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INSTRUCTIONS
AND
PARTS MANUAL
CWP-5
PROGRAMMABLE
CIRCLE 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-CWP-5-IPM-0218
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: 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.
2
ELECTRIC SHOCK can kill.
1) The equipment is not waterproof.
Using the unit in a wet environment
may result in serious injury. Do not
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.
first unplugging the power cord or
serious injury may result.
connections are made in accordance
with all applicable local and national
electrical safety codes. If none exist,
950.
5) Never remove or bypass the equip-
ment power cord ground. Verify the
equipment is grounded in accordance
with all applicable local and national
electrical safety codes. If none exist,
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 with
as required by the machine or serious
damage may result.
2) Always verify both the pinion and
3) Do not leave the equipment
unattended.
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.
moving except by removing power or
by using the STOP control.
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 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 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
4
CWP-5 PROGRAMMABLE
CIRCLE WELDER
INSTRUCTIONS AND PARTS MANUAL
TABLE OF CONTENTS
PAGE
5 ........Introduction / Features
6-7 .......Setup and Operation
8-9 .......CWP-1570 Control Panel
9-10 .....Programming Instructions
12 .......CWP-1570 Control Panel - Open Box / Exploded View
13 .......CWP-1570 Control Panel - Open Box / Parts List
14-16 ...CWP-1570 Control Panel - Wiring Diagram (Parts 1-3)
17 .......Technical Data / Dimensions
18 .......CWP-5 Circle Welder / Exploded View
19 .......CWP-5 Circle Welder / Parts List
20 .......CWP-5 Circle Welder / Wiring Diagram / Electrical Component Chart
21 .......CWO-3139 (CWO-3139-M) Universal Power Cable / Wiring Diagram
21 .......Outside View of Plugs / Wiring Diagrams
22 .......MUG-1621-1.5 Cable 18" / MUG-1634-3 Shielded Cable / Wiring Diagrams
22 .......MUG-1634-3 Shielded Cable / Wiring Diagrams
23 .......CBP-1670 Motorized Racking System / Exploded View / Parts List
23 .......CBP-1675 Vertical Racker / Exploded View / Parts List
24 .......CBP-1590 Drive Box / Exploded View / Parts List
24 .......CWO-1685 Horizontal Racker / Exploded View / Parts List
25 .......CWO-3001 Shaft Assembly / Exploded View / Parts List
25 .......CWP-1580 Wire Reel Mount Assembly / Exploded View / Parts List
26 .......CWO-3059 Large Brush Holder and Support / Exploded View / Parts List
26 .......CWO-3384 P.M. Motor Assembly / Exploded View / Parts List
27 .......CBP-1595-5 Encoder Assembly / Exploded View / Parts List / Wiring Diagram
28 .......CWO-3462 Small Brush Holder Assembly / Exploded View / Parts List
28 .......CWO-3461 Small Retainer Block Assembly / Detail View
29 .......CWP-5 Gun Assemblies
30 .......#4 Gun and Cable Assembly / Exploded View / Parts List
31 .......CWP-5 Drive Roll Kits
34-35 ...Set-up Instructions For CWP-5 / CB-1P Used In Sprinkler Fabrication
36 .......Set-up Diagram For CWP-5 / CB-1P Used In Sprinkler Fabrication
37-39 ...Preventive Maintenance / CWP-5 Circle Welder
INTRODUCTION
The CWP-5 Circle Welder is designed for circular single or multi-pass welding of couplings on sprinkler pipe utilizing MIG or FLUX CORED process, with gas shielding. For 1-12 in. (25.4-304.8 mm) diameter welds. The CWP-5 can accommodate couplings in both on-center and hillside positions.
FEATURES
• Amperage & wire speed control
• Wire feeder with one set of drive rolls
• 1/12 HP P.M. motor and rotational speed control
• 300 AMP Gun & cable assembly
• Gas shielding kit with 120 VAC solenoid valve
• 5/8" (16 mm) gas cup
• Burn back control
• 50 ft. (15 m) power cable
• 50 ft. (15 m) gas shielding hose
• 50 ft. (15 m) weld cable
• Quick disconnects for all cables
• Weld contact switch
• Cold wire inch switch
• Wire direction switch
• Pre and post flow controls
• Wire reel adaptor for 30 lb. (14 kg) spools
• Adjustable vertical and horizontal torch positioning system
• Microprocessor controlled rise and fall with 5" (125 mm) of travel
• Brushes and collector rings for welding current, rated at 300 AMPS 100% duty cycle
• Brushes and collector rings for all controls, eliminate cable and hose wrap
5
6
SETUP AND OPERATION
POWER SOURCE
Use only constant voltage type power sources with this circle welder machine. If using a multiple process power source, be sure that it is set for constant voltage output as per the instructions in the manual for the power source. Set the power source polarity switch or properly connect the electrodes and work leads for the correct electrode polarity.
FIXTURING
All circle welders have to be fixtured in some manner from the top of the shaft. This may be achieved in one of the following: column & boom, manipulator or carriage & monorail.
GUNS AND CABLES
All circle welders come equipped with a gun and cable assembly. It is our recommendation that at least once a week the liner be taken out of the cable and soaked overnight in a solvent solution. To keep the wire moving it is also recommended that a felt clip be saturated with a product like Ferro Slick and fed thru the incoming tube of the wire feeder at least once a day.
ADDITIONAL CABLES
The circle welders are supplied with the following cables:
1. CWO-3139 50' (15 m) power cable that connects the power source to the cable connector on the top gear of the machine.
2. CWO-3019 50' (15 m) weld cable that connects the lead coming out of the top of the machine using the quick connect connector to your power supply.
3. CWO-9406 50' (15 m) gas shielding hose that connects the gas fitting on the top of the shaft to your shielding gas supply. MIG models, only.
WIRE SPEED AND VOLTAGE ADJUSTMENT using the control on the power source.
WHEEL ADJUSTMENT
The CWP-5 Racking System CBP-1670 and the Small Horizontal Racker
CWO-1685 are equipped with adjustable wheels. Always check these components for proper wheel adjustment before using the machine. The wheels need adjustment if you can cock or wiggle the components out of alignment. The wheels should be snug but not prohibit movement along the path of travel. The wheels with the hex stand offs are adjustable, as shown in Figure 1. To adjust the wheels, loosen the hex bolt (A) until the adjustable bushing (B) can be rotated. Correct the wheel alignment by rotating the adjustable bushing (B). Once adjusted, hold the adjustable bushing (B) while tightening the hex bolt (A). Recheck alignment.
B A
Figure 1: Wheel Adjustment
SETUP AND OPERATION, CONT’D.
MACHINE CONTROLS
Please refer to pages 8-9 in this manual entitled CWP-1570 Control Panel for descriptions of the various control parameters that are available.
WELD STARTING POSITION
Proper positioning of the electrode is crucial to a successful weld. The CWP-5 rotates in a clockwise direction. Depending on the job, whether on-center or hillside, or the process, the optimum starting point of the weld may vary. The desired starting position should be entered at setup as an angle to the pipe axis direction, as shown in Figure 3.
The default start position (start angle = 0.00°) is shown as A and B in Figure 3. For an on-center joint, this would be the topmost point. For a hillside joint, -90.00° is the topmost point (C in Figure 3) and 90.00° is the lowest point.
During setup, enter the Start Angle in hundredths of degrees: 4500 is 45.00°. The machine makes one revolution from the start point for each pass. Overlap is only added to the last pass.
A
C
B
Figure 3: Weld Start Position for On-center (left) and Offset or Hillside (right) nozzles.
MAKING A WELD
1. Connect the ground cable to the workpiece. The ground cable must make good electrical contact with the work.
2. Set Weld ON/OFF Switch to the OFF position.
3. Depress red STOP button.
4. Position the welding gun at the start position using the Racking System CBP-1670 and the rotation controls. Position the electrode in the joint. The end of the electrode may be lightly touching the work.
5. Depress the black RESET button to set a new Home position.
6. Using the keypad, call up the desired program number or input a new program. When finished, press
“D” to review the program data.
7. Set the Weld ON/OFF Switch to the ON position.
8. Depress the green START button to begin the weld program.
9. Turn on the FLUX RECOVERY VACUUM Switch to the ON position.
10. The CWP-5 will automatically stop at the end of the weld program.
WARNING: When using an open arc process, it is necessary to use correct eye, head and body protection.
7
8
CWP-1570 CONTROL PANEL
The CWP-1570 control panel, (shown below), controls all aspects of the CWP-5 machine and the weld and provides real time displays for Rotation Speed, Volts, and Current. The panel is divided into three major sections - Rotation Controls, Keypad and Wire Feeder Controls.
ROTATION CONTROL KEYPAD
12
WIRE FEEDER CONTROL
13
1 14
15
2
4
3
5
16 17
6 18 19
9
8
10
20 21
11 7
1 ROTATION SPEED (REF. # ONLY)
2 SPEED CONTROL
3 STOP / PAUSE
4 START / RESUME
5 RESET
6 MANUAL JOG
7 CONTROL POWER
8 POWER INDICATOR
9 CIRCUIT BREAKER
10 MIRROR IMAGE
11 WELD ON/OFF
12 KEYPAD
13 VOLTS METER
14 CURRENT METER
15 WIRE FEED SPEED
16 WIRE DIRECTION
17 FLUX VACUUM
18 PREFLOW
19 POSTFLOW
20 PURGE / COLD INCH
21 BURNBACK
CWP-1570 CONTROL PANEL, CONT’D.
ROTATION CONTROLS
The rotation controls are located on the left portion of the control panel (Items 1-11 on page 8). Use these controls to maneuver the electrode to the starting position, to start or interrupt the weld and to control the rotation speed. A brief description of each item is provided below.
ROTATION SPEED Displays reference # only
SPEED CONTROL Controls speed of rotation. Turn right to increase; left to decrease
STOP / PAUSE Immediately stops welding and rotation. Does not burnback or purge
START / RESUME Starts or resumes program
RESET Resets home or weld start position
MANUAL JOG Manually position welding electrode for vertical and horizontal axes
CONTROL POWER Enables / Disables power to control panel
POWER INDICATOR When lit, indicates power ON to control panel
CIRCUIT BREAKER Protects control box electronics
MIRROR IMAGE
WELD ON/OFF
Reverses rotation direction
ON enables weld. OFF disables weld for dry run
KEYPAD
The keypad (Item 12 on page 8) is the second section of the control panel. This is used for programming and inputting dimensions. Refer to the section titled “Programming” (below) for more detailed information. An overview of the key functions is provided below.
ALPHA KEYS Press keys A, B, C, D, or E for the function desired, as described in the
“Programming” section of this manual.
DIGIT KEYS Use the digit keys to enter pipe diameters or dimensions.
ENTER Push the ENTER button to store the numeric value entered.
BACKSPACE Use BACKSPACE to remove the last digit keyed in before pushing the ENTER button, if a correction is required.
SHIFT The blank key in the top right corner of the keypad is the SHIFT key. Use this key to access additional programming options.
ARROW KEYS Used to jog vertical axis during auto-run program to set new torch position.
PROGRAMMING
FUNCTION KEYS
All programming is done using the PENDANT CONTROL . Use the following Alpha Keys for programming:
A: To enter dimensions.
B: To enter the time delay for puddle build-up.
C: To change Program Number in memory (numbers 0 – 99).
D: To display the dimensions of the weld.
E: To enter the number of passes (1 – 99).
Three other useful key functions are:
Shift 9: Set units, English (inch) or metric (meters)
Shift 8: Test drives & encoders
Shift E: Version number (have this information ready when calling for service)
DATA REQUIRED
1. Small diameter (nozzle size)
2. Large diameter (pipe it fits on)
3. Offset distance between centerlines
9
When entering data, use the diameter of the cylinder along whose intersection the cut has been made. Usually this will be the inside diameter of the nozzle or the outside diameter of the pipe it fits on. This will also allow for any bevel, if necessary. If no offset, enter “0” or just press “Enter”.
NOTE: If the STOP / RESUME button is pressed, the machine will be in pause mode, and cannot be programmed. Press the RESET button to get back to the ready mode for programming.
ON-CENTER
NOZZLE
OFFSET
NOZZLE
DATA ENTRY
When entering data with the pendant keypad, multiply inches, degrees, or seconds by 100 and enter the number without a decimal point. For metric dimensions, multiply mm X 10 or cm X 100.
Example: 350 for 3.5 inches,
800 for 80 mm, on metric machines
Press “ENTER” on the keypad after the number is entered.
SAVING PROGRAMS
The machine has 100 storage areas or welds, numbered 0 to 99 in memory. Push the “C” button on the pendant keypad to change (or set) the program number and enter the desired number. Program data is retained until reprogrammed. At any time, one of these numbers is selected, it will stay selected even when power is shut off and turned back on, it will not change until the program number is changed by the operator.
Settings for time delay and number of passes are not saved as part of a program.
WIRE FEEDER CONTROLS
The third section of the control panel is the wire feeder controls (Items 12-21 on page 8). An overview of each wire feeder control is provided below. For more detailed information, refer to the Lincoln Operating manual.
VOLTS Displays actual voltage during welding
CURRENT Displays actual current (amps) during welding
WIRE FEED SPEED Controls the feed speed of the wire. Turn left for slower speeds; right for higher speeds.
WIRE DIRECTION Controls the direction the wire is being fed through the feeder. UP to return wire to the spool. DOWN to feed the wire to the gun in order to weld.
FLUX VACUUM Turns the Flux Recovery Vacuum ON and OFF.
PREFLOW Controls flow of shielding gas to the work before the arc is established. The gas solenoid valve is energized immediately when the gun trigger is closed, but the time delay before the wire feeder is energized is adjustable from 0 to 1.5 seconds.
Turn the knob LEFT for shorter delays, RIGHT for longer delays.
POSTFLOW Controls flow of shielding gas to the work after the welding has stopped.
Adjustable from 0.5 to 4.5 seconds. Turn the knob LEFT for shorter delays, RIGHT for longer delays.
PURGE / COLD INCH Control some wire feeder functions without energizing the welding power source.
The momentary UP position energizes the gas solenoid, but not the wire feeder or
10 welding power source. The momentary DOWN position energizes the wire feeder but not the gas solenoid or the welding power source.
BURNBACK Provides a precise time delay that allows the wire to be burned off at the end of the weld. This is useful for those applications where higher speed, fine wire feeding is used and there is a tendency for the electrode to overrun at the end of the weld and cause “sticking” in the crater. The delay is adjustable for optimum burnback depending on wire size, process, procedure, etc.
EXAMPLE
The following is a step-by-step example for setting up and running the CWP-5.
BASIS:
Weld a 2" nozzle onto a 10" header, with an offset of 2" and a weld overlap of 5°. Weld a single pass, and allow 0.3 seconds for puddle build-up at the start of the weld. Assign program number 01 to this weld.
Step 1. Setup fixturing for the CWP-5.
• Setup machine on carriage with monorail and pipe stands, as described on page 32.
Step 2. Install the CWP-5
• Connect ground cable to work piece; ensure good contact
• Set the Weld switch to OFF
• Power ON the Control Panel
• Set travel speed using the rotation control box
Step 3. Position the welding gun.
• Press the red [STOP] button
• Using rotation controls and CBP-1670 racking system, place the electrode at the weld start
(as shown in Figure 2 on page 7)
• Press the black [RESET] button
Step 4. Program the weld.
• Press [SHIFT], [9] to select units
• Press [C] to set the program number
[0], [1], then [ENTER] or [1], then [ENTER]
• Press [A] to set dimensions
At the “Enter Small Diameter” prompt, enter the nozzle diameter.
[2], [0], [0], then [ENTER]
At the “Enter Large Diameter” prompt, enter the vessel diameter.
[1], [0], [0], [0], then [ENTER]
At the “Offset” prompt, enter the offset distance.
[2], [0], [0], then [ENTER]
At the “Overlap” prompt, enter the amount of the overlap in degrees.
[5], [0], [0], then [ENTER]
• Press [B] to enter time delay for puddle build-up
Note: This value is universal and not associated with program number.
[3], [0], then [ENTER]
• Press [D] to display or review the program dimensions
• Press [E] to set number of passes
[1], then [ENTER]
Step 5. Start the weld.
• Set the Weld switch to ON
• Depress the green [START] button
Step 6. End the weld.
• The CWP-5 will automatically stop after completing the number of passes entered
• Depress the red [STOP] button after the weld has stopped and before repositioning the machine
11
CWP-1570 CONTROL PANEL - OPEN BOX / EXPLODED VIEW
1
2
4 4
7
5 6
8
18
19
4
9
12
10 11
13
14
15
23
31
29
25
46
26
47
28
47
30
22
24
27
46
33
34
36
32
47
47
35
37
38
20
39
13 21
40 41
44
45
3
16
17
42
48
43
12
CWP-1570 CONTROL PANEL - OPEN BOX / PARTS LIST
21
21
22
22
23
24
25
25
15
16
17
18
19
19
20
20
25
25
26
27
27
28
ITEM QTY PART NO.
1
2
3
4
5
5
6
7
8
9
10
11
12
12
1
1
1
3
1
1
1
1
1
1
1
1
1
1
BUG-2923
BUG-2924
BUG-1415
PRS-1065
SWT-0S42
SWT-1113
SWT-1112
SWT-1111
BUG-1562
BUG-5757
13 12 FAS-0104
13 12 SCF-1001
13 12 WAS-0201
14
14
1
1
1
1
MDS-1011
BUG-1764
BUG-6051
PCB-1350
Self-clinching Nut, 4-40
Lockwasher, #4 Internal Star
Bezel Display
Meter Display Board
Terminal, Panel Mount w/fast.
Lincoln Timer Board
SCW WTE 0481 Screw, Pan Hd, 6-32x1/4
SWT-0809
1
2
2
2
1
1
1
1
1
1
2
1
1
1
1
1
3
1
1
1
CWP-1571
CWP-1573
CWP-1572
ARM-2279
LDC-1103
BUG-5757
MDS-1011
MTR-1008
MDS-1011
MTR-1007
FHO-0188
CWO-6076
CWO-6759
LDC-1109
BUG-6031
FAS-0124
FAS-1320
WAS-0221
MUG-1156
BUG-1770
FAS-0124
BUG-9909
DESCRIPTION
Enclosure, hinged
Legend Plate, Rotation
Legend Plate, Wire Feed
Toggle Switch
Circuit Breaker, 0.7 amp
Reset Seal, Transparent
Pilot Light
Joystick
Toggle Switch, DPDT
Push Button, N.O., Green
Push Button, N.O., Red
Push Button, N.O., Black
Potentiometer, 10k, 3 Turn
Knob, Black, Large
Screw, Pan Hd, Blk, 4-40x3/8
Toggle Switch, DPDT
Potentiometer
Knob, Black, Large
Bezel Display
DPM LED 8-50 VDC
Bezel Display
Ammeter LED 8-36 VDC
Fuse Holder
Fuse, 5 Amp, Fast Acting
Panel Connector, 6T-M
Power Resistor
Filter
Screw, Pan Hd, 8-32x3/8
Hex Nut, 8-32
Lockwasher, #8, Internal Star
Panel Connector, 4T-F
Motor Control Board
Screw, Pan Hd, 8-32x3/8
Panel Connector, 6T-M
36
36
37
38
39
40
41
42
34
34
34
34
34
35
36
36
42
43
44
44
44
44
45
45
45
46
46
46
2
1
4
4
1
1
1
1
1
1
4
4
1
2
2
1
1
1
4
1
1
1
1
1
4
1
1
1
2
1
1
4
ITEM QTY PART NO.
29
29
29
30
31
31
31
32
33
1
2
BUG-6028
FAS-0115
FAS-1310
BUG-9486
CWO-6520
FAS-0124
FAS-1320
MS-2A18-11S
BUG-1034
CON-1202S
SRK-144B
RES WTE 0111
DESCRIPTION
Terminal Block, Kulka
Screw, Pan Hd, 6-32x1/2
Hex Nut 6-32
Panel Connector, 2T-M
4-Quadrant Speed Control
Screw, Pan Hd, 8-32x3/8
Hex Nut, 8-32
Panel Connector, 5T-F
Panel Connector, 4T-M
Panel Connector, 2T-F
Shrink Tube
470 ohm 1/4 w 5% carbon film-TR
CAP WTE 0071 .1UF 250V 10% .4" Radial
SRK WTE 1346 1/8" Black Shrink Tube
BUG-9856
8
8
8
CBP-6030
FAS-0204
BUG-6029
CBP-1511
FAS-0124
FAS-0224
LDC-1107
LDC-1108
STOF-2009
SCW WTE 0264 Screw, Pan Hd, #6 x 1/4
PCB-1351
BUG-1383
BUG-1384
BUG-1404
FAS-0114
BMV-1530
BMV-1570
FAS-0114
FAS-0215
FAS-1310
WAS-0211
47 24 FAS-0204
47 24 FAS-1305
47 24 WAS-0201
48 1 PCB-1355
Panel Connector, 2T-F
Control Module
Screw, Rnd Hd Slt, 4-40x3/8
Bracket
Transformer Bracket
Screw, Pan Hd, 8-32x3/8
Screw, Rnd Hd, 8-32x3/8
Transformer
LN7 WTE 1352 Circuit Breaker, 250V 2.5A
Ground Lead Protector Reset
Stand-Off, 6-32, 1/4x1/4
Motor Control Board
Relay, 4PDT, 3A 120V, Plug-in
Relay Socket & Spring
Relay Bracket
Screw, Pan Hd, 6-32x3/8
Power Supply
PC Board Stand-off
Screw, Pan Hd, 6-32x3/8
Screw, Rnd Hd, 6-32x1/2
Hex Nut. 6-32
Lockwasher, #6 Internal Star
Screw, Rnd Hd, 4-40x3/8
Hex Nut, 4-40
Lockwasher, #4 Internal Star
Relay, 3PDT, 24 VDC for LN7
*ITEMS NOT SHOWN.
*The following items are used to secure Control Box to Mounting Arms, but are not shown:
QTY PART NO. DESCRIPTION
4 FAS-2358 Screw, Hex Hd, 1/4-20 x 3
4 BUG-1069-2 Spacer
4 WAS-0240 Washer, 1/4 SAE Flat
4 FAS-1351 Hex Nut, 1/4-20
13
CWP-1570-WD CONTROL PANEL / WIRING DIAGRAM (1 OF 3)
14
CWP-1570-WD CONTROL PANEL / WIRING DIAGRAM (2 OF 3)
15
CWP-1570-WD CONTROL PANEL / WIRING DIAGRAM (3 OF 3)
16
TECHNICAL DATA
Amperage:
Input Voltage:
Voltage:
Wire Sizes:
0-300 amps
115 VAC
0-50 VAC
.035 - .062" (.8 - 1.6 mm)
Rotation Speed:
Cam Range:
.5-6.0 rpm
5" (125 mm)
Welding Diameter: 1 - 12" (25 - 300 mm)
Shielding Gas:
Height:
Net Weight:
Shipping Weight:
Solenoid Control
30" (762 mm)
155 lbs. (71 kg)
200 lbs. (91 kg)
DIMENSIONS
26"
(660 mm)
1"-12"
(25-300 mm)
WELDING
DIAMETER
30"
(762 mm)
30"
(762 mm)
17
CWP-5 CIRCLE WELDER / EXPLODED VIEW
25
9
7
26
2
8
10
24
16
5
20
19
11
14
21
4
13
27
28
3
23
22
17
18
15
6
12
1
18
CWP-5 CIRCLE WELDER / PARTS LIST
ITEM QTY PART NO.
1
18
19
20
21
22
23
24
25
10
11
12
13
14
15
16
17
26
27
28
2
3
4
5
6
7
8
9
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
CWO-3001
CWO-1685
CWP-1580
CWO-3059
CWO-3199
CWP-1570
CWO-3384-PCW
CWO-3417
CBP-1595-5
CWO-3456
CWO-3462
CWP-1575
CWO-3468
CWO-3935
CWO-4050
CWO-4060
CWO-4088
CWO-4092
CWO-5075
CWO-5220
CWO-5734
FAS-0376
CWP-1574
CWO-8056
CBP-1670
CWP-1576
CWO-6008
CWO-2005
DESCRIPTION
CWP-5 Shaft Assembly
Small Horizontal Racker
Wire Reel Assembly
Brush Holder & Support Assembly
CWP-5 Housing Assembly
Dual Control Box
P.M. Motor Assembly
Motor & Transmission Plate Assembly
Encoder Assembly
CWP-5 Collector
Small Brush Retainer Assembly
Slide Bar Mounting Assembly
LN-7 Wire Feeder Assembly
Terminal Block Assembly CWP-5
1" Bearing With Fasteners
1-1/4" Bearing With Fasteners
Wire Feeder Mount Plate
Cable Support
1-1/4" Trantorque
Guard Assembly
Gear, Alum (0716112) 2" Bore
Hex Hd Cap Scr 5/16-18 x 5/8"
Control Box Mounting Arm 1
Solenoid Adaptor Kit
CBP Racking System
Control Box Mounting Arm
CWP-5 Shunt Bar
Wire Feeder Guard
NOTE: See CWP-5 Circle Welder Wiring Diagram (page 20) for wiring and cable information.
19
CWP-5 CIRCLE WELDER / WIRING DIAGRAM
1
11
14
3
20
2
TO
POWER
CABLE
5
4
8
15,16
IN FROM
WELDER
SUPPLY
UNIT
WHT
BLK
RED
ORG
12
GRN
WHT
BLK
RED
ORG
6
13
9
10
7
ELECTRICAL COMPONENT CHART
ITEM DESCRIPTION PART NO.
1 Weld Cable Inlet 2/0 CWO-3020-2/0
2 Weld Cable
3 Weld Cable 50’
4 Large Brush Holder & Support
5 Power Cable
6 GMA Pigtail
CWO-3013
CWO-3019
CWO-3059
CWO-3139*
CWO-3331
7 Dual Control Box
8 P.M. Motor Assembly
9 CWP-5 Collector
10 Small Brush Retainer Assembly
11 LN-7 Wire Feeder Assembly
12 Terminal Block
13 Rotation Encoder Assembly
14 Solenoid Adapter Kit
15 Shunt Bar
16 CWP-5 Shunt Cable
17 Cable 18"
18 Shielded Cable
CWP-1570
CWO-3384
CWO-3456
CWO-3462
CWO-3468
CWO-3935
CBP-1595-5
CWO-8056
CWO-6008
CWP-1585
MUG-1621-1.5
MUG-1634-3
*CWO-3139 Universal CWO-3139-M for Miller Welders
18
17
IN FROM Y-DRIVE
IN FROM VACUUM
CWO-3139 (CWO-3139-M) UNIVERSAL POWER CABLE / WIRING DIAGRAM
ORN CONTACT #1
2
CWO-3139
1
RED CONTACT #2
WHT 110 NEUTRAL
BLK 110 LINE
GRN 110 GROUND
3
ELECTRICAL COMPONENT CHART
ITEM DESCRIPTION PART NO.
CWO-3139
QTY
1 Plug, Straight, 5 Pin, Female CON-PS05F
2 Panel Connector 2T-F WER WTE 0667
1
600"
CWO-3139-M
QTY
3 Power Receptacle
4 14 Pin Miller Connector Assy
TERM WTE 0602
CWO-3142
5
1
CWO-3139-M
2
4
OUTSIDE VIEW OF PLUGS / WIRING DIAGRAMS
1
21
MUG-1621-1.5 CABLE 18" / MUG-1634-3 SHIELDED CABLE / WIRING DIAGRAMS
C
D
A
B
C
D
A
B
MUG-1634-3 SHIELDED CABLE / WIRING DIAGRAMS
C
D
A
B
E
F
C
D
A
B
E
F
22
CBP-1670 CWP-5 MOTORIZED RACKING SYSTEM / EXPLODED VIEW /
PARTS LIST
5
6
1
2
ITEM QTY PART NO.
1
2
3
4
5
6
2
1
1
1
2
2
ABR-1070
CBP-1675
CWO-1695
CWO-3023-1 Torch Angle Adjuster 16"
FAS-1351
FAS-2351
DESCRIPTION
V-Guide Ways 19"
Motorized Vertical Racker
Attachment Block
Hex Nut 1/4-20
Screw, Hex Hd Cap 1/4-20 x 1-1/4"
1
3
4
6
5
CBP-1675 VERTICAL RACKER / EXPLODED VIEW / PARTS LIST
3
6
F
2
8
A
F
4
A
5
7
10
A = Adjustable Wheel Placement
F = Fixed Wheel Placement
1
9,11
ITEM QTY PART NO.
1
2
3
4
5
6
7
8
9
10
11
1
1
2
2
1
2
2
2
2
3
2
CBP-1590
CWO-1677
CWO-1680
CWO-1681
CWO-1682
CWO-1694
FAS-0555
FAS-0557
FAS-0559
FAS-2551
WAS-0240
DESCRIPTION
Drive Box
Mount Plate
W2 Fixed Leg & Wheel Assembly
W2 Adj Leg & Wheel Assembly
Racker Mount Bar
Stand-Off
Screw, Soc Hd Cap 1/4-20 x 1/2
Screw, Soc Hd Cap 1/4-20 x 3/4
Screw, Soc Hd Cap 1/4-20 x 1
Screw, Soc Hd Cap 1/4-20 x 1 1/4
Washer, SAE 1/4
23
CBP-1590 DRIVE BOX / EXPLODED VIEW / PARTS LIST
ITEM QTY PART NO.
1
2
3
4
5
6
7
8
9
10
*11
1
1
1
8
1
4
4
4
4
1
1
BUG-1550
BUG-6040
BUG-9909
CBP-1585
CBP-1586
FAS-0204
FAS-0517
FAS-0527
DESCRIPTION
Gear Motor (150:1)
Gear / Encoder Assembly
Panel Connector, 6-T, M
Drive Box
Drive Plate
Screw, Rnd Hd Slt 4-40 x 3/8
Screw, Soc Hd Cap 6-32 x 3/4
FAS-1305
GOF-3014
Screw, Soc Hd Cap 8-32 x 3/4
Hex Nut 4-40
Drive Pinion
MUG-1634-3 Shielded Cable 3'-6-T, F&M
* = Not Shown
5
4
4 2
9
3
10
6
1
21
18
17
15
4
24
A
A
20
5
F
A
6
F
13
9
F
16
8
20
10
22
12 F = FIXED WHEEL PLACEMENT
A = ADJUSTABLE WHEEL PLACEMENT
1
7
CWO-1685 HORIZONTAL RACKER / EXPLODED VIEW / PARTS LIST
14
22
19
7
F
A
3
2
11
14
15
16
17
18
19
20
21
22
23
6
7
8
9
10
11
12
13
ITEM QTY PART NO.
1
2
3
4
5
1 BUG-2032
1 CWO-1671
1 CWO-1678
1 CWO-1679
2 CWO-1680
2 CWO-1681
1 CWO-1686
2 CWO-4020
2 CWO-4021
1 CWO-4112
1 FAS-0355
2 FAS-0534
2 FAS-0557
2 FAS-0559
1 FAS-1307
1 FAS-1351
1 MUG-1141
1 MUG-1142
1 MUG-1144
2 MUG-1453
1 MUG-1579
3 WAS-0240
1 WAS-0243
DESCRIPTION
Knob, Black
Racker Shield
Racker Plate
Pinion 11T
W2 Fixed Leg & Wheel Assembly
W2 Adj. Leg & Wheel Assembly
Mount Plate (Small Racker)
Fixed Leg & Wheel Assembly
Adj. Leg & Wheel Assembly
Bracket
Hex Hd Cap Scr 1/4-20 x 1/2"
Soc Hd Cap Scr 10-24 x 3/8"
Soc Hd Cap Scr 1/4-20 x 3/4"
Soc Hd Cap Scr 1/4-20 x 1"
Hex Jam Nut 3/4-16
Hex Nut 1/4-20
Bearing Collet
Knob, Locking
Shaft
Stand-Off
Retaining Ring
1/4" SAE Washer
1/4" Split Lock Washer
CWO-3001 SHAFT ASSEMBLY / EXPLODED VIEW / PARTS LIST
1 1 2 3
ITEM QTY PART NO.
1
2
3
2
1
1
CWO-4003
CWO-5781
BUG-9096
DESCRIPTION
O-Ring
CWP-5 Shaft
Outlet Bushing, Oxygen
CWP-1580 WIRE REEL MOUNT ASSEMBLY / EXPLODED VIEW
5
8
6
5
2
7
8
4
1
3
Included
With Item
Four
2
3
4
5
6
7
8
ITEM QTY PART NO.
1 1
1
1
1
4
2
2
4
CWO-5977
CWO-3743
CWO-4081
WFU-1041
FAS-2375
FAS-0559
FAS-1370
WAS-0251
DESCRIPTION
Vertical Mount Plate
Horizontal Mount Plate
Wire Reel Mount Bar
2" O.D. Spindle Kit
Hex Hd Cap Scr 5/16-18 x 2"
Soc Hd Cap Scr 1/4-20 x 1"
Hex Nut 5/16-18
5/16 Lock Washer
25
CWO-3059 LARGE BRUSH HOLDER AND SUPPORT / EXPLODED VIEW /
PARTS LIST
10
9
11 4
12
2
8
12
1
3
6
6
7
12
11 5
8
6
7
8
9
10
11
12
13
ITEM QTY PART NO.
1
2
3
4
5
1 CWO-4036
1 CWO-4037
1 CWO-3263
2 CWO-3264
2 CWO-4337
2 CWO-5548
1 CWO-5549
2 FAS-0305
1 FAS-0309
2 FAS-0357
2 WAS-0243
1 WAS-0280
3 WAS-0281
DESCRIPTION
Large Brush Holder Support
Attachment Bar
Large Brush Holder
Spring Clip
Large Brush 1-1/2" x 3/4" x 2"
Micarta Spacer
Micarta Bushing
Hex Hd Cap Scr 1/2-13 x 2"
Hex Hd Cap Scr 1/2-13 x 1"
Hex Hd Cap Scr 1/4-20 x 3/4
1/4" Split Lock Washer
1/2" SAE Flat
1/2" Split Lock Washer
CWO-3384 P.M. MOTOR ASSEMBLY / EXPLODED VIEW / PARTS LIST
1
4
2
3
ITEM QTY PART NO.
1
2
3
4
1
1
1
3
CWO-5691
CWO-4069
CWO-4147
DESCRIPTION
P.M. Motor 146
Gear, P.M. Motor 146
P.M. Motor Bracket #970
TERM-WTE-1508 #8 Fork Blue 14RB-8FL T&B
26
CBP-1595-5 ENCODER ASSEMBLY / EXPLODED VIEW / PARTS LIST /
WIRING DIAGRAM
1
15
14
3
2
13
12
4
5
6
7
8
16 14
9
11
6
10
11 1
ITEM QTY PART NO.
1
10
11
12
13
14
15
16
*17
2
3
4
5
6
7
8
9
1
1
1
1
2
2
1
1
2
1
1
4
1
1
4
1
1
CBP-1549
FAS-0124
MUG-1592
BUG-6044
FAS-0115
SFX-1218
MUG-1593
MUG-1594
FAS-0227
CBP-1589
CBP-1598
FAS-1305
MUG-1596
MUG-1156
FAS-0204
CAP-1105M
DESCRIPTION
Encoder, 512 CPR
8/32 x 3/8 Pan Hd, Di-Chrome
Bracket
Flexible Coupling
6-32 x 1/2 Pan Head, Zinc
Bearing-Flg 1/4 ID x 3/8 OD x 5/16 Lg
Pod
Plate
Rnd Hd Scr 8-32 x 3/4
Gear Shaft Assembly
Connector Cable
Hex Nut 4-40
Enclosure
Panel Connector, 4-T, F
Rnd Hd Slt Scr 4-40 x 3/8 Zinc
1Uf 50V 10% Radial
MUG-1621-1.5 Cable 18"
* = Not Shown
27
CWO-3462 SMALL BRUSH HOLDER ASSEMBLY / EXPLODED VIEW /
PARTS LIST
1
3
2
5
6
4
ITEM QTY PART NO.
1
2
3
4
5
6
7
8
9
10
11
12
1
1
2
1
1
1
1
4
4
4
4
4
CWO-3461
CWO-9076
FAS-0539
FAS-2351
WAS-0240
WAS-0243
CWO-5626
CWO-5831
CWO-5874
CWO-5875
CWO-5876
DESCRIPTION
Small Retainer Block Assembly
Retainer Support
Soc Hd Cap Scr 10-24 x 1"
Hex Hd Cap Scr 1/4-20 x 1/1/4"
1/4" Washer
1/4" Split Lock Washer
Small Brush Retainer BLK
Brush 1/8" x 1/8" x 7/8"
Brush Holder
Cap
Clip
TERM-WTE-0602 #6 Fork Blue
CWO-3461 SMALL RETAINER BLOCK ASSEMBLY / DETAIL VIEW
1
3
2
4
7 8,9,10,11
WHITE 10"
BLACK 10"
RED 10"
ORANGE 10"
12
28
CWP-5 GUN ASSEMBLIES
CWO-1500-A #4 1/16 GUN ASSEMBLY MIG/FLUX
CWO-8002
CWO-8006
CWO-8007
CWO-8008
CWO-8011
CWO-8523
CWO-1500-D
CWO-1500-E
CWO-1500-B
CWO-1500-C
#4 .035 GUN ASSEMBLY MIG/FLUX
CWO-8003
CWO-8006
CWO-8007
CWO-8008
CWO-8009
CWO-8523
#4 .045 GUN ASSEMBLY MIG/FLUX
CWO-8004
CWO-8006
CWO-8007
CWO-8008
CWO-8009
CWO-8523
#4 5/64 GUN ASSEMBLY MIG/FLUX
CWO-8005
CWO-8006
CWO-8007
CWO-8008
CWO-8012
CWO-8523
#4 .052 GUN ASSEMBLY MIG/FLUX
CWO-8001
CWO-8006
CWO-8007
CWO-8008
CWO-8011
CWO-8523
1/16 WIRE SIZE
14H-116 CONTACTOR TIP 10
24A-62-SS NOZZLE
34A NOZZLE INSULATOR
54A GAS DIFFUSER
44-116-15 CABLE LINER
40902 400 AMP CABLE
1
1
1
1
1
.035 WIRE SIZE
14H-35 CONTACTOR TIP
24A-62-SS NOZZLE
34A NOZZLE INSULATOR
54A GAS DIFFUSER
44-3545-15 CABLE LINER
40902 400 AMP CABLE
1
1
1
1
10
1
.045 WIRE SIZE
14H-45 CONTACTOR TIP
24A-62-SS NOZZLE
34A NOZZLE INSULATOR
54A GAS DIFFUSER
44-3545-15 CABLE LINER
40902 400 AMP CABLE
1
1
1
1
10
1
5/64 WIRE SIZE
14H-564 CONTACTOR TIP 10
24A-62-SS NOZZLE
34A NOZZLE INSULATOR
54A GAS DIFFUSER
44-564-15 CABLE LINER
40902 400 AMP CABLE
1
1
1
1
1
.052 WIRE SIZE
14H-52 CONTACT TIP
24A-62-SS NOZZLE
34A NOZZLE INSULATOR
54A GAS DIFFUSER
44-116-15 CABLE LINER
40902 400 AMP CABLE
1
1
1
1
10
1
29
#4 GUN AND CABLE ASSEMBLY / EXPLODED VIEW / PARTS LIST
6
8
9
6
7
6
9
6
7
5
10
2
3
1
1
PARTS LIST
ITEM QTY PART NO. DESCRIPTION
1 1 CWO-8001 14H-52 Contact Tip
1
1
1
1
CWO-8002 14H-116 Contact Tip
CWO-8003 14H-35 Contact Tip
4
5
6
1
1
1
1
1
1
2
CWO-8004 14H-45 Contact Tip
CWO-8005 14H-564 Contact Tip
CWO-8006 24A-62-55 Nozzle
CWO-8007 34A Nozzle Insulator
CWO-8008 54A Gas Diffuser
CWO-8014 64A-60 Conductor Tube
CWO-8017 185 Case w/Binder Screws
7
8
9
10
1
1
2
1
CWO-8018 104 Cable Connector Block
CWO-8025 174 Connector Plug w/ O-Rings
CWO-8019 234-12 Cable Hose Support
CWO-8523 40902 400 AMP cable
*
* 1
1
CWO-8009 44-3545-15 Cable Liner
CWO-8011 44-116-15 Cable Liner
* 1 CWO-8012 44-564-15 Cable Liner
* ITEM NOT SHOWN
4
1
3
2
X
X
X
X
X
X
X
X
X
X
WIRE SIZE
.035
.045
.052
1/16 5/64
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X X
X
30
CWP-5 DRIVE ROLL KITS
PART NO. DESCRIPTION
CWO-7026-.035 DRIVE ROLL KIT .035 (0.9mm) SOLID WIRE
CWO-7026-.035C DRIVE ROLL KIT .035 (0.9mm) CORED WIRE
CWO-7026-.052 DRIVE ROLL KIT .045-.052 (1.0-1.3mm) SOLID WIRE
CWO-7026-.052C DRIVE ROLL KIT .045-.052 (1.0-1.3mm) CORED WIRE
CWO-7026-1/16 DRIVE ROLL KIT 1/16 (1.6mm) SOLID/CORED WIRE
CWO-7026-3/32 DRIVE ROLL KIT .068-3/32 (1.7-2.4mm) SOLID/CORED WIRE
31
ACCESSORIES
KBUG-5050 Stand Alone Weaver
The compact oscillator provides a pendulum weaving motion to the gun. Speed, width and dwells are independently adjustable.
CWO-3670 Step Adaptor for Thread-O-Lets
CWO-3675 Step Adaptor for Groove-O-Lets
The Step Adaptor is a stepped centering device used to center the machine on threaded I.D. couplings. The range of the Step Adaptor is 1/2" to 4" (13-102 mm) diameter.
CWO-5790 Cone Adaptor
The Cone Adaptor is a tapered centering device used to center the machine on pipe stubbies. The range of the Cone Adaptor is 1-1/4" to 4" (32-102 mm) diameter.
32
CARRIAGES
CWO-4530 151 Carriage
The 151 Carriage mounts on a standard monorail. The carriage allows the operator to move the machine the length of the pipe, while utilizing a lever to position the machine vertically on the work piece.
CWO-4540 151P Carriage
The 151P Carriage mounts on a standard monorail. The carriage allows the operator to move the machine the length of the pipe, while utilizing a winch to position the machine vertically on the work piece.
CWO-4550 151M Carriage
The 151M Carriage mounts on a standard monorail, or “bridge crane” type setups. The carriage allows the operator to move the machine the length of the pipe, while utilizing an electric motor to mechanically position the machine vertically on the work piece.
33
SET-UP INSTRUCTIONS FOR CWP-5 / CB-1P USED IN SPRINKLER FABRICATION
SUPPORTING FIXTURE AND PIPE STANDS
The first priority should be given to where the fixture is to be placed. The burning of the holes and welding of the couplings should be the last part of the operation performed on the pipe. It is important that a flow pattern or line be looked at, so that when the pipe is taken out of the fixture, it is finished and ready for shipment.
The mono rail consists of a 4" x 8" x 1/4" wall rectangular tubing with a 3/8" x 3" flat bar welded to the tubing (See pg. 32). The flat bar has to project 1" above the top of the tubing. “C” clamps are to be used to hold the flat bar against the tubing with no gaps. The “C” clamp may be walked down the tubing as it is being tack welded. If the beam has a bow in it, take to following steps:
1. Determine exactly where the center of the bow is. This may be accomplished by putting a string along the front side of the monorail. Place 1/2" nuts between the string and the monorail and measure the gap between the string and the monorail. Always measure on the same side of the string.
2. After you have determined where center of the bow is, take a hand torch and heat the outside of the bow. The outside of the bow should be the side the flat bar is welded to. Take a piece of chalk and draw a triangle with a 2" base under the bottom of the flat bar with the top or point of the triangle pointing down. Do the same on the top of the monorail against the flat bar with the top or point pointing towards the face of the monorail. Heat these two areas so that they become cherry red in color. After the heat has been applied, take a large rag and a bucket of water and cool the heated area. After the area has been cooled, check the beam again. Repeat as necessary.
PIPE STANDS
The pipe stands consist of 3" pipe in floor flanges with a 2-1/2" or 3" angle welded to the top of the pipe, and they should be spaced and aligned as shown (See pg. 32). The two stands should have some sort of clamping device to hold the pipe in place. The clamping device can be anything from a pipe vise to a chain and boom. The clamping device must be staggered.
After the pipe stands and supporting columns are in place, the monorail is to be placed on the supporting columns. The pipe stands and the supporting columns must be level and plumb. These items may have to be shimmed. With these items level, the monorail may be put in place on the supporting columns and held in place by two “C” clamps. Put a level on the face of the beam in the vertical position and on the bottom in the horizontal position. The beam should be level both ways, and if not, the beam will have to be shimmed. If the monorail has a twist, which may occur, level one end so that the other end needs to be pulled back.
Next, put a piece of 8" pipe in the pipe stands and clamp down. Take a center head and find the center of the pipe on each end and in the middle. You can now use two methods to check to see if the monorail is aligned with the pipe below. They are as follows:
1. Use a plumb bob off the face of the monorail and measure from the center of the pipe to the plumb bob. The distance should be 5-11/16" in all three locations.
2. The second method is to put one carriage on the monorail and attach the CB-1P to it. With the center pin in the burning machine, check all three locations. The burning machine must be plumb on the carriage if this method is used.
34
SET-UP INSTRUCTIONS FOR CWP-5 / CB-1P USED IN SPRINKLER FABRICATION
INSTALLING CARRIAGES AND MACHINES ON THE MONORAIL
Assemble carriages and put them on the rail.
The CWP-5 welder is put on the carriage that is nearest to the welding power source and the CB-1P cutter nearest to the plasma power source.
Put the CB-1P cutter machine on the 8" pipe in the stands and bring the carriage to the machine. Lower the shaft coupling over the main shaft on the cutter. Ensure that shaft is fully inserted into the shaft coupling. Rotate the machine so that the plasma leads are in front and parallel to the carriage and tighten the set screws in the shaft coupling to secure the main shaft to the vertical slide assembly.
Next put the CWP-5 welder on the 8" pipe and bring its carriage to it. Lower the shaft coupling down over the main shaft. Rotate the machine so that the welding lead on top of the machine will be on your left.
This will put the electrical connector on the right. Tighten the set screws in the shaft coupling to secure the main shaft to the vertical slide assembly.
It is important for the machines to hang plumb. Left to right adjustments are made by loosening the two bolts that connect the shaft coupling to the vertical rail. Front to back adjustments are done by adjusting the position of the vertical rail support plate. Move the plate by adjusting the eight nuts on the four studs.
Note: Once machines are plumb verify that the machines are centered over the pipe stand.
CARRIAGE ADJUSTMENT
Vertical Rail
Front To Back Adjustment Front To Back Adjustment
Front To Back Adjustment
Left To Right Adjustment
Vertical Rail Support Plate
Front To Back Adjustment
Shaft Coupling
35
36
5.31" (135 mm) 1" (25 mm)
3/4" x 6" x 26" BAR (19 x 152 x 660 mm) TACK WELD 1/8" x 1" (3x25 mm) LONG ON 16" (406 mm) CENTERS 1-1/2" (38 mm) PIPE
22" (559 mm)
10 HARNESS SNAPS WITH SWIVEL
3/8" (9.5 mm) x 3" (76 mm) FLA
4" x 8" x 1/4" (102 x 203 x 6 mm) W
1/4" (6 mm) CABLE
8' (2.4 m)
3" (76 mm) PIPE
6' (1.8 m)
5' (1.5 m)
5' (1.5 m)
6' (1.8 m)
PREVENTIVE MAINTENANCE / CWP-5 CIRCLE WELDER
IMPORTANT: Make sure the input power at the power source is turned off and the 50' weld cable is disconnected from the circle welder prior to working inside the circle welder.
AFTER DAILY USE:
Refer to CWP-5 Exploded View and Parts List. (Pg. 18-19)
Racking System item #25:
Inspect gear rack, hardened ways and wheels (remove all dirt, grease, weld spatter and rust). Check hardened ways for nicks and replace if necessary. Lubricate with a dry teflon or graphite spray lubricant.
Adjust wheels for snug fit and smooth operation. Lubricate racker pinion with a dry teflon or graphite spray lubricant.
Small Horizontal Racker item #2:
Inspect wheels (remove all dirt, grease, weld spatter and rust). Adjust wheels for snug fit and smooth operation. Lubricate racker pinion and wheels with a dry teflon or graphite spray lubricant.
Slide Bar Mounting Assembly item #12:
Inspect hardened ways (remove all dirt, grease and weld spatter). Check hardened ways for nicks and replace if necessary. Lubricate with a dry teflon or graphite spray lubricant.
Refer to CWP-5 Electrical Component Chart. (Pg. 20)
Power Cable item #5:
Inspect cable connector to make sure threads are not stripped and that the connector is not cracked.
Check the cable for cuts, missing insulation and burn spots, replace if necessary.
CWP-5 Collector item #9:
Inspect cable connector to make sure threads are not stripped and that the connector is not cracked.
Ensure that the connector is fastened properly to the large aluminum gear item #21 on the CWP-5
Exploded View Parts List.
EVERY SIX MONTHS:
Refer to CWP-5 Exploded View and Parts List. (Pg. 18-19)
Aluminum Gear item #21
Do not grease this gear. Inspect gear teeth (remove all dirt, grease and weld spatter). Lubricate with a dry teflon or graphite spray lubricant. Replace gear if excessively worn.
P.M. Motor Assembly item #7:
Do not grease this pinion. Inspect the drive pinion (remove all dirt, grease and weld spatter). Lubricate with a dry teflon or graphite spray lubricant. Replace pinion if excessively worn. Check set screw and tighten if necessary. Adjust motor assembly using the four adjustable mounting fasteners so that proper gear mesh is achieved between the aluminum gear item #27 and the motor drive pinion.
Wire Reel Assembly item #3:
Periodically coat the wire wheel shaft with a thin layer of grease as needed. Inspect the shoe assembly and replace if excessively worn.
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PREVENTIVE MAINTENANCE / CWP-5 CIRCLE WELDER
Refer to CWP-5 Electrical Component Chart. (Pg. 20)
Dual Control Box item #7:
Open control box use an air hose to blow out dust and dirt. Check all wires for breaks and replace if necessary. Check all electrical connectors and plugs. If an electrical component fails refer to CWP-1570
Control Panel Exploded View and Parts List for replacement parts or to return for service.
LN-7 Wire Feeder Assembly item #11:
Check brushes for wear. Brushes should be replaced when their length is less than 1/4 inch. Replace strain relief on wire if pulled out of motor housing.
Large Brush Holder & Support item #4:
Inspect brush holder. Make sure constant tension is being applied on the brushes. Brushes should move freely within the brush holder. Check brushes for arc build-up. If brushes are pitted they will need replaced. Remove the brushes and sand them to ensure a smooth contact surface. Make sure all fasteners are tight.
Small Brush Retainer Assembly item #10:
Inspect black brush holders for cracks and replace if needed. Check and make sure all wires are soldered properly to the holders. Replace the brushes when their length is less than 1/2 inch long.
Remove the brushes and sand them to ensure a smooth contact surface. Make sure all fasteners are tight.
Terminal Block item #12:
Inspect the plastic terminal strip and make sure it is not cracked, replace if necessary. Make sure all terminal connections are tight. Make sure all ground wires are connected to the mounting screws of the terminal strip.
EVERY TWELVE MONTHS:
Refer to CWP-5 Exploded View and Parts List. (Pg. 18-19)
1" Bearing With Fasteners item #15:
Do not grease the bearing, it is greased for life by the manufacturer. If the grease fitting has not been removed and plugged we suggest that you do so now. Earlier models may not have been plugged at time of assembly.
1-1/4" Bearing With Fasteners item #16:
Do not grease the bearing, it is greased for life by the manufacturer. If the grease fitting has not been removed and plugged we suggest that you do so now. Earlier models may not have been plugged at time of assembly.
P.M. Motor Assembly item #7:
Bodine gear motor lubrication. Fill gear motor to oil level indicator with worm gear oil conforming to
AGMA#5EP compounded (SAE#90) oil or Bodine lubricant (#L-23). Do not overfill.
LN-7 Wire Feeder Assembly item #13:
Apply graphite grease to the gear teeth. Inspect the drive roll portion of the assembly, clean as necessary. Do not use solvents on the idle roll because it may wash the lubricant out of the bearings. Do not apply grease to the drive rolls.
Encoder Assembly item #9:
Inspect for excessive wear and tear. Keep the transmission assembly clean and lubricate with Lubriplate
#630-AA.
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PREVENTIVE MAINTENANCE / CWP-5 CIRCLE WELDER
Refer to CWP-5 Electrical Component Chart. (Pg. 20)
CWP-5 Collector item #9:
The collector ring should be sanded once a year. If the collector ring is pitted too badly it should be replaced. Inspect all wires coming out of the collector ring for cut or missing insulation. All wires should be fastened to the center shaft with a nylon cable tie. Tighten four set screws if needed.
Weld Cable Inlet 2/0 item #1:
Ensure that the cable is fastened tightly to the collector ring. Inspect the cable for cut or missing insulation. Make sure the micarta insulation tube on the cable is in good condition. Replace the cable if necessary.
Solenoid Adaptor Kit item #14:
Inspect for damage. Replace if necessary.
GMA Pigtail item #6:
Inspect the cable for cuts or missing insulation. Ensure that the elbow connector is not damaged. Ensure that all terminal ends are snug. Replace cable if necessary.
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WARRANTY
Limited 3-Year Warranty*
Model ________________________________
Serial No. _____________________________
Date Purchased: _______________________
Where Purchased: ______________________
For a period ending one (1) year from the date of invoice, Manufacturer warrants that any new machine or part is free from defects in materials and workmanship and Manufacturer agrees to repair or replace at its option, any defective part or machine. HOWEVER, if the invoiced customer registers the Product
Warranty by returning the Warranty Registration Card supplied with the product within 90 days of the invoice date, or by registering on-line at www.bugo.com, Manufacturer will extend the warranty period an additional two (2) years which will provide three (3) total years from the date of original invoice to customer. This warranty does not apply to machines which, after Manufacture’s inspection are determined by Manufacturer to have been damaged due to neglect, abuse, overloading, accident or improper usage. All shipping and handling charges will be paid by the customer.
The foregoing express warranty is exclusive and Manufacturer makes no representation or warranty
(either express or implied) other than as set forth expressly in the preceding sentence. Specifically,
Manufacturer makes no express or implied warranty of merchantability or fitness for any particular purpose with respect to any goods. Manufacturer shall not be subject to any other obligations or liabilities whatsoever with respect to machines or parts furnished by Manufacturer.
Manufacturer shall not in any event be liable to Distributor or any customer for any loss of profits, incidental or consequential damages or special damages of any kind. Distributor’s or customer’s sole and exclusive remedy against Manufacturer for any breach of warranty, negligence, strict liability or any other claim relating to goods delivered pursuant hereto shall be for repair or replacement (at
Manufacturer’s option) of the machines or parts affected by such breach.
Distributor’s Warranty:
In no event shall Manufacturer be liable to Distributor or to any customer thereof for any warranties, representations or promises, express or implied, extended by Distributor without the advance written consent of Manufacturer, including but not limited to any and all warranties of merchantability or fitness for a particular purpose and all warranties, representations or promises which exceed or are different from the express limited warranty set forth above. Distributor agrees to indemnify and hold Manufacturer harmless from any claim by a customer based upon any express or implied warranty by Distributor which exceeds or differs from Manufacturer’s express limited warranty set forth above.
HOW TO OBTAIN SERVICE:
If you think this machine is not operating properly, re-read the instruction manual carefully, then call your Authorized BUG-O dealer/distributor. If they cannot give you the necessary service, the MODEL and SERIAL numbers.
*Bug-O System’s warranty applies to Bug-O components only. Where other brands of power sources, wire feeders or sub components are a part of Bug-O Equipment, please refer to that specific Manufacturer’s manual for warranty specifications on their components.
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