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: 1.503.538.2185 N. America Toll-Free: 1.800.333.8311 Fax: 1.503.538.7600 E-mail: Info@cpmt.com
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: 1.503.538.2185 N. America Toll-Free: 1.800.333.8311 Fax: 1.503.538.7600 E-mail: Info@cpmt.com
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: 1.503.538.2185 N. America Toll-Free: 1.800.333.8311 Fax: 1.503.538.7600 E-mail: Info@cpmt.com
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: 1.503.538.2185 N. America Toll-Free: 1.800.333.8311 Fax: 1.503.538.7600 E-mail: Info@cpmt.com
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:
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2712 E. Second Street Newberg, Oregon 97132 USA Worldwide Telephone: 1.503.538.2185 N. America Toll-Free: 1.800.333.8311 Fax: 1.503.538.7600 Email: info@cpmt.com
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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.
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