INSTRUCTIONS
AND
PARTS MANUAL
STW-2000
PROGRAMMABLE
STIFFENER
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.
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.
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.
3)Never open the equipment without first 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.
EQUIPMENT DAMAGE
POSSIBLE.
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.
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.
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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 specified 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 theAC 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.
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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-LCorner 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-BCapture 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
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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 fill, 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 DriveAssembly, Work Piece and Capture WheelAssemblies.
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 touchProgramming 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.
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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
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Emergency Stop |
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Programming Center |
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Voltage |
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Voltage |
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Control (A) |
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Control (A) |
Wire Speed |
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Wire Speed |
Control (A) |
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Control (B) |
Wire Jog (A) |
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Wire Jog (B) |
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Wire Feeder |
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Wire Feeder |
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Power Indicator |
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Power Indicator |
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Light |
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Light |
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Feeder |
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Feeder |
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On/Off (A) |
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On/Off (B) |
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Shield Gas |
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Shield Gas |
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Travel Manual |
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Purge (A) |
Purge (B) |
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Jog |
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Main Weld |
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Main Weld |
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Cycle Start |
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Cycle Stop |
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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.Briefly push Function Select (cycle settings) button. LED No. 3 and 5 should light, and display shows the end crater fill 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.
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CONTROLS (PROGRAMMING CENTER CONT’D.):
Digital Readout
Weld Length |
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Backup Distance |
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Travel Speed |
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Postflow |
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Preflow |
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Skip Length |
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Increase Value |
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Straight/Skip |
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Select |
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Decrease Value |
Skip |
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Indicator |
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Straight Indicator |
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Function Select |
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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) |
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Width 4"-12" (102-305 mm) |
Wire Spool Capacity: |
10, 20, 60 lbs. each side |
DIMENSIONS: |
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36"
14" (914 mm) (356 mm)
19.50"
(495 mm)
47" |
24" |
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(1194 mm) |
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(610 mm) |
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STW-2000 STIFFENER WELDER / MAJOR COMPONENTS
12
1
3
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