Climax AUTOBOREWELDER BW3000 User manual

BW3000
BW3000 AUTOBOREWELDER
OPERATING MANUAL
P/N 52815
February 2019
Revision 7

P/N 52815, Rev. 7 Page A
©2019 CLIMAX or its subsidiaries.
All rights reserved.
Except as expressly provided herein, no part of this manual may be reproduced, copied, transmitted, dissem-
inated, downloaded, or stored in any storage medium, without the express prior written consent of CLIMAX.
CLIMAX hereby grants permission to download a single copy of this manual and of any revision hereto onto
an electronic storage medium to be viewed and to print one copy of this manual or any revision hereto, pro-
vided that such electronic or printed copy of this manual or revision must contain the complete text of this
copyright notice and provided further that any unauthorized commercial distribution of this manual or any
revision hereto is prohibited.
At CLIMAX, we value your opinion.
For comments or questions about this manual or other CLIMAX documentation, please e-mail
[e-mail].
For comments or questions about CLIMAX products or services, please call CLIMAX or e-mail
[email protected]. For quick and accurate service, please provide your representative with the following:
• Your name
• Shipping address
• Telephone number
• Machine model
• Serial number (if applicable)
• Date of purchase
CLIMAX World Headquarters
2712 East 2nd Street
Newberg, Oregon 97132 USA
Telephone (worldwide): [phone]
Toll-free (North America): 1-800-333-8311
Fax: [phone]
H&S Tool World Headquarters
715 Weber Dr.
Wadsworth, OH 44281 USA
Telephone: [phone]
Fax: [phone]
hstool.com
CLIMAX | H&S Tool (UK Headquarters)
Unit 7 Castlehill Industrial Estate
Bredbury Industrial Park
Horsfield Way
Stockport SK6 2SU, UK
Telephone: [phone]
CLIMAX | H&S Tool (European Headquarters)
Am Langen Graben 8
52353 Düren, Germany
Telephone: [phone]
E-mail: [email protected]
CLIMAX | H&S Tool (Asia Pacific Head-
quarters)
316 Tanglin Road #02-01
Singapore 247978
Telephone: [phone]
Fax: [phone]
CLIMAX | H&S Tool (Middle East Headquarters)
Warehouse #5, Plot: 369 272
Um Sequim Road
Al Quoz 4
PO Box 414 084
Dubai, UAE
Telephone: [phone]

Page B BW3000 Operating Manual
CLIMAX GLOBAL LOCATIONS

P/N 52815, Rev. 7 Page C
LIMITED WARRANTY
CLIMAX Portable Machine Tools, Inc. (hereafter referred to as “CLIMAX”) warrants that all new machines
are free from defects in materials and workmanship. This warranty is available to the original purchaser for a
period of one year after delivery. If the original purchaser finds any defect in materials or workmanship
within the warranty period, the original purchaser should contact its factory representative and return the
entire machine, shipping prepaid, to the factory. CLIMAX will, at its option, either repair or replace the
defective machine at no charge and will return the machine with shipping prepaid.
CLIMAX warrants that all parts are free from defects in materials and workmanship, and that all labor has
been performed properly. This warranty is available to the customer purchasing parts or labor for a period of
90 days after delivery of the part or repaired machine or 180 days on used machines and components. If the
customer purchasing parts or labor finds any defect in materials or workmanship within the warranty period,
the purchaser should contact its factory representative and return the part or repaired machine, shipping pre-
paid, to the factory. CLIMAX will, at its option, either repair or replace the defective part and/ or correct any
defect in the labor performed, both at no charge, and return the part or repaired machine shipping prepaid.
These warranties do not apply to the following:
• Damage after the date of shipment not caused by defects in materials or workmanship
• Damage caused by improper or inadequate machine maintenance
• Damage caused by unauthorized machine modification or repair
• Damage caused by machine abuse
• Damage caused by using the machine beyond its rated capacity
All other warranties, express or implied, including without limitation the warranties of merchantability and
fitness for a particular purpose are disclaimed and excluded.
Terms of sale
Be sure to review the terms of sale which appear on the reverse side of your invoice. These terms control and
limit your rights with respect to the goods purchased from CLIMAX.
About this manual
CLIMAX provides the contents of this manual in good faith as a guideline to the operator. CLIMAX cannot
guarantee that the information contained in this manual is correct for applications other than the application
described in this manual. Product specifications are subject to change without notice.

Page D BW3000 Operating Manual
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P/N 52815, Rev. 7 Page i
TABLE OF CONTENTS
CHAPTER/SECTION PAGE
1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 HOW TO USE THIS MANUAL - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1
1.2 SAFETY ALERTS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1
1.3 GENERAL SAFETY PRECAUTIONS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2
1.4 MACHINE-SPECIFIC SAFETY PRECAUTIONS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3
1.5 RISK ASSESSMENT AND HAZARD MITIGATION - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4
1.6 RISK ASSESSMENT CHECKLIST - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5
1.7 GLOSSARY - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7
2 OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.1 FEATURES AND COMPONENTS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10
2.1.1 Features - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 14
2.1.2 Stock components - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 15
2.1.3 Torches and torch accessories - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 17
2.1.4 Consumables - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 20
2.1.5 Cables and conduits - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 20
2.2 ACCESSORIES - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 22
2.2.1 Wirefeeder accessories - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 23
2.2.2 Mounting accessories - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 24
2.2.3 BoreWelder accessories - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 24
2.2.4 Plate, offset head protector (inverted operation) - - - - - - - - - - - - - - - - - - - - - - 25
2.3 CONTROLS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 26
2.4 DIMENSIONS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 28
2.5 SPECIFICATIONS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30
2.6 ITEMS REQUIRED BUT NOT SUPPLIED - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 31
3 SETUP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
3.1 RECEIPT AND INSPECTION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 33
3.2 LIFTING AND RIGGING - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 34
3.3 MACHINE ASSEMBLY - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 34
3.3.1 Mounting system (when not using the boring bar interface)- - - - - - - - - - - - - - - - - 34
3.3.2 Attaching the BW3000 using the adjustable base - - - - - - - - - - - - - - - - - - - - - 35
3.3.3 Attaching the control box - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 37
3.3.4 Adjusting parallelism using the torch extension as a guide - - - - - - - - - - - - - - - - - 37
3.3.5 Centering the BoreWelder with the torch extension (coarse center)- - - - - - - - - - - - - 39
3.3.6 Installing a welding torch and setting the clearance - - - - - - - - - - - - - - - - - - - - 40
3.3.7 Fine centering with the adjustable base - - - - - - - - - - - - - - - - - - - - - - - - - - 42
3.3.8 Understanding the boring bar interface - - - - - - - - - - - - - - - - - - - - - - - - - - 43

Page ii BW3000 Operating Manual
TABLE OF CONTENTS (CONTINUED)
CHAPTER/SECTION PAGE
3.3.9 Adjusting the reach - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 43
3.3.10 Attaching the wirefeed conduit and loading wire - - - - - - - - - - - - - - - - - - - - - - 43
3.3.11 Attaching the weld cables and gas hose- - - - - - - - - - - - - - - - - - - - - - - - - - 44
3.3.12 Setting the axial and rotational start positions - - - - - - - - - - - - - - - - - - - - - - - 45
4 OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
4.1 PRE-OPERATION CHECKS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 47
4.2 CHOOSING THE CONTROL SETTINGS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 48
4.2.1 Setting the wire speed - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 49
4.2.2 Setting the step- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50
4.2.3 Setting the arc voltage - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50
4.2.4 Choosing shielding gas and setting the gas flow rate - - - - - - - - - - - - - - - - - - - 51
4.3 PRE-WELD CHECKLIST - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 52
4.4 STARTING, STOPPING, AND INTERRUPTING THE WELD PROCESS - - - - - - - - - - - - - - - - - - - 52
4.4.1 Starting to weld- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 52
4.4.2 Stopping the weld - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 53
4.5 USING ARC INTERRUPT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 53
4.6 USING AUTO SKIP - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 53
4.7 USING PIE MODE AND CARRIAGE RETURN - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 54
4.7.1 Pie mode- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 54
4.7.2 Carriage return - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 55
4.8 WELDING TIPS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 56
4.8.1 Achieving the smoothest and least violent arc action - - - - - - - - - - - - - - - - - - - 56
4.8.2 Avoiding wire flip by using a wire with a large cast - - - - - - - - - - - - - - - - - - - - - 56
4.8.3 Cleaning glass inclusions from the bore - - - - - - - - - - - - - - - - - - - - - - - - - - 57
4.8.4 Providing appropriate axial movement each revolution- - - - - - - - - - - - - - - - - - - 57
4.9 WELDING IN THE HORIZONTAL AXIS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 58
4.9.1 Procedure for horizontal axis welding - - - - - - - - - - - - - - - - - - - - - - - - - - - 58
4.9.2 Offset head settings when using extensions in the horizontal axis - - - - - - - - - - - - - 60
5 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
5.1 MAINTENANCE CHECKLIST - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 62
5.2 MAINTENANCE TASKS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 62
5.2.1 BoreWelder maintenance - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 62
5.2.2 BoreWelder adjustments - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 64
5.2.3 Wirefeeder maintenance and adjustments- - - - - - - - - - - - - - - - - - - - - - - - - 65
5.2.4 Torches, conduits, and cables - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 66
5.2.5 Control box maintenance - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 68

P/N 52815, Rev. 7 Page iii
TABLE OF CONTENTS (CONTINUED)
CHAPTER/SECTION PAGE
5.3 TROUBLESHOOTING - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 68
5.3.1 Common welding problems and their cures - - - - - - - - - - - - - - - - - - - - - - - - 71
5.3.2 Mechanical/electrical troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - 74
6 STORAGE AND SHIPPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
6.1 STORAGE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 77
6.1.1 Short-term storage - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 77
6.1.2 Long-term storage - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 78
6.2 SHIPPING - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 78
6.3 DECOMMISSIONING - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 78
APPENDIX A ASSEMBLY DRAWINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
APPENDIX B SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

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