INSTRUCTIONS
AND
PARTS MANUAL
CWP-7
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-7-IPM-0614
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
PHONE: 412-331-1776 http://www.bugo.com FAX: 412- 331- 0383
USA
SAFETY
PROTECT YOURSELF AND OTHERS FROM SERIOUS INJURY OR DEATH. KEEP
CHILDREN AWAY. BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE
AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
ELECTRIC SHOCK can kill.
1) The equipment is not waterproof. Using the unit in a wet environment may result in serious injury. Do not touch equipment when wet or standing in a wet location.
2) The unused connectors have power on them. Always keep the unused
connectors covered with the supplied protective panels. Operation of the machine without the protective panels may result in injury.
3) Never open the equipment without first unplugging the power cord or serious injury may result.
4) Verify the customer-supplied power connections are made in accordance with all applicable local and national electrical safety codes. If none exist, use International Electric Code (IEC) 950.
5) Never remove or bypass the equip-
ment power cord ground. Verify the equipment is grounded in accordance with all applicable local and national electrical safety codes. If none
exist, use International Electric Code (IEC) 950.
2
EQUIPMENT DAMAGE
POSSIBLE.
1) Do not plug in the power cord with
out first verifying the equipment is OFF and the cord input voltage is the same as required by the machine or serious damage may result.
2) Always verify both the pinion and wheels are fully engaged before apply-
ing power or equipment damage may occur.
3) Do not leave the equipment
unattended.
4) Remove from the worksite and store in a safe location when not in use.
FALLING EQUIPMENT
can cause serious
personal injury and
equipment damage.
Faulty or careless user installation is
possible. As a result, never stand or
walk underneath equipment.
MOVING PARTS can
cause serious injury.
READ INSTRUCTIONS.
1) Never try to stop the pinion from
moving except by removing power or by using the STOP control.
Read the instruction manual before
installing and using the equipment.
2) Do not remove any protective panels, covers or guards and operate
equipment.
HIGH FREQUENCY WARNINGS
SPECIAL PRECAUTIONS ARE REQUIRED WHEN USING PLASMA,
TIG OR ANY WELDING PROCESS THAT USES HIGH FREQUENCY
TO STRIKE AN ARC.
WARNING: HIGH FREQUENCY CAN EFFECT MACHINE OPERATION AND THEREFORE, WELD QUALITY.
Read the precautions below before installing and using the equipment.
PRECAUTIONS:
1)Some plasma or welding cables are strong sources of high frequency interference. NEVER lay a plasma or welding cable across the controls of the machine.
2) Always physically separate the plasma or welding cable leads from the machine
cables. For example, the plasma or welding cable leads should NEVER be bundled
with a pendant cable or the machine power cord. Maximize the 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
CWP-7 CIRCLE WELDER
INSTRUCTIONS AND PARTS MANUAL
TABLE OF CONTENTS
PAGE
5.......... Introduction / Features / Setup and Operation
8-9........CWP-1570 Control Panel
9-10......Programming Instructions
11..........CWP-1570 Control Panel - Open Box / Exploded View
12.........CWP-1570 Control Panel - Open Box / Parts List
13-15....CWP-1570-WD Control Panel - Wiring Diagram (Parts 1-3)
16.........Technical Data / Dimensions
17........ CWP-1700 CWP-7 Circle Welder / Exploded View
18........ CWP-1700 CWP-7 Circle Welder / Parts List
19........ CWP-1700 CWP-7 Circle Welder / Wiring Diagram / Electrical Component Chart
20........ CWO-3495 CW-7 Collector / Exploded View / Parts List
21........ CWO-3139 Universal Power Cable / Exploded View / Parts List
21........ CWO-3139-M Miller Power Cable/ Exploded View / Parts List
22........ CWO-1690 Horizontal Racker / Exploded View / Parts List
22........ CBP-1640 Motorized Racking System / Exploded View / Parts List
23........ CWO-2005 Wire Feeder Guard / Exploded View / Parts List
24........ CWO-3496 Shaft Assembly / Exploded View / Parts List
24........ CWO-3498 Wire Reel Mount Assembly / Exploded View / Parts List
25........ CWO-3063 Large Brush Holder and Support / Exploded View / Parts List
25........ CWO-3194 Housing Assembly / Exploded View / Parts List
25........ CWO-3361 P.M. Motor Assembly #147 / Exploded View / Parts List
26........ CWE-1530 Small Brush Holder Assembly / Exploded View / Parts List
26........ CWO-3461 Small Retainer Block Assembly / Detail View
27........ CW-7 Gun Assemblies (MIG-FLUX CORED)
28........ CW-7 Gun Assemblies (SUB ARC)
29........ CW-7 Drive Roll Kits
29........ CWO-3690-_ K231 Subarc Gun Assembly / Exploded View / Parts List
30........ CWO-3700-_ Subarc Gun Assembly / Exploded View / Parts List
30........ CWO-3490 CW-7 Flux Hopper Assembly / Exploded View / Parts List
31........ #5 Gun & Cable Assembly / Exploded View / Parts List
32........ 3- Jaw Expandable Chucks
33........ Optional Motorized Racking Equipment / CWO-1690-MH / Exploded View / Parts List
34........ Optional Horizontal Motorized Racking / CWP-3351 / Exploded View / Parts List
35........ Optional Motorized Racking Equipment / PRS-1100 / Exploded View / Wiring Diagram
36........ Optional Motorized Racking Equipment / PRS-1100 / Parts List
37........ Optional Motorized Racking Equipment / CWP-3363 / Exploded View / Parts List
37........ Optional Motorized Racking Equipment / PRS-1075 / Exploded View / Parts List
38........ Preventive Maintenance / CWP-7 Circle Welder
41........ Warranty
4
INTRODUCTION
The CWP-7 Circle Welder is designed for welding of nozzles into vessels or domed heads utilizing SUBARC, MIG or FLUX CORED PROCESS, with gas shielding. The CWP-7 mounts on a 3-Jaw Chuck welding
diameter 6" to 24" O.D.
FEATURES:
• Amperage & wire speed control
• Wire feeder with one set of drive rolls
• 1/12 HP P.M. motor and rotational speed control
• K231 sub-arc gun (sub-arc only)
• 500 AMP gun & cable assembly (MIG only)
• Gas shielding kit with 120 VAC solenoid valve (MIG only)
• 5/8" (16 mm) gas cup (MIG only)
• Burn back control
• 50 ft. (15 m) power cable
• 50 ft. (15 m) gas shielding hose (MIG only)
• 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 60 lb. (27 kg) spools
• Adjustable vertical and horizontal torch positioning system
• Rise and fall - microprocessor controlled
• Brushes and collector rings for welding current, rated at 500 AMPS 100% duty cycle
• Brushes and collector rings for all controls, eliminates cable and hose wrap
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.
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.
5
SETUP AND OPERATION, CONT'D.
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-3040 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.
WHEEL ADJUSTMENT:
B
The CWP-7 Racking System CWO-1665 and the Large Vertical Racker
CWO-1690 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. 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.
A
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-7 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.
6
SETUP AND OPERATION, CONT'D.
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-1640 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-7 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
CWP-1570 CONTROL PANEL
The CWP-1570 control panel, (shown below), controls all aspects of the CWP-7 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.
WIRE FEEDER CONTROL
KEYPAD
ROTATION CONTROL
12
13
14
1
15
2
4
5
3
6
16
17
18
19
10
9
8
20
11
7
1
2
3
4
5
6
7
8
9
10
11
8
21
ROTATION SPEED (REF. # ONLY)
SPEED CONTROL
STOP / PAUSE
START / RESUME
RESET
MANUAL JOG
CONTROL POWER
POWER INDICATOR
CIRCUIT BREAKER
MIRROR IMAGE
WELD ON/OFF
12
13
14
15
16
17
18
19
20
21
KEYPAD
VOLTS METER
CURRENT METER
WIRE FEED SPEED
WIRE DIRECTION
FLUX VACUUM
PREFLOW
POSTFLOW
PURGE / COLD INCH
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
Reverses rotation direction
WELD ON/OFF
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. 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
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. 10
CWP-1570 CONTROL PANEL - OPEN BOX / EXPLODED VIEW
1
4
4
2
3
5
16
6
7
8
17
18
9
10
4
11
12
19
13
14
15
20
39
22
24
23
25
46
26
29
47
34
47
30
41
42
48
43
33
47
28
40
21
32
46
27
13
35
47
36
44
31
37
45
38
11
CWP-1570 CONTROL PANEL - OPEN BOX / PARTS LIST
ITEM
1
2
3
4
5
5
6
7
8
9
10
11
12
12
13
13
13
14
14
15
16
17
18
19
19
20
20
21
21
22
22
23
24
25
25
25
25
26
27
27
QTY
1
1
1
3
1
1
1
1
1
1
1
1
1
1
12
12
12
1
1
1
1
3
1
1
1
1
1
1
1
1
1
1
1
1
2
2
2
1
1
2
PART NO.
CWP-1571
CWP-1573
CWP-1572
ARM-2279
BUG-2923
BUG-2924
BUG-1415
PRS-1065
SWT-0S42
SWT-1113
SWT-1112
SWT-1111
BUG-1562
BUG-5757
FAS-0104
SCF-1001
WAS-0201
MDS-1011
BUG-1764
BUG-6051
PCB-1350
SCW WTE 0481
SWT-0809
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
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
Self-clinching Nut, 4-40
Lockwasher, #4 Internal Star
Bezel Display
Meter Display Board
Terminal, Panel Mount w/fast.
Lincoln Timer Board
Screw, Pan Hd, 6-32x1/4
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
ITEM
28
29
29
29
30
31
31
31
32
33
34
34
34
34
34
35
36
36
36
36
37
38
39
40
41
42
42
43
44
44
44
44
45
45
45
46
46
46
47
47
47
48
QTY
1
1
2
2
1
1
4
4
1
1
1
1
1
1
1
1
1
4
1
1
2
2
1
1
1
4
4
1
1
1
1
2
1
4
4
8
8
8
24
24
24
1
PART NO.
BUG-9909
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
CAP WTE 0071
SRK WTE 1346
BUG-9856
CBP-6030
FAS-0204
BUG-6029
CBP-1511
FAS-0124
FAS-0224
LDC-1107
LN7 WTE 1352
LDC-1108
STOF-2009
SCW WTE 0264
PCB-1351
BUG-1383
BUG-1384
BUG-1404
FAS-0114
BMV-1530
BMV-1570
FAS-0114
FAS-0215
FAS-1310
WAS-0211
FAS-0204
FAS-1305
WAS-0201
PCB-1355
DESCRIPTION
Panel Connector, 6T-M
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
.1UF 250V 10% .4" Radial
1/8" Black Shrink Tube
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
Circuit Breaker, 250V 2.5A
Ground Lead Protector Reset
Stand-Off, 6-32, 1/4x1/4
Screw, Pan Hd, #6 x 1/4
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, 1/4-20x3
4 BUG-1069-2 Spacer
4 WAS-0240
Washer, 1/4 SAE Flat
4 FAS-1351
Hex Nut, 1/4-20
12
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
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












































 



















































































CWP-1570-WD CONTROL PANEL / WIRING DIAGRAM (1 OF 3)
13














14

B
C


 
 






















A
D






























































 








































CWP-1570-WD CONTROL PANEL / WIRING DIAGRAM (2 OF 3)

















 

 


















6
10
5
9
13
2
1
11
7
3
14
12
8
4






CWP-1570-WD CONTROL PANEL / WIRING DIAGRAM (3 OF 3)
15
TECHNICAL DATA:
Amperage:
Input Voltage:
Voltage:
Wire Sizes:
Rotation Speed:
Welding Diameter:
Shielding Gas:
Height:
Net Weight:
Shipping Weight:
0-500 amps
115 VAC
0-50 VAC
.035-3/32" (.8-2.4 mm)
.2-2.2 rpm
6"-24" (150-600 mm)
Solenoid Control (MIG only)
38" (965.2 mm)
250 lbs. (113.6 kg)
380 lbs. (173.0 kg)
DIMENSIONS:
35.401"
(899.19 mm)
36.893"
(937.082 mm)
38"
(965.2 mm)
WELDING
DIAMETER
6"-24"
(150-600 mm)
16
CWP-1700 CWP-7 CIRCLE WELDER / EXPLODED VIEW
25
9
22
13
20*
29
24
5
30
3
26
17
15
21
18
28
27
14
12
10
1
16
6
7
32
28
2
8
31
20
19
23
4
11
*Shown with optional flux recovery system
17
CWP-1700 CWP-7 CIRCLE WELDER / PARTS LIST
ITEM
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
*20
21
22
23
24
25
26
27
28
29
30
31
32
*33
*34
QTY
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
2
1
1
1
1
1
1
PART NO.
CBP-1640
CWO-1690
CWO-2005
CWP-1570
CWO-3063
CWO-3194
CWO-3204
CWP-1717
CWO-3218
CBP-1595-5
CWO-3287
CWO-3288
CWO-3312
CWP-1812
CWP-1820
CWO-3361
CWE-1530
CWO-3468
CWP-1772
CWO-3490
CWO-3495
CWO-3020-3/0
CWO-3496
CWP-1725
CWO-3499
CWO-3955
CWO-4088
CWO-4340
CWO-5074
CWE-1048
CWP-1773
CWP-1774
CWO-8057
CWE-1050-3/0
DESCRIPTION
Motorized Racking System
Large Horizontal Racker
Wire Feed Guard
Dual Control Box
Brush Holder & Support Assy.
CW-7 Housing Assy.
Slide Bar Mounting Assy.
Collector Shield
Cable Support Bar
Encoder Assy.
Base Plate
Motor & Transmission Plate Assy.
Lifting Lug Assy.
Flux Hopper Mount Arm
Flux Hopper Bracket
P.M. Motor Assy. #147
Small Brush Retainer Assy.
LN-7 Wire Feeder Assy.
Control Box Mt. Plate
Flux Hopper (Standard) see p.29
CW-7 Collector
Weld Cable Inlet 3/0
Shaft Assy., CW-7 AB, ABG
Wire Reel Assy.
CW-7 Guard Assy.
Terminal Block Assy.
Wire Feeder Mount Plate
1-1/2" Flange Bearing
1-1/2" I.D. Trantorque
10" Diameter Aluminum Gear
Control Box Arm, Left
Control Box Arm, Right
Solenoid Adaptor Kit (not shown)
Weld Cable 3/0 (not shown)
Notes: 1.See page 18 for wiring and cable information.
*CWO-2020 (Optional) Flux Hopper Assembly is installed on Subarc models only 120 VAC
*CWO-2025 (Optional) Flux Hopper Assembly is installed on Subarc models only 240 VAC
18
CWP-1700 CWP-7 CIRCLE WELDER / WIRING DIAGRAM
8
2
7
14
5
10
11












19
3
15
12







4
18

13


9
16
17
6


1
ELECTRICAL COMPONENT CHART
ITEM
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
DESCRIPTION
Dual Control Box
Brush Holder & Support Assy.
Power Cable
GMA Pigtail
P.M. Motor Assy.
Small Brush Retainer Assy.
LN-7 Wire Feeder Assy.
Weld Cable 3/0
CW-7 Collector
Weld Cable Inlet 3/0
CW-5 Terminal Block
Shunt Bar 500-50
Rotation Encoder Assy.
Solenoid Adaptor Kit
Shunt Cable
Cable 18"
Shielded Cable
Motor Power Pigtail
Power Cord Flux Recovery
*CWO-3139 For Universal Welders
PART NO.
CWP-1570
CWO-3063
CWO-3139*
CWO-3331
CWO-3361
CWE-1530
CWO-3468
CWO-3478
CWO-3495
CWE-1050-3/0
CWO-3955
CWO-6008
CWP-1595-5
CWO-8057
CWP-1585
MUG-1621-1.5
MUG-1634-4
CWP-1720
CWO-2029
CWO-3139-M For Miller Welders.
19
CWO-3495 CW-7 COLLECTOR / EXPLODED VIEW / PARTS LIST
ITEM
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
QTY
6
1
7
1
1
2
1
1
1
1
2
4
4
4
2
2
4
4
1
PART NO.
CWO-3127
CWO-5741
CWO-5744
CWO-5747
CWO-5748
CWO-5806
CWO-5752
CWO-5745
CWO-5746
CON WTE 0383
TERM-5494
FAS-0215
FAS-0455
FAS-1310
FAS-0393
WAS-0260
FAS-0204
FAS-1305
BUG-1034
DESCRIPTION
Brass Ring 4.250" Dia x .188 Thk
Brass Ring 4.250" Dia x 3.000 Thk
Micarta Spacer
Micarta Spacer w/Notch
Micarta Sleeve .500" Dia x 3.750" Lg
Micarta Sleeve .500" Dia x 5.375" Lg
Micarta Sleeve 1.875" Dia x 4.50" Lg
Top Plate CW-5 Collector
Bottom Plate CW-5 Collector
5 Pos Box Mounting Connector Plug
#8 Red Ring Connector
6-32 X 1/2" Rnd Hd Scr
1/4"-20 X 1/2" Soc Hd Set Scr
6-32 Hex Nut
Hex Hd Cap Scr 3/8-16 x 6"
3/8" SAE Washer
Rnd Hd Slot Scr 4-40 x 3/8 Zinc
Hex Nut 4-40
Panel Connector, 4-T, M
CWO-3139 UNIVERSAL POWER CABLE / EXPLODED VIEW / PARTS LIST
CWO-3139-M MILLER POWER CABLE / EXPLODED VIEW / PARTS LIST
21
CWO-1690 HORIZONTAL RACKER / EXPLODED VIEW / PARTS LIST
ITEM QTY
1
1
17
2
1
3
1
4
1
5
2
6
2
2
7
1
8
2
9
2
10
2
3
11
1
12
1
13
1
5F
14
1
6A
15
2
16
1
17
2
18
2
18
1
16
13
14
15
5F
6A
12
11
7
4
PART NO.
BUG-2032
CWO-1671
CWO-1678
CWO-1679
CWO-1680
CWO-1681
CWO-1687
CWO-4326
CWO-4327
FAS-0557
FAS-1307
MUG-1141
MUG-1142
MUG-1144
MUG-1453
MUG-1579
WAS-0240
FAS-0559
DESCRIPTION
Knob, Black
Racker Shield
Racker Plate
Pinion 11T
W2 Fixed Leg & Wheel Assy.
W2 Adj. Leg & Wheel Assy.
Mount Plate (Large Racker)
Fixed Leg & Wheel Assy.
Adj. Leg & Wheel Assy.
Soc Hd Cap Scr 1/4-20 x 3/4"
Hex Jam Nut 3/4-16
Bearing Collet
Knob, Locking
Shaft
Stand-Off
Retaining Ring
1/4" SAE Washer
Soc Hd Cap Scr 1/4-20 x 1"
F = FIXED WHEEL PLACEMENT
A = ADJUSTABLE WHEEL PLACEMENT
8F
10
9A
8F
9A
CBP-1640 MOTORIZED RACKING SYSTEM / EXPLODED VIEW / PARTS LIST
2
1
3
4
6
5
22
ITEM QTY
1
1
2
1
3
1
4
1
5
1
6
1
PART NO.
ABR-1050
ABR-1060
CBP-1675
CWO-1695
CWO-3023-1
CWO-3460
DESCRIPTION
V-Guide Ways 40"
V-Guide Ways 33"
Motorized Vertical Racker
Attachment Block
Torch Angle Adjuster 16"
33# Load Spring Assy.
CWO-2005 WIRE FEEDER GUARD / EXPLODED VIEW / PARTS LIST
6
4
5
3
2
1
ITEM QTY PART NO.
1
1 BUG-3209 2
1 CWO-2008 3
2 FAS-0535 4
1 HDW-1001 5
2 BUG-3197 6
2 BUG-3198 DESCRIPTION
Hinge 3/4" X 2" Lg
Plastic Guard
Soc Hd Cap 10-24 X 1/2"
Steel Hair Pin Zinc Plated
Binding Post, #8-32 X 3/16 Lg
Binding Post Screw, #8-32 X 3/16 Lg
23
CWO-3496 SHAFT ASSEMBLY / EXPLODED VIEW / PARTS LIST
3
1
ITEM QTY
1
1
2
2
3
1
PART NO.
BUG-9096
CWO-4049
CWO-5778
2
2
DESCRIPTION
Outlet Bushing, Oxygen
O-Ring, Oxygen, Fuel
Shaft CW-7AG / CW-7ABG
CWO-3498 WIRE REEL MOUNT ASSEMBLY / EXPLODED VIEW / PARTS
LIST
ITEM QTY
1
1
2
1
3
2
4
2
5
2
1
2
4
5
3
24
PART NO.
BUG-3293
CWP-1728
FAS-1301
FAS-2305
WAS-0281
DESCRIPTION
Reel, 60 lbs.
Wire Reel Support Assy.
Hex Nut 1/2-13
Hex Hd Cap Scr 1/2-13 x 1-3/4"
1/2" Lock Washer
CWO-3063 LARGE BRUSH HOLDER AND SUPPORT / EXPLODED VIEW /
4
12
PARTS LIST
11
10
15
13
8
15
14
2
3
6
6
15
5
7
3
1
14
9
ITEM
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
QTY
1
1
2
4
4
2
1
1
1
1
1
2
3
2
3
PART NO.
CWO-4036
CWO-4339
CWO-3263
CWO-3264
CWO-4337
CWO-5548
CWO-5549
FAS-0304
FAS-0305
FAS-0309
FAS-0357
FAS-0359
WAS-0243
WAS-0280
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 3.5"
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
Hed Hd Cap Scr 1/4-20 x 1"
1/4" Split Lock Washer
1/2" SAE Flat Washer
1/2" Split Lock Washer
CWO-3194 HOUSING ASSEMBLY / EXPLODED VIEW / PARTS LIST
5
1
5
4
5
ITEMQTY
1
1
2
1
3
1
4
1
5
2
6
3
7
3
8
8
2
3
8
7
6
PART NO.
CWO-4133
CWO-5841
CWO-5844
CWO-5847
CWO-5973
CWO-9339
FAS-0535
FAS-0548
DESCRIPTION
1/4-18 x 1/2" NPSM Hex HD Plug, Brass
Center Tube Housing CW-7
Top Housing Plate CW-7
Lower Housing Plate CW-7
Plastic Bushing
Angle For Guard
Soc Hd Cap Scr 10-24 x 1/2"
Soc Hd Cap Scr 10-32 x 3/4"
CWO-3361 P.M. MOTOR ASSEMBLY #147 / EXPLODED VIEW / PARTS LIST
ITEM QTY
1
1
2
1
3
1
4
1
5
3
PART NO.
CWO-4067
CWO-4147
CWO-5767
FAS-0454
TER-WTE-1508
DESCRIPTION
P.M. Motor 1072
P.M. Motor Bracket #970
Gear, P.M. Motor
Set Scr 1/4-20x3/8"
#8 Fork Blue 14RB-8FL-T&B
5
1
4
3
2
25
CWE-1530 SMALL BRUSH HOLDER ASSEMBLY / EXPLODED VIEW / PARTS LIST
ITEM QTY
1
1
2
1
3
2
3 4
1
5
1
6
1
PART NO.
CWE-1531
CWE-1532
FAS-2351
FAS-0539
WAS-0240
WAS-0243
DESCRIPTION
Retainer Support Small
6 Pos Small Ret. Block Assy.
Soc Hd Cap Scr 10-24x1"
Hex Hd Cap Scr 1/4-20x1 1/4"
1/4" SAE Flat
1/4" Split Lock Washer
1
5
6
2
4
CWO-3461 SMALL RETAINER BLOCK
ASSEMBLY / DETAIL VIEW
WHITE 10"
1
BLACK 10"
2
RED 10"
3
ORANGE 10"
4
1
ITEM QTY
1
1
2
4
3
4
4
4
5
4
6
4
26
2,3,4,5
PART NO.
CWO-5626
CWO-5831
CWO-5874
CWO-5875
CWO-5876
TERM WTE 0602
6
DESCRIPTION
Small Brush Retainer Blk
Brush 1/8" x 1/8" x 7/8"
Brush Holder
Cap
Clip
#6 Fork Blue
CWP-7 GUN ASSEMBLIES (MIG/FLUX-CORED)
CWO-1560-A#5 .035 GUN ASSEMBLY MIG/FLUX .035 WIRE SIZE
CWO-8027
CWO-8034
CWO-8035
CWO-8036
CWO-8039
CWO-8524
15H-35 CONTACT TIP
25CT-75 NOZZLE
35CT NOZZLE INSULATOR
55 SW GAS DIFFUSER
45-3545-15 CABLE LINER
50394 500 AMP CABLE
10
1
1
1
1
1
CWO-1560-B#5 .045 GUN ASSEMBLY MIG/FLUX .045 WIRE SIZE
CWO-8028
CWO-8034
CWO-8035
CWO-8036
CWO-8039
CWO-8524
15H-45 CONTACT TIP
25CT-75 NOZZLE
35CT NOZZLE INSULATOR
55 SW GAS DIFFUSER
45-3545-15 CABLE LINER
50394 500 AMP CABLE
10
1
1
1
1
1
CWO-1560-C#5 1/16 GUN ASSEMBLY MIG/FLUX 1/16 WIRE SIZE
CWO-8029
CWO-8034
CWO-8035
CWO-8037
CWO-8041
CWO-8524
15H-116 CONTACT TIP
25CT-75 NOZZLE
35CT NOZZLE INSULATOR
55 GAS DIFFUSER
45-116-15 CABLE LINER
50394 500 AMP CABLE
10
1
1
1
1
1
CWO-1560-D#5 5/64 GUN ASSEMBLY MIG/FLUX 5/64 WIRE SIZE
CWO-8031
CWO-8034
CWO-8035
CWO-8038
CWO-8085
CWO-8524
15H-564 CONTACT TIP
25CT-75 NOZZLE
35CT NOZZLE INSULATOR
55 GAS DIFFUSER
45-564-15 CABLE LINER
50394 500 AMP CABLE
10
1
1
1
1
1
CWO-1560-E#5 3/32 GUN ASSEMBLY MIG/FLUX 3/32 WIRE SIZE
CWO-8032
CWO-8034
CWO-8035
CWO-8042
CWO-8038
CWO-8524
15H-332 CONTACT TIP
10
25CT-75-NOZZLE1
35CT NOZZLE INSULATOR
1
45H-332-15 CABLE LINER
1
55H-GAS DIFFUSER
1
50394 500 AMP CABLE
1
CWO-1560-G#5 .052 GUN ASSEMBLY MIG/FLUX .052 WIRE SIZE
CWO-8024
CWO-8034
CWO-8035
CWO-8036
CWO-8041
CWO-8524
15H-52 CONTACT TIP
25CT-75 NOZZLE
35CT NOZZLE INSULATOR
55 SW GAS DIFFUSER
45-116-15 CABLE LINER
50394 500 AMP CABLE
10
1
1
1
1
1
27
CWP-7 GUN ASSEMBLIES (SUB ARC)
CWO-1700-A#5 .035 GUN ASSEMBLY SUB ARC .035 WIRE SIZE
CWO-8027
CWO-8036
CWO-8039
CWO-8054
CWO-8524
15H-35 CONTACT TIP
55 SW GAS DIFFUSER
45-3545-15 CABLE LINER
25-SA NOZZLE FLUX CONE
50394 500 AMP CABLE
10
1
1
1
1
CWO-1700-B#5 .045 GUN ASSEMBLY SUB ARC .045 WIRE SIZE
CWO-8028
CWO-8036
CWO-8039
CWO-8054
CWO-8524
15H-45 CONTACT TIP
55 SW GAS DIFFUSER
45-3545-15 CABLE LINER
25-SA NOZZLE FLUX CONE
50394 500 AMP CABLE
10
1
1
1
1
CWO-1700-C#5 1/16 GUN ASSEMBLY SUB ARC 1/16 WIRE SIZE
CWO-8029
CWO-8037
CWO-8041
CWO-8054
CWO-8524
15H-116 CONTACT TIP
55 GAS DIFFUSER
45-116-15 CABLE LINER
25-SA NOZZLE FLUX CONE
50394 500 AMP CABLE
10
1
1
1
1
CWO-1700-D#5 5/64 GUN ASSEMBLY SUB ARC 5/64 WIRE SIZE
CWO-8031
CWO-8038
CWO-8042
CWO-8054
CWO-8524
15H-564 CONTACT TIP
55 GAS DIFFUSER
45-116-15 CABLE LINER
25-SA NOZZLE FLUX CONE
50394 500 AMP CABLE
10
1
1
1
1
CWO-1700-E#5 3/32 GUN ASSEMBLY SUB ARC 3/32 WIRE SIZE
CWO-8032
CWO-8038
CWO-8042
CWO-8054
CWO-8524
15H-332 CONTACT TIP
55H-GASS DIFFUSER
45-332-15 LINER
25-SA NOZZLE FLUX CONE
50394 500 AMP CABLE
10
1
1
1
1
CWO-1700-G#5 .052 GUN ASSEMBLY SUB ARC .052 WIRE SIZE
28
CWO-8024
CWO-8036
CWO-8041
CWO-8054
CWO-8524
15H-52 CONTACT TIP
55 SW GAS DIFFUSER
45-116-15 CABLE LINER
25-SA NOZZLE FLUX CONE
50394 500 AMP CABLE
10
1
1
1
1
CW-7 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
CWO-3690-_ K231 SUBARC GUN ASSEMBLY / EXPLODED VIEW / PARTS LIST
2
3
4
5
1
6
11a
7
8
9
12
13
14
ITEM
1
2
3
4
5
6
*7
8
9
10
11
11A
12
13
14
15
QTY
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
PART NO.
PXS-15106-3/32
PXT-10570
PXS-10493-1
PXS-121312
PXT-9967-10
CWO-8052
PXS-10125-_
PXS-10138
PXT-9078-1
PXT-9967-30
PXT-13835
PXT-3835-IN
BUG-3161-P
BUG-3163
BUG-3164
BUG-3165
DESCRIPTION
Nozzle Insert
Socket Head Screw
Nozzle Insulator
Hex Hd Scr 1 1/2" & Nut 1/2"-13
Nozzle Body Roll Pin
Nozzle Body
Contact Tip (Specify Wire Size*)
Flux Cone Plug (Insulator)
Thumb Screw
Flux Cone Roll Pin
3/4"X7" Flux Hose W/Fbr Ins
Fiber Insulator
Cone Body Assembly
Locking Ferrule
Flux Cone (Kp2085-1)
Retaining Nut
11
*WIRE SIZES AVAILABLE:
PART NO.
CWO-3690-1/16
10 CWO-3690-5/64
CWO-3690-3/32
WIRE SIZE
1/16" (1.6 mm)
5/64" (2.0 mm)
3/32" (2.4 mm)
*REPLACEMENT CONTACT TIPS AVAILABLE:
PART NO.
AFW-2291
CWO-8048
CWO-8049
WIRE SIZE
1/16" (1.5 mm)
5/64" (2.0 mm)
3/32" (2.4 mm)
15
29
CWO-3700-_ SUBARC GUN ASSEMBLY / EXPLODED VIEW / PARTS LIST
1
2
ITEM QTY
1
1
2
2
3
1
4
1
5
1
6
1
1
1
7
1
PART NO.
CWO-3698
CWO-1817
CWO-3697
CWO-3695-1/2
CWO-3670-72
CWO-3690-1/16
CWO-3690-5/64
CWO-3690-3/32
FAS-0452
DESCRIPTION
Adaptor-LN7
Bulk Head Connector QCB
QCC 72" (1829 mm) Liner
Adaptor K231 1/2"
Weld Cable 4/0 Assy 72" (1829 mm) Lg
Sub-Arc Nozzle 1/16"
Sub-Arc Nozzle 5/64"
Sub-Arc Nozzle 3/32"
Set Scr 1/4-20 x 1/4
3
2
5
4
7
6
CWO-3490 CW-7 FLUX HOPPER ASSEMBLY / EXPLODED VIEW / PARTS LIST
5
ITEM QTY PART NO.
1
1
CWO-3757
2
1
CWO-3760
3
1
CWO-3478
4
1
CWO-3769
5
1
GOF-3019
N/S 48" 1000-4-001
DESCRIPTION
Hopper Support Rod
Clamp Block 1/2"
3/4" Hose Barb
Flux Hopper Steel 12"
Handle w/Bolts
3/4" ID x 1" OD Clear Hose
4
1
3
2
30
#5 GUN AND CABLE ASSEMBLY / EXPLODED VIEW / PARTS LIST
6
9
8
6
7
6
8
7
6
5
11
4
1
2
10
3
PARTS LIST
ITEM
QTY PART #
DESCRIPTION
WIRE SIZE
.035
.045 .052
1/16
5/64
3/32
1
1
CWO-8024
15H-52 Contact tip
1
1
CWO-8027
15H-35 Contact Tip
1
1
CWO-8028
15H-45 Contact Tip
1
1
CWO-8029
15H-116 Contact Tip
1
1
CWO-8031
15H-564 Contact Tip
1
1
CWO-8032
15H-332 Contact Tip
2
1
CWO-8034
25CT-75 Nozzle Insulator
X
X
X
X
X
X
3
1
CWO-8035
35CT Nozzle Insulator
X
X
X
X
X
X
4
1
CWO-8036
55SW Gas Diffuser
X
X
X
4
1
CWO-8037
55 Gas Diffuser
4
1
CWO-8038
55H Gas Diffuser
X
X
5
1
CWO-8045
65-60 Conductor Tube
X
X
X
X
X
X
6
2
CWO-8017
185 Case w/Binder Screws
X
X
X
X
X
X
7
2
CWO-8018
104 Cable Connector Block
X
X
X
X
X
X
8
1
CWO-8052
Cable Hose Support
X
X
X
X
X
X
9
1
CWO-8053
175 Connector Plug w/O-Rings
X
X
X
X
X
X
10
1
CWO-8054
25-SA Nozzle Flux Cone
X
X
X
X
X
X
11
1
CWO-8524
50394 500 AMP Cable
X
X
X
X
X
X
*
1
CWO-8039
45-4535-15 Cable Liner
X
X
*
1
CWO-8041
45-116-15 Cable Liner
X
X
*
1
CWO-8042
45-332-15 Cable Liner
*
1
CWO-8085
45-564-15 Cable Liner
X
X
X
X
X
X
X
X
X
* ITEMS NOT SHOWN
31
3-JAW EXPANDABLE CHUCKS
3-Jaw Expandable Chucks
Mounts and automatically centers the Circle Welder on
nozzles with or without flanges. As shown below.
CWO-3660
CWO-3661
CWO-3662
32
CWO-3663
PART NO.
CWO-3660
CWO-3661
CWO-3362
CWO-3663
FOR NOZZLE I.D.’S
2"-10" (51mm-254mm)
8"-16" (204-405 mm)
10"-24" (255-610 mm)
15.75"-47.25" (610-1065 mm)
WEIGHT
69.3 lbs. (31.3 kg)
36 lbs. (16 kg)
51 lbs. (23 kg)
64 lbs. (29 kg)
OPTIONAL MOTORIZED RACKING EQUIPMENT / CWO-1690-MH / EXPLODED
VIEW / PARTS LIST
1
11
2
6
13
14
18
3
5
4
19
18
9
15
12
17
16
15
16
ITEM
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
QTY
1
2
2
1
1
2
2
2
4
2
2
1
2
1
1
2
4
4
4
PART NO.
BUG-1550
CWO-1680
CWO-1681
CWO-1687
CWO-1693
CWO-1694
CWO-4326
CWO-4327
FAS-0527
FAS-0557
FAS-0559
GOF-3014
WAS-0240
CWO-1696
BUG-9486
GOF-3036
FAS-0504
FAS-0525
FAS-1305
10
8
7
DESCRIPTION
Gear Motor (150:1)
W2 Fixed Leg & Wheel
W2 Adj. Leg & Wheel
Mount Plt Large Racker
Racker Motor MT Plt
Stand-Off
Fixed Leg & Wheel
Adj. Leg & Wheel
Soc Hd Cap 8-32 x 3/4"
Soc Hd Cap 1/4-20 x 3/4"
Soc Hd Cap 1/4-20 x 1"
Drive Pinion w/ Key
1/4" SAE Washer
Motor Enclosure
Panel Connector 2-T, M
QD Female
Soc Hd Cap 4-40 x 3/8"
Soc Hd Cap 8-32 x 1/2"
Hex Nut 4-40
33
OPTIONAL HORIZONTAL MOTORIZED RACKING / CWP-3351 / EXPLODED
VIEW / PARTS LIST
2
11
12
13
3
4
1
6
5
10
21
20
8
19
18
16
17
7
11
13, 11
8
16
ITEM QTY
1
1
2
1
3
2
4
1
5
1
6
2
7
1
8
5
9
2
10
1
11
6
12
2
13
4
14
4
15
4
16
10
17
1
18
1
19
1
20
4
21
4
34
PART NO.
CWP-3355
CWO-5933
CWO-5565
CWP-3354
CWP-3353
CWP-3362
CWO-3865
CWO-9038
CWO-9065
CWP-3356
FAS-1301
WAS-0281
WAS-0280
FAS-2591-SS
FAS-1444-SS
FAS-0359-SS
FAS-0399
WAS-0262
WAS-0260
FAS-0555
WAS-0243
15
9
14
DESCRIPTION
Hvy Duty Rack 150:1 No Mounting Bracket
Jaw Coupling 3/8" & 5/8" Bores With Spider
5/8" Pillow Block
Screw for Mtrzd Hrz Hvy Duty Rack
Mtrzd Hrz Slide Hvy Duty Rack
Stud 1/2-13 All Thread
1"-6 Acme Nut and Bar Assembly
Hold Down Clip
T-3 Track 36" Lg
Horiz P.M. Motor Bracket #970 Mod
Hex Nut 1/2-13
1/2 Split Lockwasher Zinc Plated
1/2 SAE Flat
Soc Hd Cap Scr 3/8-16 x 1-1/4 Stainless Steel
Phil Pan Hd Scr 10/32 x 3/8" Stainless Steel
Hex Hd Cap Scr 1/4-20 x 1" Stainless Steel
Hex Hd Cap Scr 3/8-16 x 1"
3/8" Split Lock Washer Zinc Plated
3/8 Washer Zinc Plated
Soc Hd Cap Scr 1/4-20 x 1/2
1/4" Split Lock Washer Zinc Plated
OPTIONAL MOTORIZED RACKING EQUIPMENT / PRS-1100 / EXPLODED VIEW /
WIRING DIAGRAM
35
OPTIONAL MOTORIZED RACKING EQUIPMENT / PRS-1100 / PARTS LIST
ITEM
1
COMPONENT ITEM
PRS-1111
2
BUG-2923
BUG-2952
BUG-2933
3
BUG-2924
4
BUG-5001
BUG-5002
BUG-5003
5
PRS-1110
6
PRS-1112
7
MUG-1156
8
BUG-1404
9
BUG-1411
10
BUG-1384
11
BUG-1383
BUG-1551
BUG-9636
12
BUG-9902
13
CAS-1770
14
BUG-9446
15
BUG-9445
16
BUG-9628
17
FAS-0124
18
FAS-1320
19
WAS-0221
20
SCW WTE 0514
21
FAS-0204
22
FAS-1305
23
WAS-0201
24
FAS-0112
N/S
SFX-1292
GOF-3115
36
DESCRIPTION
Input End Panel
.7 Amp Circuit Breaker
.5 Amp Circuit Breaker
2 Amp Circuit Breaker
“Reset Seal, Transparent”
Transformer 115VAC
Transformer 240VAC
Transformer 42VAC
Enclosure
Output End Panel
Panel Connector, 4-T, F
Relay Bracket
Hold Down Spring
Relay Socket & Spring
Relay, 4Pdt, 3A 120V, Plug In
Relay 3A, 240VAC
Relay 48VAC
Panel Connector, 6-T, F
Speed Control (Iron Rotor)
Cord Grip
Power Cord (120VAC Shown)
Line Cord 240VAC
Cap & Chain Assy
8/32 X 3/8 Pan Hd, Di-Chrome
Hex Nut 8-32
#8 Internal Star Lockwasher
#8-32 X 3/8" Pan Head, Zinc
Rnd Hd Slt Scr 4-40 X 3/8 Zinc
Hex Nut 4-40
#4 Internal Star Lockwasher
Pan Hd Slt 6-32 X 1/4 Black
Bumper, Cylindrical .14 X .50"
120VAC
240VAC
1
42VAC
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
10
3
3
1
8
8
8
6
4
OPTIONAL MOTORIZED RACKING EQUIPMENT / CWP-3363 / EXPLODED VIEW /
PARTS LIST
2
3
2
ITEM QTY
1
1
2
4
3
4
3
PART NO.
CWO-1687
CWO-4326
CWO-4327
DESCRIPTION
Plate
Wheel & Leg Assy., Fixed
Wheel & Leg Assy., Adjustable
1
2
3
3
2
OPTIONAL MOTORIZED RACKING EQUIPMENT / PRS-1075 / EXPLODED VIEW /
PARTS LIST
37
PREVENTIVE MAINTENANCE / CWP-7 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-7 Exploded View Parts List. (Pg. 11)
Racking System Item #1:
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.
Large Horizontal Racker Item #2:
Inspect wheels and 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 #6:
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-7 Electrical Component Chart. (Pg. 13)
Power Cable Item #4:
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.
CW-7 Collector Ring Item #11:
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 #27 on the CW-5 Exploded View
Parts List.
EVERY SIX MONTHS:
Refer to CWP-7 Exploded View Parts List. (Pg. 11)
Aluminum Gear Item #29
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 #17:
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 #29 and the motor drive pinion.
5" Cam Assembly Item #7:
Inspect the slide rails and the cam pinion. Remove all dirt, grease and weld spatter. Do not grease slide
rails or cam pinion. Lubricate with a dry teflon or graphite spray lubricant. Replace cam pinion if excessively
worn. Tighten all fasteners as needed.
Wire Reel Assembly Item #22:
Periodically coat the wire wheel shaft with a thin layer of grease as needed. Inspect the shoe assembly
and replace if excessively worn.
38
PREVENTIVE MAINTENANCE / CWP-7 CIRCLE WELDER
Refer to CWP-7 Electrical Component Chart. (Pg. 13)
GMA Wire Feed Control Item #6:
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 CWO-3332
Wire Feeder Control electrical component chart for replacement parts or return for service.
M-14 Rotation Control Item #15:
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 CWO-6210
Rotation Control electrical component chart for replacement parts or return or service.
LN-7 Wire Feeder Assembly Item #9:
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.
Brush Holder & Support Item #3:
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 #8:
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 #13:
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-7 Exploded View Parts List. (Pg. 11)
1-1/2" Bearing With Fasteners Item #26:
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 #15:
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 #17:
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.
Transmission 5:1 Assembly Item #14:
Inspect for excessive wear and tear. Keep the transmission assembly clean and lubricate with Lubriplate
#630-AA.
39
PREVENTIVE MAINTENANCE / CWP-7 CIRCLE WELDER
Refer to CWP-7 Electrical Component Chart. (Pg. 13)
CW-7 Collector Item #11:
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 3/0 Item #12:
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 #16:
Inspect for damage. Replace if necessary.
GMA Pigtail Item #5:
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.
40
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, write or phone us to tell us exactly what
difficulty you have experienced. BE SURE to mention the MODEL and SERIAL numbers.
41