Climax BW5000 User Manual

BW5000 AUTOBOREWELDER

A powerful welding and cladding system
that rotates around the work piece.

High Quality

• The Climax BW5000 AutoBoreWelder with

Auto-Skip is an affordable, highly
configurable, circumferential weld cladding
system, which provides a durable platform for
multiple configurations of weld overlay

• The BW5000 rotates around stationary parts.

The wire feed, step, and weld wire rotate
together under the stationary head unit,
retaining consistent wire placement as the
machine rotates

• The BW5000 allows for a wide range of exotic

alloys with multiple configurations to meet
your needs

• The BW5000 utilizes a CLX step feed system,

allowing 100% coverage, creating precision
welds of any thickness required between

0.125 and 0.35 inches. (3.175 and 8.89 mm)

3

2014

BW5

Flexible and Dependable Performance

• The modular BW5000 system allows efficient

and rapid shifts in various configurations like
welding bores, facing outside diameters, and
conical seats

• Any commercially available alloy can be

used, such as Inconel™, Hastelloy™,
Monel™, or stainless steel

• The step process reduces waste while

maintaining 100% coverage of the bore and
allowing weld overlay thickness to be as large
or as small as needed

• Flange faces, gasket surfaces and conical

seats can also be welded automatically by
utilizing an optional variable angle for conical
seats

• The BW5000 can interface with most CV

power supplies that are remote interconnect
capable, and 350 Amp, 100% duty cycle.
Clad transfer modes include GMAW-S (short
circuit), GMAW-P (pulse waveform), and
FCAW-G (gas shielded flux core). All GMAW

transfer modes are supported by the BW5000.

Minimize Cost, Waste and Downtime

• The BW5000 allows large parts to be welded

without rotating them, making it ideal for field
work, setting up on large equipment that could
never be rotated, and gets the job done 75%
faster than traditional hand welding methods.

• After welding operations are complete, the

BW5000 packs up to require only 1 cubic yard
of storage space.

• The BW5000 can deposit 12 pounds of metal

per hour — hour after hour

• Increase both the welding and production

capacity

• Build up or clad bores from 12 to 144 inches

(304.8 to 3657.6 mm)

SPECIFICATIONS

144

96

72

60

48

36

18

10 12 24 36 48 60 144

18

Bore Depth in Inches

Bore Diameter In Inches. Not to scale.

Typical

Welding

Ranges

LEGEND

Intended operating range

Possible under ideal
conditions

Physical access to the
machine within the bore
becomes a limiting factor

Call Bortech for custom
applications beyond 144 in.

Small bore torch required
below 24 in.

BoreWelder 1202

US Metric

Welding Process Metal - Inert - gas (MIG) Short Arc, Pulse, or Spray

Max. Wire Spool Size 2 inches ID x 14 inches OD 50.8 mm ID x 381 mm OD

Stroke 10, 20, 30, 40 and 50 inches 254, 508, 762, 1016 and 1270 mm

ID Diameter Range 12 to 144 inches 304.8 to 3657.6 mm

O.D. Welding Diameter Range 12 to 120 inches 304.8 to 3048.0 mm

Conical Seat Capability: 10 inch stroke 254.0 mm stroke
Capable of tracking conical seats & cones from 12 to 144 inches in diameter 304.8 to 3657.6 mm diameter

Small Bore Diameters 12 inches 304.8 mm

WELD RANGE INFORMATION

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

Configure your BW5000 in 6 simple steps:

1 Select a Base Unit
2 Select Machine Ranges
3 Select Controls
4 Select Feed Stroke (Auxiliary Slide Guide Rod)
5 Select Line Bar
6 Select Power Supply Cables
7 Select Accessories
8 Select Consumables
To generate the correct part number for the machine you require,
simply select the part number needed in each step as appropriate,
and contact your Climax representative.

NOTE: Conguration options shown are for vertical axis
welding. Please contact us for conguration options to enable

horizontal axis (out of position) welding.

1 Base Unit 71991

Includes: Weld Head, Wire Feed, Wire Feed Conduit &
Control Cable, 12 inch (304.8 mm) and 36 inch (914.4
mm) Line Bars, Standard Torch, Stepping Unit, Tool
Kit, Packaging, Consumables Package, Positive Weld
Cable 25 feet, Shield Gas Hose, and Extra Liner.

2 Machine Ranges

Radial Rod Kit for Welding Range: 24 - 72 inch (609.6 - 72079

1828.8 mm) ID / 24 - 48 inch (609.6 - 1219.2 mm) OD,
(includes one each 16, 24 & 38 inch (406.4, 609.6 &

965.2 mm Radial Rod).
Radial Rod Kit for Welding Range: 24 - 96 inch (609.6 - 72068

2438.4 mm) ID / 24 - 72 inch (609.6 - 1828.8 mm) OD,
(includes one each 16, 24, 38 & 60 inch (406.4, 609.6,

965.2 & 1524.0 mm) Radial Rod).
Radial Rod Kit for Welding Range: 24 - 120 inch 71989
(609.6 - 3048.0 mm) ID / 24 - 96 inch (609.6 -

2438.4 mm) OD, (includes one each 16, 24, 38 & 60
inch (406.4, 609.6, 965.2 & 1524.0 mm) Radial Rod).

Radial Rod Kit for Welding Range: 24 - 144 inch (609.6 - 71990

3657.6 mm) ID / 24 - 120 inch (609.6 - 3048.0 mm) OD,
(includes 1 each 16, 24 & 38 inch (406.4, 609.6 &

965.2 mm), two 60 inch (1524.0 mm) Radial Rods and
one 96 inch (2438.4 mm) Wirefeed Conduit).

3 Controls

120V Controller with Plastic Connectors 71037
230V Controller with Plastic Connectors 71105

5 Line Bar (Depth Into Bore)

Bars cannot be combined for additional length. Base Unit

comes with 12 & 36 inch (304.8 & 914.4 mm) line bars.

Line Bar 72 inch (1828.8 mm) 67544

Line Bar 96 inch (2438.4 mm) 72071

6 Power Supply Cables

ESAB 350MPI 14 Pin, 25 feet (7.6 m) 69916
Eutectic Pulsarc 6000 or ESAB LAI 550P, 25 feet (7.6 m) 45490
Lincoln Multi Weld 6 pin, 25 feet (7.6 m) 55327
Lincoln 14 pin, 25 feet (7.6 m) 32042
Miller Millermatic 10 pin, 25 feet (7.6 m) 46670
Miller XMT 14 pin, 25 feet (7.6 m) 34217
Miller 14 pin w/100V Pigtail, 25 feet (7.6 m) 29824
Miller Deltaweld 5 pin, 25 feet (7.6 m) 69918
Blank one end, 25 feet (7.6 m) 36874
Universal, 25 feet (7.6 m) 69920

7 Accessories

Small Bore Kit, 12 - 24 inch (304.8 - 609.6 mm) ID 71988
Conical Seat Step Mechanism, 10 inch (254.0 mm)
Stroke (Taper Seat Welding) 70193

8 Consumables

Gas Diffuser for Torch 67547
Nozzle for Torch 67548
Insulator for Torch 67549
Contact Tip 0.045 inch (1.1 mm) 67555
Contact Tip 0.062 inch (1.6 mm) 67557
Feed Roll V-Groove 0.045/0.062 inch (1.1/1.6 mm) 67453
Feed Roll V-Groove 0.045/0.052 (1.1/1.3 mm) + 1⁄16 Knurled 70488

4 Feed Stroke (Auxiliary Slide Guide Rod) Cannot be Combined

to Increase Length.

Auxiliary Slide Guide Assembly, 10 inch (254.0 mm) travel 70427
Auxiliary Slide Guide Assembly, 20 inch (508.0 mm) travel 70428
Auxiliary Slide Guide Assembly, 30 inch (762.0 mm) travel 70103
Auxiliary Slide Guide Assembly, 40 inch (1016.0 mm) travel 70429
Auxiliary Slide Guide Assembly, 50 inch (1270.0 mm) travel 70104

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]

OPERATIONAL DIMENSIONS

Head assembly

Mounting plate

1.5 inch (38.1 mm) split

90 degree coupling

(keyed optional)

8 inch (203.2 mm) support

Aux torch adjuster

8 inch (203.2mm)
support

Radial rod mount /

clamping collar

Standard torch

Portable wirefeeder

junction box

8 inch (203.2 mm) clamping
torch support rod

Aux step unit

Aux slide guide rod

2 inch (50.8 mm)
accessory mount

1.5 inch (38.1 mm)
accessory mount

Radial rod

2 inch (50.8 mm) split clamping collar

Line bar

Wire reel support

Spool bracket

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]

OPERATIONAL DIMENSIONS

23.0 (584.2)

14.9 (378.5)

13.8 (350.5)

Dimensions in Inch (mm)

10.7

(271.8)

Aux. Guide Rod (Stroke)
16 - 10 (406.4 - 254.0)
26 - 20 (660.4 - 508.0)
36 - 30 (914.4 - 762.0)
46 - 40 (1168.4 - 1016.0)

26.0

56 - 50 (1422.4 - 1270.0)

(660.4)

11.0

(279.4)

3.0

(76.2)

6.5

(165.1)

11.4

(289.6)

Radial Rods
16 (406.4)
24 (609.6)
38 (965.2)
60 (1524.0)

Any two may be combined
to increase length up to
120 inches (3048.0 mm)

10.8

(274.32)

Line Bars
12 (304.8 mm)
36 (914.4 mm)
72 (1828.8 mm)
96 (2438.4 mm)

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 LOCATIONS

Edmonton

World Headquarters

Portland

Houston

Monterrey

Cincinnati

European Headquarters

Manchester

Charlotte

Baton Rouge

Manchester

Cologne

Production Facilities

Rental Locations

International Distributors

Regional Sales & Technical Support Offices

Gdansk

Singapore

Perth

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.

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]

Rentals

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

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]

Copyright © 2014 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.