BUG-O Systems STW-3000 User Manual

INSTRUCTIONS

AND

PARTS MANUAL

STW-3000

PROGRAMMABLE

STIFFENER

WELDER

Please record your equipment identication 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-3000-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 15317-9564 USA

PHONE: [phone] http://www.bugo.com FAX: [phone]

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
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 equipment
power cord ground. Verify the

equipment is grounded in accordance

with all applicable local and national
electrical safety codes. In none exist,
use International Electric Code (IEC)

950.

EQUIPMENT DAMAGE

POSSIBLE.

1. Do not plug in the power cord without
rst 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 verify 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.

READ INSTRUCTIONS.

Read the instruction manual before
installing and using the equipment.

2

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.

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 separa-
tion between any machine cables and the plasma or welding cables.

3) Strictly follow the grounding procedures specied 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-3000

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-3000 Stiffener Welder / Major Components / Parts List
11 ... Wiring Detail
12 ... Wiring Detail / Electrical Component Chart
13 ... STW-2140-L Corner Follower Left / Exploded View / Parts List
14 ... STW-2140-R Corner Follower Right/ Exploded View / Parts List
15 ... STW-2150-L Gun Hinge Left / Exploded View / Parts List
16 ... STW-2150-R Gun Hinge Right / Exploded View / Parts List
17 ... STW-2170-A Capture Wheel Assembly “A” / Exploded View / Parts List
18 ... STW-2170-B Capture Wheel Assembly “B” / Exploded View / Parts List
19 ... STW-2115 Drive Latch / Exploded View / Parts List
20 ... STW-2060 Flow-Meter & Valve Assembly / Exploded View / Parts List
22 ... STW-2120 Drive Unit Assembly / Exploded View
23 ... STW-2120 Drive Unit Assembly / Parts List
24 ... STW-2195 Spool Support Bracket / Exploded View / Parts List
25 ... Accessories (Spools)

26 ... 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
feature programmable control of weld length and travel speed, skip length, reverse drive crater ll, pre­weld 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 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 right hand side of the control box to the “ON” position.
Ensure both welding torches are active by toggling the Weld Contactor Switches located on each
side 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. If the Emergency Stop Switch remains depressed, no input 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
lower left 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.
Coarse torch angle adjustment should be made with the positioning of the corner followers. The
Corner Followers are also equipped with a gun angle adjustment knob to achieve the desired torch

angle and correct position of the welding wire with respect to the joint. 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. Wire feeder wire speed and voltage are set independently from each
other utilizing the Lincoln LN-10 Controller. 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 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: Set on Lincoln LN-10 Control.

WIRE SPEED CONTROL: Set on Lincoln LN-10 Control.

WIRE JOG: Jog wire forward and reverse using the controls on the Lincoln LN-10 Control.

WELD CONTACTOR ON/OFF SWITCH: Allows operator to turn the contactor on or off for the

assigned welding torch.

SHIELD GAS PURGE: Allows operator to activate shield gas solenoid to purge welding gun and
check the gas rate on the assigned 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.

Emergency Stop

Shield Gas

Purge (A)

Travel

Manual

Jog

Weld

Contactor

Switch A

Programming Center

Shield Gas
Purge (B)

Main Weld

Cycle Start

Weld

Contactor
Switch B

Main Weld

Cycle Stop

6

CONTROLS (PROGRAMMING CENTER):

DIGITAL DISPLAY: Visual display to supply welding motion information to operator.

SHIELDING GAS PREFLOW: Programmable time to allow the ow of shielding gas prior to striking

the arc.

TRAVEL SPEED: Speed at which the unit moves during welding.

WELD LENGTH: Distance the unit travels forward while welding in Skip mode.

BACKUP DISTANCE: Distance the unit travels in reverse after completed weld length.

SHIELDING GAS POSTFLOW: Programmable time to allow the ow of shielding gas after the arc

has extinguished.

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 WELD INDICATOR LIGHT: When illuminated the machine will weld in skip mode.

CONTINUOUS WELD INDICATOR LIGHT: When illuminated the machine will weld in continuous

mode.

Note: It is possible to change from Continuous to Skip welding “on-the-y”. To change modes, press
the Continuous/Skip Select button. If the machine is making a continuous weld, the backup function
and postow will occur immediately. The machine will move the programmed skip distance and
proceed to make the programmed skip welds. If the machine is making a skip weld, the machine will
continue to weld until the Continuous/Skip Select button or the Stop button is pressed.

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); hold Cycle Stop button in, and turn power
on. Release Stop button. LED No.1 and 3 should light; and the display shows the start puddle
build time.

2. Adjust delay time as required using UP and DOWN arrow buttons.

3. Briey push Function Select (cycle settings) button. LED No. 3 and 5 should light, and display
shows the end crater ll time.

4. Adjust delay time as required.

5. Push Function Select button again, then power off.

6. 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

Backup Distance

Postow Time

Skip Length

Preow Time

Increase Value

Decrease Value

Function Select

Skip Weld

Indicator

Continuous/Skip

Select

Continuous Weld

Indicator

8