BUG-O CWP-7 Technical reference manual
INSTRUCTIONS
AND
PARTS MANUAL
CWP-7
CIRCLE WELDER
Please record your equipment identication 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-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
2
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.
EQUIPMENT DAMAGE
POSSIBLE.
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
rst 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.
READ INSTRUCTIONS.
Read the instruction manual before
installing and using the equipment.
1) Do not plug in the power cord with
out rst 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 work site and store
in a safe location when not in use.
1) Never try to stop the pinion from
moving except by removing power or
by using the STOP control.
2) Do not remove any protective panels,
covers or guards and operate
equipment.
MOVING PARTS can
cause serious injury.
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.
3
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 specied 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.
HIGH FREQUENCY WARNINGS
WARNING: HIGH FREQUENCY CAN EFFECT MACHINE
OPERATION AND THEREFORE, WELD QUALITY.
SPECIAL PRECAUTIONS ARE REQUIRED WHEN USING PLASMA,
TIG OR ANY WELDING PROCESS THAT USES HIGH FREQUENCY
TO STRIKE AN ARC.
Read the precautions below before installing and using the equipment.
4
TABLE OF CONTENTS
CWP-7 CIRCLE WELDER
INSTRUCTIONS AND PARTS MANUAL
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
5
INTRODUCTION
The CWP-7 Circle Welder is designed for welding of nozzles into vessels or domed heads utilizing SUB-
ARC, 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 ow 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.
6
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 tting on the top of the shaft to your
shielding gas supply.
WHEEL ADJUSTMENT
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
B
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.
Figure 3: Weld Start Position for On-center (left) and Offset or Hillside (right) nozzles.
C
B
A
7
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 nished, 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.
SETUP AND OPERATION, CONT'D.
8
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.
1 ROTATION SPEED (REF. # ONLY) 12 KEYPAD
2 SPEED CONTROL 13 VOLTS METER
3 STOP / PAUSE 14 CURRENT METER
4 START / RESUME 15 WIRE FEED SPEED
5 RESET 16 WIRE DIRECTION
6 MANUAL JOG 17 FLUX VACUUM
7 CONTROL POWER 18 PREFLOW
8 POWER INDICATOR 19 POSTFLOW
9 CIRCUIT BREAKER 20 PURGE / COLD INCH
10 MIRROR IMAGE 21 BURNBACK
11 WELD ON/OFF
12 13
14
15
21
17
19
16
18
20
1
2
435
10
8
9
6
11 7
ROTATION CONTROL KEYPAD WIRE FEEDER CONTROL
9
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.
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
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 ts on)
3. Offset distance between centerlines
10
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 ow 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 ow 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, ne 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.
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 ts 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 pro-
grammed. Press the RESET button to get back to the ready mode for programming.
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.
ON-CENTER
NOZZLE OFFSET
NOZZLE
11
CWP-1570 CONTROL PANEL - OPEN BOX / EXPLODED VIEW
4 4
4
56
78
2 3
1
10
911
12
13
14
15
16
17
18
19
13
20 21
22
29
28
26
25
23 24
27
30
31
39
37
38
36
32
33
35
34
40 41
42
43
44
45
46 46
47
47
47
47
48
12
CWP-1570 CONTROL PANEL - OPEN BOX / PARTS LIST
ITEM QTY PART NO. DESCRIPTION
1 1 CWP-1571 Enclosure, hinged
2 1 CWP-1573 Legend Plate, Rotation
3 1 CWP-1572 Legend Plate, Wire Feed
4 3 ARM-2279 Toggle Switch
5 1 BUG-2923 Circuit Breaker, 0.7 amp
5 1 BUG-2924 Reset Seal, Transparent
6 1 BUG-1415 Pilot Light
7 1 PRS-1065 Joystick
8 1 SWT-0S42 Toggle Switch, DPDT
9 1 SWT-1113 Push Button, N.O., Green
10 1 SWT-1112 Push Button, N.O., Red
11 1 SWT-1111 Push Button, N.O., Black
12 1 BUG-1562 Potentiometer, 10k, 3 Turn
12 1 BUG-5757 Knob, Black, Large
13 12 FAS-0104 Screw, Pan Hd, Blk, 4-40x3/8
13 12 SCF-1001 Self-clinching Nut, 4-40
13 12 WAS-0201 Lockwasher, #4 Internal Star
14 1 MDS-1011 Bezel Display
14 1 BUG-1764 Meter Display Board
15 1 BUG-6051 Terminal, Panel Mount w/fast.
16 1 PCB-1350 Lincoln Timer Board
17 3 SCW WTE 0481 Screw, Pan Hd, 6-32 x 1/4
18 1 SWT-0809 Toggle Switch, DPDT
19 1 LDC-1103 Potentiometer
19 1 BUG-5757 Knob, Black, Large
20 1 MDS-1011 Bezel Display
20 1 MTR-1008 DPM LED 8-50 VDC
21 1 MDS-1011 Bezel Display
21 1 MTR-1007 Ammeter LED 8-36 VDC
22 1 FHO-0188 Fuse Holder
22 1 CWO-6076 Fuse, 5 Amp, Fast Acting
23 1 CWO-6759 Panel Connector, 6T-M
24 1 LDC-1109 Power Resistor
25 1 BUG-6031 Filter
25 2 FAS-0124 Screw, Pan Hd, 8-32 x 3/8
25 2 FAS-1320 Hex Nut, 8-32
25 2 WAS-0221 Lockwasher, #8, Internal Star
26 1 MUG-1156 Panel Connector, 4T-F
27 1 BUG-1770 Motor Control Board
27 2 FAS-0124 Screw, Pan Hd, 8-32 x 3/8
ITEM QTY PART NO. DESCRIPTION
28 1 BUG-9909 Panel Connector, 6T-M
29 1 BUG-6028 Terminal Block, Kulka
29 2 FAS-0115 Screw, Pan Hd, 6-32 x 1/2
29 2 FAS-1310 Hex Nut 6-32
30 1 BUG-9486 Panel Connector, 2T-M
31 1 CWO-6520 4-Quadrant Speed Control
31 4 FAS-0124 Screw, Pan Hd, 8-32 x 3/8
31 4 FAS-1320 Hex Nut, 8-32
32 1 MS-2A18-11S Panel Connector, 5T-F
33 1 BUG-1034 Panel Connector, 4T-M
34 1 CON-1202S Panel Connector, 2T-F
34 1 SRK-144B Shrink Tube
34 1 RES WTE 0111 470 ohm 1/4 w 5% carbon lm-TR
34 1 CAP WTE 0071 .1UF 250V 10% .4" Radial
34 1 SRK WTE 1346 1/8" Black Shrink Tube
35 1 BUG-9856 Panel Connector, 2T-F
36 1 CBP-6030 Control Module
36 4 FAS-0204 Screw, Rnd Hd Slt, 4-40x3/8
36 1 BUG-6029 Bracket
36 1 CBP-1511 Transformer Bracket
37 2 FAS-0124 Screw, Pan Hd, 8-32 x 3/8
38 2 FAS-0224 Screw, Rnd Hd, 8-32 x 3/8
39 1 LDC-1107 Transformer
40 1 LN7 WTE 1352 Circuit Breaker, 250V 2.5A
41 1 LDC-1108 Ground Lead Protector Reset
42 4 STOF-2009 Stand-Off, 6-32, 1/4 x 1/4
42 4 SCW WTE 0264 Screw, Pan Hd, #6 x 1/4
43 1 PCB-1351 Motor Control Board
44 1 BUG-1383 Relay, 4PDT, 3A 120V, Plug-in
44 1 BUG-1384 Relay Socket & Spring
44 1 BUG-1404 Relay Bracket
44 2 FAS-0114 Screw, Pan Hd, 6-32 x 3/8
45 1 BMV-1530 Power Supply
45 4 BMV-1570 PC Board Stand-off
45 4 FAS-0114 Screw, Pan Hd, 6-32 x 3/8
46 8 FAS-0215 Screw, Rnd Hd, 6-32 x 1/2
46 8 FAS-1310 Hex Nut. 6-32
46 8 WAS-0211 Lockwasher, #6 Internal Star
47 24 FAS-0204 Screw, Rnd Hd, 4-40x3/8
47 24 FAS-1305 Hex Nut, 4-40
47 24 WAS-0201 Lockwasher, #4 Internal Star
48 1 PCB-1355 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
13
CWP-1570-WD CONTROL PANEL / WIRING DIAGRAM (1 OF 3)
14
A
B
C
D
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: 0-500 amps
Input Voltage: 115 VAC
Voltage: 0-50 VAC
Wire Sizes: .035-3/32" (.8-2.4 mm)
Rotation Speed: .2-2.2 rpm
Welding Diameter: 6"-24" (150-600 mm)
Shielding Gas: Solenoid Control (MIG only)
Height: 38" (965.2 mm)
Net Weight: 250 lbs. (113.6 kg)
Shipping Weight: 380 lbs. (173.0 kg)
DIMENSIONS
35.401"
(899.19 mm)
38"
(965.2 mm)
36.893"
(937.082 mm)
WELDING
DIAMETER
6"-24"
(150-600 mm)
17
CWP-1700 CWP-7 CIRCLE WELDER / EXPLODED VIEW
22
9
5
30
13
25
3
18
32
27
12
15
28
29
16
21
14
4
11
8
23
7
2
24
26
17
19
6
10
31
20
1
20*
28
* Shown with optional ux recovery system
18
CWP-1700 CWP-7 CIRCLE WELDER / PARTS LIST
ITEM QTY PART NO. DESCRIPTION
11 CBP-1640 Motorized Racking System
2 1 CWO-1690 Large Horizontal Racker
3 1 CWO-2005 Wire Feed Guard
4 1 CWP-1570 Dual Control Box
5 1 CWO-3063 Brush Holder & Support Assembly
6 1 CWO-3194 CW-7 Housing Assembly
7 1 CWO-3204 Slide Bar Mounting Assembly
8 1 CWP-1717 Collector Shield
9 1 CWO-3218 Cable Support Bar
10 1 CBP-1595-5 Encoder Assembly
11 1 CWO-3287 Base Plate
12 1 CWO-3288 Motor & Transmission Plate Assembly
13 1 CWO-3312 Lifting Lug Assembly
14 1 CWP-1812 Flux Hopper Mount Arm
15 1 CWP-1820 Flux Hopper Bracket
16 1 CWO-3361 P.M. Motor Assembly #147
17 1 CWE-1530 Small Brush Retainer Assembly
18 1 CWO-3468 LN-7 Wire Feeder Assembly
19 1 CWP-1772 Control Box Mt. Plate
*20 1 CWO-3490 Flux Hopper (Standard) see p.29
21 1 CWO-3495 CW-7 Collector
22 1 CWO-3020-3/0 Weld Cable Inlet 3/0
23 1 CWO-3496 Shaft Assembly, CW-7 AB, ABG
24 1 CWP-1725 Wire Reel Assembly
25 1 CWO-3499 CW-7 Guard Assembly
26 1 CWO-3955 Terminal Block Assembly
27 1 CWO-4088 Wire Feeder Mount Plate
28 2 CWO-4340 1-1/2" Flange Bearing
29 1 CWO-5074 1-1/2" I.D. Trantorque
30 1 CWE-1048 10" Diameter Aluminum Gear
31 1 CWP-1773 Control Box Arm, Left
32 1 CWP-1774 Control Box Arm, Right
*33 1 CWO-8057 Solenoid Adaptor Kit (not shown)
*34 1 CWE-1050-3/0 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
19
ELECTRICAL COMPONENT CHART
ITEM DESCRIPTION PART NO.
1Dual Control Box CWP-1570
2Brush Holder & Support Assembly CWO-3063
3Power Cable CWO-3139*
4GMA Pigtail CWO-3331
5P.M. Motor Assembly CWO-3361
6Small Brush Retainer Assembly CWE-1530
7 LN-7 Wire Feeder Assembly CWO-3468
8Weld Cable 3/0 CWO-3478
9CW-7 Collector CWO-3495
10 Weld Cable Inlet 3/0 CWE-1050-3/0
11 CW-5 Terminal Block CWO-3955
12 Shunt Bar 500-50 CWO-6008
13 Rotation Encoder Assembly CWP-1595-5
14 Solenoid Adaptor Kit CWO-8057
15 Shunt Cable CWP-1585
16 Cable 18" MUG-1621-1.5
17 Shielded Cable MUG-1634-4
18 Motor Power Pigtail CWP-1720
19 Power Cord Flux Recovery CWO-2029
10
11
3
CWP-1700 CWP-7 CIRCLE WELDER / WIRING DIAGRAM
*CWO-3139 For Universal Welders CWO-3139-M For Miller Welders.
1
5
7
4
12
14
2
13
8
9
6
19
18
15
16
17
20
CWO-3495 CW-7 COLLECTOR / EXPLODED VIEW / PARTS LIST
ITEM QTY PART NO. DESCRIPTION
16 CWO-3127 Brass Ring 4.250" Dia x .188 Thk
2 1 CWO-5741 Brass Ring 4.250" Dia x 3.000 Thk
3 7 CWO-5744 Micarta Spacer
4 1 CWO-5747 Micarta Spacer w/Notch
5 1 CWO-5748 Micarta Sleeve .500" Dia x 3.750" Lg
6 2 CWO-5806 Micarta Sleeve .500" Dia x 5.375" Lg
7 1 CWO-5752 Micarta Sleeve 1.875" Dia x 4.50" Lg
8 1 CWO-5745 Top Plate CW-5 Collector
9 1 CWO-5746 Bottom Plate CW-5 Collector
10 1 CON WTE 0383 5 Pos Box Mounting Connector Plug
11 2 TERM-5494 #8 Red Ring Connector
12 4 FAS-0215 6-32 x 1/2" Rnd Hd Scr
13 4 FAS-0455 1/4"-20 x 1/2" Soc Hd Set Scr
14 4 FAS-1310 6-32 Hex Nut
15 2 FAS-0393 Hex Hd Cap Scr 3/8-16 x 6"
16 2 WAS-0260 3/8" SAE Washer
17 4 FAS-0204 Rnd Hd Slot Scr 4-40 x 3/8 Zinc
18 4 FAS-1305 Hex Nut 4-40
19 1 BUG-1034 Panel Connector, 4-T, M
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