Climax BW3000 User Manual

BW3000 AUTOBOREWELDER

Advanced Automated Step Welding System

11

2013
BW3

for Bore, Flange, and Valve Repair.

The Climax BW3000 AutoBoreWelder is an
automated step welding system that provides
a new degree of welding performance and
precision. Weld time is dramatically reduced
while producing precise, uniform, high quality
welds as compared to hand welding techniques.

Unmatched Weld Quality and Precision

• Provides complete weld coverage at the start

and nish of the bore

• Reaches up to 5 feet (152.4 cm) into the bore.
Using torch extension support, can extend
upward using extended reach torch options.

• Lays up to 5 lbs (2.27 kg) of metal per hour.

• Arc time increases 50 - 100% over hand­welding, cutting weld time in half.

Built-In Cost Savings

• Precise, uniform welds means less wire is
consumed, reducing cost.

• All congurations come ready for a push-pull

wire feeder which prevents wire buckling and

waste when using low column-strength wire.

• Consistent and uniform weld reduces cutting

tool wear, reducing cutting time by up to 50%.

Single Point PLC-Based Control System Enhances
Operator Safety and Control of Welding Process

• Adjust all welding functions from one central
location.

• Weld operator safety is enhanced by allowing

operator to stand back from the weld as it is
being laid.

• Quickly adjust “step” size and direction, rotation
speed and direction, wire feed rate, arc voltage,
arc interrupt, contractor control, gas purge and

extended utilization of Auto-Skip function.

Flexible and Versatile

• Welds in any orientation: vertical, horizontal, or
inverted.

• Allows alternating of uphill and downhill welds

in a horizontal bore when welding multiple

passes

• Patented “offset head” provides radial
adjustments of the torch while maintaining

proper torch angle in relation to the work

piece.

• Wide range of travel speeds and amperage for

challenging in-eld conditions or working with

exotic metals.

• With proper options, can weld with any wire -

stelite, nickel, exotic metals.

• Can be congured to perform clad overlay with

nickel alloys, bronze, and exotic metals.

• Four operating modes available: Auto-Skip,
Pie, Carriage Return, and Contiuous Weld.

• Patented step process outperforms spiral

welding by providing complete weld coverage
with innitely adjustable step, allowing bead

placement from 0.40 - 0.220 inches (1.0 - 5.6 mm).

• Auto-skip feature allows “weld only” or “skip

only” areas to be designated.

• Allows rapid completion of work on out-of­round bores, bores with keyways.

• Precisely welds conical valve seats.

One Setup for Welding & Boring

• Climax BoreWelder Interface Kit simplies the

boring & welding setup process.

• Quickly attach the BW3000 AutoBoreWelder
directly to the Climax BB3000, BB4500 or

BB5000 Boring Machine mounting xtures.

• Interface kit makes it easy to switch between

bore welding and line boring without losing
bearing alignment.

• Interface kit ensures perfect alignment for both
welding and machining.

• One setup for both welding and boring saves

time and gets the job done quickly.

Weld & Bore at the Same Time

• Weld one section while boring out another,

using multiple bearing mounts.

• Simultaneous operation cuts work time in half!

Rugged, Fitted Protective Case for Easy, Safe
Transport:

• Packaged in heavy-duty, shock-resistant
case for safe, dust and water-proof storage,

convenient organization and easy transport

of the BW3000 AutoBoreWelder and its
components.

• Select from shop-style wire feeder, or

enclosed eld-style wire feeder in shock-

resistent waterproof case.

SPECIFICATIONS, APPLICATIONS

US Metric

Welding Process MIG (GMAW)

Axial Travel 6 or 12 inches 152.4 or 304.8 mm
(longer reach requires torch extension)

Step Range 0.040 - 0.220 inches 1.0 - 5.6 mm

Wire Diameter Range 0.023 - 0.045 inches 0.58 - 1.14 mm

Amperage Rating 175A Continuous

Total Extended Reach 39 inches 990.6 mm

Torch Welding Diameter Ranges

ID Bores #00 through #12 0.88 - 54 inches 22.4 - 1371.6 mm
OD Torches, max dia. 14, 28, or 56 inches 355.6, 711.2 or 1422.4 mm

Face Torch 1.0 - 20.0 inches 25.4 - 508.0 mm

Torch Extensions 3, 6, 12, and 18 inches 76.2, 152.4, 304.8 and 457.2 mm

Unsupported Torch Reach 60 inches 1524.0 mm

Control Box Voltages 120 VAC 50/60Hz or 230 VAC 50/60 Hz

Wire feeder

4-roll drive system accepts standard spools 30 lb spools 13.6 kg spools

Power Supply Requirements: Recommended 300 Amp Rating CV power source with remote voltage control capability
(power supply not included in BW3000 AutoBoreWelder Package)

Weights and Dimensions

Weights and Dimensions vary for each

package. Final weights will be determined

at the time of your order;

Standard BW3000 is shipped in 3 boxes:

(Weights and Dimensions are approximate)

Box #1 8 x 16 x 19 Inches

(203 x 407 x 483 mm)

Weight: 21 Lbs (9.53 kg)

Box #2 9 x 18 x 21

(229 x 457 x 533 mm)

Weight: 27 Lbs (12.25 kg)\

Box #3 20 x 30 x 13 Inches

(508 x 762 x 330 mm)

Weight: 106 Lbs (48 kg)

APPLICATIONS

The BW3000 is widely used by
these industries:

Mining & Heavy Construction

Power Generation
Pulp & Paper

Typical Applications:

• Bores, pivot points, buckets

and hitches

• Valve and pump repairs

• Gears and gear boxes

• Motor housings and shafts

• Electric motor repair

• Loader bucket & hitch repair

• Nozzles on pressure vessels and heat

exchangers

• Compressors and turbines

• Shaft OD repair

• Mud pumps

• Hydraulic cylinder eyes

• Presses

• Castings and injection molds

• Continuous miners and drag lines

• Rotary crushers

• Jaw crusher pitman arms

• Whole tree chippers

All dimensions should be considered reference. Contact your Climax Representative for precision dimensions. Specifications are subject to change without notice. There are no systems or components
on this machine that are capable of producing hazardous EMC, UV or other radiation hazards. The machine does not use lasers nor does it create hazardous materials such as gasses or dust.

page 2

Climax Portable Machining & Welding Systems Web site: climaxportable.com

Worldwide Phone: [phone] N. America Toll-Free: 1.800.333.8311 Fax: [phone] E-mail: [e-mail]

TOOL CONFIGURATIONS

Congure your BW3000 in 15 easy steps.

To congure your BW3000 Boring Machine:

1 Select a Base Unit
2 Select a Connector
3 Select Controls

4 Select Control Cables
5 Select Power Supply Cables

6 Select a Wire Feeder

7 Select Wire Feed Accessories

8 Select a Top Mount Feeder
9 Select Wire Feed Conduits
10 Select Torches
11 Select Specialty Torches
12 Select Mounting Options
13 Select Torch Extensions

14 Select Consumables

15 Select Miscellaneous Accessories

To congure the boring machine you require, simply select the option you

need in each step, then contact your Climax representative.

1 Base Unit (All machines are AutoSkip and Push/Pull Ready.
All wire feeders are also Push/Pull Ready)

Tool Kit (Wrenches, Manual, Gloves), Packaging, 69970
Rod, Collar, Torch Extension Kit, Consumables Package,
Positive Weld Cable, Shield Gas Hose, and Extra Liner.

2 Connectors

Metal

Welding Head 6 inch (152.4 mm) 54421
Auto Skip Push/Pull Ready
Welding Head 12 inch (304.8 mm) 54425
Auto Skip Push/Pull Ready

Plastic

Welding Head 6 inch (152.4 mm) 54419
Auto Skip Push/Pull Ready
Welding Head 12 inch (304.8 mm) 54423
Auto Skip Push/Pull Ready

3 Controls

Metal

120V Controller 70462
230V Controller 70463

Plastic

120V Controller 70464
230V Controller 70465

4 Control Cables

Metal

Control Cable 8 foot (2.4 m) 58276
Control Cable 15 foot (4.6 m) 58615

Plastic

Control Cable 8 foot (2.4 m) 29866
Control Cable 15 foot (4.6 m) 35400
Control Cable 20 foot (6.1 m) 61429

5 Power Supply Cables

Metal Connectors

Power Supply Cable Assembly, 58679
19 PIN ESAB, 25 foot (7.6 m)
Power Supply Cable Assembly, 69915
Eutectic Pulsarc 6000 or ESAB LAI 550P, 25 foot (7.6 m)
Power Supply Cable Assembly, 53985
Lincoln Multiweld 350 6 Pin, 25 foot (7.6 m)
Power Supply Cable Assembly, 53991
Lincoln 14 Pin, 25 foot (7.6 m)
Power Supply Cable Assembly, 53988

Lincoln 14 Pin, 50 foot (15.2 m)

Power Supply Cable Assembly, 68227
Millermatic Welders 10-Pin, 25 foot (7.6 m)
Power Supply Cable Assembly, 53249
Miller 14 Pin, 25 foot (7.6 m)
Power Supply Cable Assembly, 58564

Miller 14 Pin, 50 foot (15.2 m)

Power Supply Cable Assembly, 53990
Blank End

Plastic Connectors

Power Supply Cable Assembly, 69916
ESAB 350MPI 14 Pin, 25 foot (7.6 m)
Power Supply Cable Assembly, 45490
Eutectic Pulsarc 6000 or ESAB LAI 550P, 25 foot (7.6 m)
Power Supply Cable Assembly, 55327
Lincoln Multi Weld 6 Pin, 25 foot (7.6 m)
Power Supply Cable Assembly, 32042
Lincoln 14 Pin, 25 foot (7.6 m)
Power Supply Cable Assembly, 46670
Miller Millermatic 10 Pin, 25 foot (7.6 m)
Power Supply Cable Assembly, 34217
Miller X mT 14 Pin, 25 foot (7.6 m)
Power Supply Cable Assembly, 29824
Miller 14 Pin W/ 100V Pigtail, 25 foot (7.6 m)
Power Supply Cable Assembly, 69918
Miller Deltaweld 5 Pin, 25 foot (7.6 m)
Power Supply Cable Assembly, 36874
Blank One End, 25 foot (7.6 m)
Power Supply Cable Assembly, 69920
Universal, 25 foot (7.6 m)

6 Wire Feeders, Push/Pull Ready

Metal

Wire Feeder, Shop Style, 65054

Push/Pull Ready 24 VAC

Wire Feeder, Enclosed, 66946

Push/Pull Ready 24 VAC

Plastic

Wire Feeder, Shop Style, Push/Pull Ready 24 VAC 69812
Wire Feeder, Enclosed, Push/Pull Ready 24 VAC 44993

7 Wire Feed Accessories

(recommended when using push/pull wire feeder)

Wire Straightener 35357

page 3

Climax Portable Machining & Welding Systems Web site: climaxportable.com

Worldwide Phone: [phone] N. America Toll-Free: 1.800.333.8311 Fax: [phone] E-mail: [e-mail]

Tool ConfiguraTions

8 Top Mount Feeder
Metal

Top Mount Feeder 64288

Plastic

Top Mount Feeder 44992

9 Wire Feed Conduits

Wire Feed Conduit 2 foot (0.6 m) 31894
Wire Feed Conduit 3 foot (0.9 m) 31895
Wire Feed Conduit 4 foot (1.2 m) 35574
Wire Feed Conduit 5 foot (1.5 m) 34813
Wire Feed Conduit 6 foot (1.8 m) 69889
Wire Feed Conduit 8 foot (2.4 m) 69890
Wire Feed Conduit 10 foot (3.0 m) 34043

Wire Feed Conduit 12 foot (3.7 m) 55707

Wire Feed Conduit 15 foot (4.6 m) 45256

10 Torches

#00 to #5 Torch Kit 69896

0.88 to 13 inch (22.4 to 330.2 mm)
#00 to #5 Torch & Bearing Clearance Kit 70197

0.88 to 27 inch (22.4 to 685.8 mm)
Torch Bearing Clearance Package 63916
12 to 27 inch (304.8 to 685.8 mm)
#00 Torch, 0.88 - 1.8 inch (22.4 - 45.7 mm) dia. 29063
#0 Torch, 1.75 - 3 inch (44.5 - 76.2 mm) dia. 28448
#1 Torch, 2.75 - 5.5 inch (69.9 - 139.7 mm) dia. 29064
#2 Torch, 4.5 - 7.5 inch (114.3 - 190.5 mm) dia. 29032

#3 Torch, 6 - 9 inch (152.4 - 228.6 mm) dia. 29033

#4 Torch, 8 - 11 inch (203.2 - 279.4 mm) dia. 29034

#5 Torch, 10 - 13 inch (254.0 - 330.2 mm) dia. 29035

*** NOTE: #6 - #12 Torches Require Counterbalance ***

#6 Torch, 12 - 15 inch (304.8 - 381.0 mm) dia. 30345
#7 Torch, 14 - 17 inch (355.6 - 431.8 mm) dia. 31792
#8 Torch, 16 - 19 inch (406.4 - 482.6 mm) dia. 30346
#9 Torch, 18 - 21 inch (457.2 - 533.4 mm) dia. 30710
#10 Torch, 20 - 23 inch (508.0 - 584.2 mm) dia. 30711
#11 Torch, 22 - 25 inch (558.8 - 635.0 mm) dia. 30712

#12 Torch, 24 - 27 inch (609.6 - 685.8 mm) dia. 30713
#13/24 Torch Kit 70196

with Belt Pulley & 10 inch (254.0 mm) Radial Mount

13 Additional Torch Extensions

Torch Extensions 3 to 12 inch (76.2 - 304.8 mm) 69895
Includes 1 each 3, 6, & 12 inch (76.2, 152.4, & 304.8 mm)
Torch Extension 3 inch (76.2 mm) 29038

Torch Extension 6 inch (152.4 mm) 29039
Torch Extension 12 inch (304.8 mm) 29040

Torch Extension 18 inch (457.2 mm) 29065

Torch Extension Support Kit 33256

14 Additional Consumables

Welding Tip #00, 0.035 inch (0.9 mm) (Each) 69521
Welding Tip #00, SPEZ Feed 0.045 inch (1.2 mm) 69554
Welding Tip #0, Standard 0.035 inch (0.9 mm) 69520
Welding Tip #0, Large Radius 0.035 inch (0.9 mm) 67997
Welding Tip #0, Standard Radius 0.045 inch (1.2 mm) 68622
Welding Tip #0, SPEZ Feed 0.045 inch (1.2 mm) 69555
Welding Tip, 0.035 inch (0.9 mm) 69865
Welding Tip, 0.045 inch (1.2 mm) Dia. 70149
Welding Tip, 0.030 inch (0.8 mm) For 11-30 70150
Welding Tip, 0.035 inch (0.9 mm) (11-35) 62642

Chromium/Zirconium

Welding Tip #00, 0.035 inch (0.9 mm) 69891

Chromium/Zirconium

Welding Tip #0, Standard 0.035 inch (0.9 mm) 70204

Chromium/Zirconium

Welding Tip 0.045 inch (1.2 mm) Dia. 70205

Chromium/Zirconium
Welding Nozzle 69866

(For All Torches Except #00 & #0) (1 Ea) Standard 21-62)

15 Miscellaneous Accessories

Remote Arc Interrupt Cable 53184
Stick Electrode Holder 36169

11 Specialty Torches

Trammel OD Torch Package 27013

- up to 14 inch (355.6 mm) Dia.

Trammel Torch 28 inch (711.2 mm) 38506
Maximum OD Capability

Extended Trammel Torch Dia. to 56 OD 53004
Face Torch 8 inch (203.2 mm) 28186
Conical Seat Torch 28020
Compact Face Torch 6 inch (152.4 mm) Swing 48013

Torch Counterbalance 30756

12 Mounting Options

Adjustable Base 29037
Adapter Kit to BB3000 1-1/4 inch (31.8 mm) Bar 26795
Adapter Kit to BB4500 1-3/4 inch (44.5 mm) Bar 43731
Adapter Kit to BB5000 2-1/4 inch (57.2 mm) Bar 26518
Tool Alignment for BB3000 1-1/4 inch (31.8 mm) Bar 26656
Tool Alignment for BB4500 1-3/4 inch (44.5 mm) Bar 36062
Radial Mount 5 inch (127.0 mm), Radius Standard Spacer 28208

Radial Mount 10 inch (254.0 mm), Radius Spacer 35006

Weld Head Support Rod 30773

Mounting Rod Extender 30831

page 4

Climax Portable Machining & Welding Systems Web site: climaxportable.com

Worldwide Phone: [phone] N. America Toll-Free: 1.800.333.8311 Fax: [phone] E-mail: [e-mail]

ACCESSORIES, WELD RANGE INFO

BoreWelder Model 306 Z Series

Bore Depth in Inches. Not to scale.

Tips

Welding Tip (Each) 0.030 (ts all standard torches) 70150
Welding Tip (Each) 0.035 (ts all standard torches) 69865
Welding Tip (Each) 0.045 (ts all standard torches) 70149
Welding Tip (Each) #00 .035 (ts #00 torch) 69521
Welding Tip (Each) #00 .045 (ts #00 torch) 69554
Welding Tip (Each) #0 .035 (ts #0 torch) 69520
Welding Tip (Each) #0 .045 (ts #0 torch) 69555

Welder Power Supply

Power supply, 208 - 575V, Miller XMT 304 42707

50/60 Hz

Power supply, 208 - 575V, 50/60 Hz as 41615

above but with Aux 120V\ Outlet

Mounting Hardware

Adjustable base (included in select packages) 29037
Radial mount 5 inches (127 mm) 28208
(included in select packages)

Radial mount 10 inches (254 mm) 35006

Mounting rod (included in all packages) 30773

Mounting rod extender 30831

Other Accessories

Welding wire, cast controlled, 30792

0.035, 33 lb (15 Kg) Spool
National Standard –ER70-S6

Diffusers (each) 69778

Liner 0.023/0.045, 16 feet (4.9 m) long 40424

Set-up & operations video CD 40439
Welding ground wire with clamp, 38276

37 feet (11.3 m)

Push/pull power feed system 44992

Gas regulator 34397

Some BW3000 parts ship in
sturdy Pelican™ cases (Case

sizes and types vary by

model)

WELD RANGE INFORMATION

60

48

36

30

24

18

12

3.5
3

6

.50 .88

Motor
Options

Typical

Welding Ranges

1.751.0 3 5 6 9 10 28 54

1.125

FAST

LEGEND

Intended operating range

Possible under ideal
conditions

Unknown

Bore Diameter In Inches. Not to scale.

STANDARD

SLOW

page 5

Climax Portable Machining & Welding Systems Web site: climaxportable.com

Worldwide Phone: [phone] N. America Toll-Free: 1.800.333.8311 Fax: [phone] E-mail: [e-mail]

CLIMAX GLOBAL LEARNING CENTER

Climax has been teaching the fundamentals and fine points of portable
machine tool operation for practically as long as we’ve been inventing and
building the tools.

At the Global Learning Center situated in our corporate headquarters near
Portland, Oregon, we provide training for machine tool operators on
portable machine tool safety and machine setup and operation. Trainees
also receive technical tips and tools to improve operational efficiencies, with
the vast majority of every program devoted to hands-on activities and skill
development.

The Climax instructional team includes specialists in shipbuilding, power
generation, civil engineering, bridge re-building, petrochemical and other
industries.

Whether it’s a regularly scheduled course at the Global Learning Center, or custom curriculum conducted at your facility, your machinists will benefit from
courses developed by some of the most respected authorities in the business.

Call us today to register for a regularly scheduled class, or talk to us about how we can customize a training program for your specialized application.

Call Climax for:

On-site Training

Need some refresher courses in
setting up and operating your Climax
machine tool?

Special Projects

Climax has been solving
complicated on-site machining and
welding problems for our customers
since 1964.

Rentals

With 16 worldwide rental depot
locations, you are never far away
from a Climax portable machine tool.

Climax Global Locations

Edmonton

World Headquarters

Portland

Houston

Monterrey

World Headquarters

2712 E. Second Street
Newberg, Oregon 97132 USA
Worldwide Telephone: [phone]
N. America Toll-Free: 1.800.333.8311
Fax: [phone]
Email: [e-mail]

Cincinnati

European Headquarters

Manchester

Baton Rouge

Manchester

Cologne

Charlotte

Production Facilities

Rental Locations

International Distributors

Regional Sales & Technical Support Offices

Gdansk

Singapore

Connect with us:

European Headquarters

Am Langen Graben 8
52353 Düren, Germany
Telephone:(+49) (0) 2421.9177.0
Fax: (+49) (0) 2421.9177.29
Email: [e-mail]

Perth

Copyright © 2013 Climax Portable Machining & Welding Systems. All Rights
Reserved. Climax has taken reasonable measures to ensure the accuracy of
the information contained in this document. However, Climax makes no
warranties or representations with respect to the information contained herein;
and Climax shall not be held liable for damages resulting from any errors or
omissions herein, or from the use of the information contained in this document.