INSTRUCTIONS
AND
PARTS MANUAL
STW-2000
PROGRAMMABLE
STIFFENER
WELDER
Please record your equipment identication 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.
LIT-STW-2000-IPM-1214
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
280 TECHNOLOGY DRIVE CANONSBURG, PENNSYLVANIA USA 15317-9564
PHONE: 412-331-1776 http://www.bugo.com FAX: 412- 331- 0383
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.
1) The equipment is not waterproof.
Using the unit in a wet environment
may result in serious injury. Do
not touch equipment when wet or
standing in a wet location.
2) The unused connectors have power
on them. Always keep the unused
connectors covered with the supplied
protective panels. Operation of the
machine without the protective panels
may result in injury.
1) Do not plug in the power cord withou
first verifying the equipment is OFF
and the cord input voltage is the same
as required by the machine or serious
damage may result.
2) Always verity both the pinion and wheels
are fully engaged before applying power
or equipment damage may occur.
POSSIBLE.
3) Never open the equipment without rst
unplugging the power cord or serious
injury may result.
4) Verify the customer-supplied power
connections are made in accordance
with all applicable local and national
electrical safety codes. If none exist,
use International Electric Code(IEC)
950.
5) Never remove or bypass the equiment
power cord ground. Verify the
equipment is grounded in accordance
with all applicable local and national
electrical safety codes. If none exist,
use International Electric Code (IEC)
950.
READ INSTRUCTIONS.
Read the instruction manual before
installing and using the equipment.
3) Do not leave the equipment unattended.
4) Remove from the worksite and store in
a safe location when not in use.
FALLING EQUIPMENT
can cause serious
personal injury and
equipment damage.
Faulty or careless user installation is
possible. As a result, never stand or
walk underneath equipment.
MOVING PARTS can
cause serious injury.
1) Never try to stop the pinion from moving
except by removing power or by using
the STOP control.
2) Do not remove any protective panels,
covers or guards and operate equipment.
2
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.
NEVER lay a plasma or welding cable across the controls of the machine.
2) Always physically separate the plasma or welding cable leads from the machine
cables. For example, the plasma or welding cable leads should NEVER be bundled
with a pendant cable or the machine power cord. Maximize the separation between
any machine cables and the plasma or welding cables.
3) Strictly follow the grounding procedures specied for the plasma or welding unit.
NOTE: Some plasma and welding units produce exceptionally large amounts of
high frequency noise. They may require a grounding rod be driven into the earth
within six feet (2 meters) of the plasma or welding unit to become compatible with
an automatic cutting or welding process.
4) If the high frequency is produced using a spark gap, adjust the points so the gap is
as small as possible. The larger the gap, the higher the voltage and the higher the
interference.
5) Some plasma or welding units will inject high frequency interference into the AC power
line. Use separate power line branches whenever possible to power the plasma or
welding source and the machine. Do not plug them into the same outlet box.
6) High frequency noise may enter the machine through the plasma or welding supply
remote contactor leads. Some plasma and welding sources can produce noise spikes
of up to several thousand volts. These sources are not compatible with automated
cutting and welding equipment. It is recommended that the remote contactor leads
on these plasma or welding sources not be connected to the machine. An alternate
solution is to purchase a separate remote contactor isolation box.
3
STW-2000
PROGRAMMABLE STIFFENER WELDER
INSTRUCTIONS AND PARTS MANUAL
TABLE OF CONTENTS
5 ... Introduction / Setup & Operation
6 ... Controls (Main)
7 ... Controls (Programming Center)
9 ... Technical Data / Dimensions
10 .. STW-2000 Stiffener Welder / Major Components / Exploded View
11 ... STW-2000 Stiffener Welder / Parts List
12 ... Wiring Detail / Left Wire Feeder Control
13 ... Wiring Detail / Right Wire Feeder Control
14 ... Wiring Detail / Motion and Solenoid Control
15 ... Wiring Detail A-A / Electrical Component Chart
16 ... STW-2080 Wire Feeder / Exploded View / Parts List
17 ... STW-2140-L Corner Follower Left / Exploded View / Parts List
18 ... STW-2140-R Corner Follower Right/ Exploded View / Parts List
19 ... STW-2150-L Gun Hinge Left / Exploded View / Parts List
20 ... STW-2150-R Gun Hinge Right / Exploded View / Parts List
21 ... STW-2170-A Capture Wheel Assembly “A” / Exploded View / Parts List
22 ... STW-2170-B Capture Wheel Assembly “B” / Exploded View / Parts List
23 ... STW-2115 Drive Latch / Exploded View / Parts List
24 ... STW-2060 Flow-Meter & Valve Assembly / Exploded View / Parts List
26 ... STW-2120 Drive Unit Assembly / Exploded View
27 ... STW-2120 Drive Unit Assembly / Parts List
28 ... STW-2195 Spool Support Bracket / Exploded View / Parts List
29 ... CSM-1100 500 AMP Air-Cooled Gun / Exploded View / Parts List
30 ... CSM-3240-XX Gun & Cable Assembly / Parts List
31 ... Accessories (Spools)
32 ... Warranty
4
INTRODUCTION:
The Programmable Stiffener Welder mechanizes two wire feeders to weld various types of stiffeners on
one or both sides simultaneously. The unit features independent wire feeder controls for voltage, wire
feed speed, cold wire jog and gas purge. When intermittent stitch welding is required the unit features
programmable control of weld length and travel speed, skip length, reverse drive crater ll, pre-weld and
post-weld gas purge times. Please see the Technical Data information in this manual for unit capacities.
SETUP & OPERATION:
(Refer to the Controls Sections pg. 6, 7 and Major Components section pg. 10, 11 in this manual.)
1. Center the unit over the work piece. Connect welding cables and wire feeder control cables for each
feeder to the welding power sources. Connect the welding gas hoses to each Flow Meter/Valve
Assembly. Plug the unit into an available 110 VAC 50/60 Hz power source.
2. Turn power “ON” to both welding power sources. Turn power “ON” to the control panel by toggling
the “ON/OFF” switch on the upper rear left hand side of the control box to the “ON” position. Turn
“ON” power to both feeders by toggling the feeder “ON/OFF” switches located on the front lower left
and right of the control box to the “ON” position.
NOTE: Ensure that the Emergency Stop Switch located on the top of the control box is in the
released position or no power will be supplied to the unit.
3. Adjust the Capture Wheel Assemblies so that they contact the side of the work. Swing the Drive
Unit into position against the work piece and engage the Drive Latch and tighten to ensure constant
pressure on the work piece between the Drive Assembly, Work Piece and Capture Wheel Assemblies.
NOTE: Move the unit forward and reverse using the Travel Manual Jog Switch located on the front
bottom center of the control box to ensure proper tension has been applied by the Drive Latch to
move the unit smoothly along the work piece.
4. Align the left and right Corner Followers and welding guns for the desired weld placement. The
Corner Followers can be adjusted up, down, in and out to achieve the placement you desire. The
Corner Followers are also equipped with a gun angle adjustment knob to achieve the desired torch
angle. Purge the shield gas to each welding gun by pressing the Shield Gas Purge button located
on the left and right sides of the control panel for each Flow Meter/Valve Assembly.
5. Set all welding parameters. Each wire feeder’s wire speed and voltage are set independently from
each other utilizing the controls to the left and right of the soft touch Programming Center located
on the control panel. All other welding parameters are set using the soft touch Programming Center.
Please refer to the controls section of the manual.
6. When you are ready to begin your weld cycle press the Weld Cycle Start button located on the
control panel below the soft touch Programming Center. To stop the weld cycle press the Weld
Cycle Stop button.
NOTE: In case of an emergency press the Emergency Stop switch located on the top of the control
box to kill all power to the unit including the weld cycle. Once the Emergency Stop switch is returned
to the released position you will need to press the Cycle Start button to resume your cycle.
5
CONTROLS (MAIN):
VOLTAGE CONTROL: Regulates welding voltage for the assigned feeder
WIRE SPEED CONTROL: Regulates the wire feed speed for the assigned feeder
WIRE JOG: Allows wire to be fed without closing the weld current contact
WIRE FEEDER POWER INDICATOR LIGHT: Illuminate when power is being supplied to the assigned
wire feeder
WIRE FEEDER ON/OFF SWITCH: Allows operator to turn power on or off to the assigned wire feeder.
SHIELD GAS PURGE: Allows operator to activate shield gas solenoid to purge welding gun and check
the gas rate on the units regulators
MAIN WELD CYCLE START: Initiates automated weld cycle
MAIN WELD CYCLE STOP: Halts automated weld cycle
TRAVEL MANUAL JOG: Allows operator to move the unit forward or backward without welding
EMERGENCY STOP: When pressed causes all functions to stop
PROGRAMMING CENTER: See controls for programming center pg. 7
Voltage
Control (A)
Wire Speed
Control (A)
Wire Jog (A)
Wire Feeder
Power Indicator
Light
Feeder
On/Off (A)
Emergency Stop
Programming Center
Voltage
Control (A)
Wire Speed
Control (B)
Wire Jog (B)
Wire Feeder
Power Indicator
Light
Feeder
On/Off (B)
Shield Gas
Purge (A)
Main Weld
Cycle Start
Travel Manual
Jog
Shield Gas
Purge (B)
Main Weld
Cycle Stop
6
CONTROLS (PROGRAMMING CENTER):
DIGITAL DISPLAY: Visual display to supply welding motion information to operator
GAS PREFLOW DELAY: Programmable time for gas to purge lines before weld start
TRAVEL SPEED: Speed at which the unit moves during welding
WELD LENGTH: Distance the unit travels forward while welding
BACKUP DISTANCE: Distance the unit travels in reverse after completed weld length
GAS POSTFLOW DELAY: Programmable time for gas to shield weld at arc stop
SKIP LENGTH: Distance between welds (Must include backup distance)
INCREASE VALUE: Pressing this button increases the value shown in the digital display
DECREASE VALUE: Pressing this button decreases the value shown in the digital display
FUNCTION SELECT: Allows the user to cycle through the welding programming functions
SKIP/CONTINUOUS MODE SELECT: Allows the user to select skip mode or continuous mode for
the welding operation
SKIP INDICATOR LIGHT: When illuminated the machine will weld in skip mode
STRAIGHT LINE INDICATOR LIGHT: When illuminated the machine will weld in continuous mode
PUDDLE DELAY:
There are two internal settings in the Control Module that do not appear in the normal setting
selection on the control panel keypad/display. These are time delays at weld start and stop, when
the wire feed is on but travel is stopped, in order to allow for puddle buildup.
To set the time delays:
1. Power off, (power switch on back of control box)
2. Hold Cycle Stop button in, and turn power on.
3. Release Stop button. (LED No.1 and 3 should light; and the display shows the start puddle
build time.)
4. Adjust delay time as required using UP and DOWN arrow buttons.
5. Briey push Function Select (cycle settings) button. LED No. 3 and 5 should light, and display
shows the end crater ll time.
6. Adjust delay time as required.
7. Push Function Select button again, then power off.
8. Power on to operate machine as usual, now with new settings in place.
7
CONTROLS (PROGRAMMING CENTER CONT’D.):
Digital Readout
Weld Length
Travel Speed
Preow
Increase Value
Decrease Value
Backup Distance
Postow
Skip Length
Straight/Skip
Select
Skip Indicator
Straight Indicator
Function Select
8
TECHNICAL DATA:
Programmable Weld/Skip Travel Speed: 0"-36" ipm (0-914 mm/min)
Programmable Reverse Drive Crater Fill: 0"-1" (0-25 mm)
Programmable Pre-Weld/Post Weld Gas Purge: 0-10 seconds
Net Weight: 250 lbs. (113 kg)
Stiffener Size Range: Height 4"-18" (102-457 mm)
Width 4"-12" (102-305 mm)
Wire Spool Capacity: 10, 20, 60 lbs. each side
DIMENSIONS:
19.50"
(495 mm)
47"
(1194 mm)
14"
(356 mm)
24"
(610 mm)
36"
(914 mm)
9
STW-2000 STIFFENER WELDER / MAJOR COMPONENTS
12
1
3
20
2
13
7
10
11
13
17
10
14
13
6
8
15
13
9 10
4
18
16
5
19
16
10
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