-3460 33# Load Spring Assembly CWO-1690 HORIZONTAL RACKER / EXPLODED VIEW / PARTS LIST ITEM QTY PART NO. -
Page 17: 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 18: Cwo-3027 Meter Kit Assembly / Exploded View / Parts List
CWO-3027 METER KIT ASSEMBLY / EXPLODED VIEW / PARTS LIST ITEM PART NO. DESCRIPTION 48" 900-4-001 2 Cond. 18 AWG. SJO Cord CSR WTE 0187 Wire Strain Relief CWO-4396 DC Volt Meter, 0-50 VDC CWO-4397 DC AMP Meter, 0-500 ADC CWO-4399 5"... -
Page 19: 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-3227 CAM SHAFT & SPACER ASSEMBLY / EXPLODED VIEW / PARTS LIST ITEM PART NO. DESCRIPTION CWO-4352 Ball Joint Rod End 3/8-24 RH... -
Page 20: Cwo-3205-11 7" Cam Assembly / Exploded View / Parts List
CWO-3205-11 7" CAM ASSEMBLY / EXPLODED VIEW / PARTS LIST ITEM PART NO. DESCRIPTION BUG-2098 Delrin Washer 3/8" BUG-9012 Locking Collar CWO-4027 End Plate CWO-4028 Center Plate CWO-4032 Knob CWO-4328 Base Plate CWO-4331 Screw CWO-4332 CWO-5199 Scale FAS-0434 Set Scr #10-24 x 3/8" FAS-0444 Set Scr #10-32 x 3/8"... -
Page 21: Cwo-3063-2 Large Brush Holder And Support / Exploded View / Parts List
CWO-3063-2 LARGE BRUSH HOLDER AND SUPPORT / EXPLODED VIEW / PARTS LIST 10 11 ITEM PART NO. DESCRIPTION CWE-1536 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... -
Page 22: Cwo-3361 P.m. Motor Assembly / Exploded View / Parts List
CWO-3361 P.M. MOTOR ASSEMBLY / 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 CWO-3359 TRANSMISSION 5:1 ASSEMBLY / EXPLODED VIEW / PARTS LIST ITEM QTY PART NO. -
Page 23: Cwe-1530 Small Brush Holder Assembly / Exploded View / Parts List
CWE-1530 SMALL BRUSH HOLDER ASSEMBLY / EXPLODED VIEW / PARTS LIST ITEM PART NO. DESCRIPTION CWE-1531 Retainer Support Small CWE-1532 6 Pos Small Ret. Block Assembly FAS-2351 Soc Hd Cap Scr 10-24x1" FAS-0539 Hex Hd Cap Scr 1/4-20x1 1/4" WAS-0240 1/4"... -
Page 24: Cwo-3332 Gma Wire Feeder Control / Exploded View / Parts List
CWO-3332 GMA WIRE FEEDER CONTROL / EXPLODED VIEW / PARTS LIST 25,26 ITEM PART NO. DESCRIPTION BUG-2255 Toggle Switch BUG-2287 Power Receptacle CON-1202S Panel Connector, 2T F CWO-6759 Panel Connector, 6T M CWO-5461 Wire Feed Control Case CWO-5462 Wire Feed Control Cover CWO-5533A Wire Feed Front Panel CWO-5533B... - Page 25 CWO-3332 GMA WIRE FEEDER CONTROL / WIRING DIAGRAM MOTOR GROUND LEAD PROTECTOR RESET POWER SOURCE INPUT WIRE MAN/AUTO RESET CIRCUIT BREAKER WHT/BLU GLP REED CBO-1013 X 2 SWITCH TIMER GOF-3037 BOARD GOF-3036 WHT/RED LIGHT OUTPUT WHT/RED C119 SOLENOID CAP WTE 1506 ABP-1069 = INDICATES CONTROL BOARD ITEMS ELECTRICAL COMPONENT CHART...
-
Page 26: Cwo-6210 Rotation Control / Exploded View / Parts List
CWO-6210 ROTATION CONTROL / EXPLODED VIEW / PARTS LIST 13 (X4) 13,14,21 15,17 15,16 21 (X4) 14 (X4) 25,26 ITEM PART NO. DESCRIPTION ARM-2279 Toggle Switch BUG-9445 Power Cord CON-PS04M Plug, Straight 4-Pin Male BUG-9687 Knob Fluted BUG-9694 Knob CSR-WTE-1597 Cord Strain Relief CWO-6216 Rotation Box Front Panel... -
Page 27: Cwo-6210 Rotation Control / Wiring Diagram / Electrical Component Chart
CWO-6210 ROTATION CONTROL / WIRING DIAGRAM / ELECTRICAL COMPONENT CHART = INDICATES ITEMS THAT ARE SUPPLIED TOGETHER. ELECTRICAL COMPONENT CHART ITEM DESCRIPTION PART NO. Toggle Switch ARM-2279 Red Neon Lamp CWO-6206 Speed Control Board w/Resistor CWO-6529 Fuse 2 amp MPD-1026 Fuse 3 amp FUS-0257 Rotary Switch... -
Page 28: Gun Assemblies (Mig-Flux Cored)
CW-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 29: Gun Assemblies (Sub Arc)
CW-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... -
Page 30: 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... -
Page 31: Cwo-3700-_ Subarc Gun Assembly / Exploded View / Parts List
Sub-Arc Nozzle 1/16" CWO-3690-5/64 Sub-Arc Nozzle 5/64" CWO-3690-3/32 Sub-Arc Nozzle 3/32" FAS-0452 Set Scr 1/4-20 x 1/4 CWO-3490 CW-7 FLUX HOPPER ASSEMBLY / EXPLODED VIEW / PARTS LIST ITEM PART NO. DESCRIPTION CWO-3757 Hopper Support Rod CWO-3760 Clamp Block 1/2"... - Page 32 #5 GUN AND CABLE ASSEMBLY / EXPLODED VIEW / PARTS LIST PARTS LIST WIRE SIZE ITEM QTY PART # 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 33: 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-3661 8"-16" (204-405 mm) 36 lbs. (16 kg) CWO-3660 CWO-3362 10"-24"... -
Page 34: Optional Motorized Racking Equipment / Cwo-1665-Mv / Exploded View / Parts List
OPTIONAL MOTORIZED RACKING EQUIPMENT / CWO-1665-MV / EXPLODED VIEW / PARTS LIST ITEM PART NO. DESCRIPTION ABR-1060-MH Motorized Horizontal V-Guide Ways 33" ABR-1060-MV Motorized Vertical V-Guide Ways 33" CWO-1675-MV Motorized Vertical Racker CWO-1695 Attachment Block CWO-3023-1 Torch Angle Adjuster 16" CWO-3460 33# Load Spring Assembly... -
Page 35: 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 36 OPTIONAL RACKING MOTORIZED RACKING / CWP-3350 / EXPLODED VIEW / PARTS LIST ITEM PART NO. DESCRIPTION CWP-3351 Motorized Vertical Heavy Duty Rack Assembly CWP-3352 Motorized Vertical Heavy Duty Rack Assembly CWP-3360 Vertical Racker for Heavy Duty WAS-0243 1/4 Split Lock Washer FAS-2353 Hex Hd Cap Scr 1/4-20 x 1-1/2 CWP-3363...
- Page 37 OPTIONAL RACKING 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 38: Optional Motorized Racking Equipment / Prs-1100/ Exploded View / Wiring Diagram
OPTIONAL MOTORIZED RACKING EQUIPMENT / PRS-1100/ EXPLODED VIEW / WIRING DIAGRAM... -
Page 39: 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 40: 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 41: Preventive Maintenance / Cw-7 Circle Welder
AFTER DAILY USE: Refer to CW-7 Exploded View Parts List. (Pg. 10, 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 42 EVERY TWELVE MONTHS: Refer to CW-7 Exploded View Parts List. (Pg. 10, 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 43 PREVENTIVE MAINTENANCE / CW-7 CIRCLE WELDER Refer to CW-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.
-
Page 44: Warranty
WARRANTY Model _____________________________ Limited 3-Year Warranty* Serial No. __________________________ Date Purchased: ____________________ Where Purchased:___________________ For a period ending one (1) year from the date of invoice, Manufacturer warrants that any new machine or part is free from defects in materials and workmanship and Manufacturer agrees to repair or replace at its option, any defective part or machine.
Need help?
Do you have a question about the CW-7 and is the answer not in the manual?
Questions and answers