BUG-O CWP-7 Instructions And Parts Manual Download

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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

Summary of Contents for CWP-7

Page 1: ... 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 ...

Page 2: ... 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 first verifying the equipment is OFF and the cor...

Page 3: ...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 plas...

Page 4: ...w 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 Rol...

Page 5: ...ontal 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 se...

Page 6: ...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...

Page 7: ... 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 a...

Page 8: ...s 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 4 3 5 10 8...

Page 9: ... 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 ...

Page 10: ...des 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 When entering data use the diame...

Page 11: ...11 CWP 1570 CONTROL PANEL OPEN BOX EXPLODED VIEW 4 4 4 5 6 7 8 2 3 1 10 9 11 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 ...

Page 12: ...UG 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 470ohm1 4w5 ca...

Page 13: ...13 CWP 1570 WD CONTROL PANEL WIRING DIAGRAM 1 OF 3 ...

Page 14: ...14 A B C D CWP 1570 WD CONTROL PANEL WIRING DIAGRAM 2 OF 3 ...

Page 15: ...15 CWP 1570 WD CONTROL PANEL WIRING DIAGRAM 3 OF 3 ...

Page 16: ...s 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 ...

Page 17: ...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 flux recovery system ...

Page 18: ...er 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...

Page 19: ...3478 9 CW 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...

Page 20: ...0 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 W...

Page 21: ...21 CWO 3139 UNIVERSAL POWER CABLE EXPLODED VIEW PARTS LIST CWO 3139 M MILLER POWER CABLE EXPLODED VIEW PARTS LIST ...

Page 22: ... Hex Jam Nut 3 4 16 12 1 MUG 1141 Bearing Collet 13 1 MUG 1142 Knob Locking 14 1 MUG 1144 Shaft 15 2 MUG 1453 Stand Off 16 1 MUG 1579 Retaining Ring 17 2 WAS 0240 1 4 SAE Washer 18 2 FAS 0559 Soc Hd Cap Scr 1 4 20 x 1 F FIXED WHEEL PLACEMENT A ADJUSTABLE WHEEL PLACEMENT 1 14 18 13 12 10 3 9A 7 6A 6A 8F 5F 2 16 11 17 8F 9A 5F 15 4 CBP 1640 MOTORIZED RACKING SYSTEM EXPLODED VIEW PARTS LIST ITEM QTY ...

Page 23: ...6 2 1 5 4 ITEM QTY PART NO DESCRIPTION 1 1 BUG 3209 Hinge 3 4 x 2 Lg 2 1 CWO 2008 Plastic Guard 3 2 FAS 0535 Soc Hd Cap 10 24 x 1 2 4 1 HDW 1001 Steel Hair Pin Zinc Plated 5 2 BUG 3197 Binding Post 8 32 x 3 16 Lg 6 2 BUG 3198 Binding Post Screw 8 32 x 3 16 Lg ...

Page 24: ...049 O Ring Oxygen Fuel 3 1 CWO 5778 Shaft CW 7AG CW 7ABG 1 3 2 2 CWO 3498 WIRE REEL MOUNT ASSEMBLY EXPLODED VIEW PARTS LIST ITEM QTY PART NO DESCRIPTION 1 1 BUG 3293 Reel 60 lbs 2 1 CWP 1728 Wire Reel Support Assembly 3 2 FAS 1301 Hex Nut 1 2 13 4 2 FAS 2305 Hex Hd Cap Scr 1 2 13 x 1 3 4 5 2 WAS 0281 1 2 Lock Washer 1 2 4 5 3 ...

Page 25: ...Hd Cap Scr 10 32 x 3 4 14 15 12 6 14 7 6 5 1 3 15 9 10 11 15 13 2 3 4 8 ITEM QTY PART NO DESCRIPTION 1 1 CWO 4036 Large Brush Holder Support 2 1 CWO 4339 Attachment Bar 3 2 CWO 3263 Large Brush Holder 4 4 CWO 3264 Spring Clip 5 4 CWO 4337 Large Brush 1 1 2 x 3 4 x 2 6 2 CWO 5548 Micarta Spacer 7 1 CWO 5549 Micarta Bushing 8 1 FAS 0304 Hex Hd Cap Scr 1 2 13 x 3 5 9 1 FAS 0305 Hex Hd Cap Scr 1 2 13 ...

Page 26: ...3461 SMALL RETAINER BLOCK ASSEMBLY DETAIL VIEW WHITE 10 BLACK 10 RED 10 ORANGE 10 1 2 3 4 ITEM QTY PART NO DESCRIPTION 1 1 CWO 5626 Small Brush Retainer Blk 2 4 CWO 5831 Brush 1 8 x 1 8 x 7 8 3 4 CWO 5874 Brush Holder 4 4 CWO 5875 Cap 5 4 CWO 5876 Clip 6 4 TERM WTE 0602 6 Fork Blue CWO 3361 P M MOTOR ASSEMBLY 147 EXPLODED VIEW PARTS LIST ITEM QTY PART NO DESCRIPTION 1 1 CWO 4067 P M Motor 1072 2 1...

Page 27: ...37 55 GAS DIFFUSER 1 CWO 8041 45 116 15 CABLE LINER 1 CWO 8524 50394 500 AMP CABLE 1 CWO 1560 D 5 5 64 GUN ASSEMBLY MIG FLUX 5 64 WIRE SIZE CWO 8031 15H 564 CONTACT TIP 10 CWO 8034 25CT 75 NOZZLE 1 CWO 8035 35CT NOZZLE INSULATOR 1 CWO 8038 55 GAS DIFFUSER 1 CWO 8085 45 564 15 CABLE LINER 1 CWO 8524 50394 500 AMP CABLE 1 CWO 1560 E 5 3 32 GUN ASSEMBLY MIG FLUX 3 32 WIRE SIZE CWO 8032 15H 332 CONTAC...

Page 28: ...1 45 116 15 CABLE LINER 1 CWO 8054 25 SA NOZZLE FLUX CONE 1 CWO 8524 50394 500 AMP CABLE 1 CWO 1700 D 5 5 64 GUN ASSEMBLY SUB ARC 5 64 WIRE SIZE CWO 8031 15H 564 CONTACT TIP 10 CWO 8038 55 GAS DIFFUSER 1 CWO 8042 45 116 15 CABLE LINER 1 CWO 8054 25 SA NOZZLE FLUX CONE 1 CWO 8524 50394 500 AMP CABLE 1 CWO 1700 E 5 3 32 GUN ASSEMBLY SUB ARC 3 32 WIRE SIZE CWO 8032 15H 332 CONTACT TIP 10 CWO 8038 55H...

Page 29: ...ber Insulator 12 1 BUG 3161 P Cone Body Assembly 13 1 BUG 3163 Locking Ferrule 14 1 BUG 3164 Flux Cone Kp2085 1 15 1 BUG 3165 Retaining Nut WIRE SIZES AVAILABLE PART NO WIRE SIZE CWO 3690 1 16 1 16 1 6 mm CWO 3690 5 64 5 64 2 0 mm CWO 3690 3 32 3 32 2 4 mm REPLACEMENT CONTACT TIPS AVAILABLE PART NO WIRE SIZE AFW 2291 1 16 1 5 mm CWO 8048 5 64 2 0 mm CWO 8049 3 32 2 4 mm CW 7 DRIVE ROLL KITS PART N...

Page 30: ...0 Assembly 72 1829 mm Lg 6 1 CWO 3690 1 16 Sub Arc Nozzle 1 16 1 CWO 3690 5 64 Sub Arc Nozzle 5 64 1 CWO 3690 3 32 Sub Arc Nozzle 3 32 7 1 FAS 0452 Set Scr 1 4 20 x 1 4 5 ITEM QTY PART NO DESCRIPTION 1 1 CWO 3757 Hopper Support Rod 2 1 CWO 3760 Clamp Block 1 2 3 1 CWO 3478 3 4 Hose Barb 4 1 CWO 3769 Flux Hopper Steel 12 5 1 GOF 3019 Handle w Bolts N S 48 1000 4 001 3 4 ID x 1 OD Clear Hose CWO 349...

Page 31: ... 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 X 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 ...

Page 32: ...s the Circle Welder on nozzles with or without flanges As shown below PART NO FOR NOZZLE I D S WEIGHT CWO 3660 2 10 51mm 254mm 69 3 lbs 31 3 kg CWO 3661 8 16 204 405 mm 36 lbs 16 kg CWO 3362 10 24 255 610 mm 51 lbs 23 kg CWO 3663 15 75 47 25 610 1065 mm 64 lbs 29 kg CWO 3661 CWO 3662 CWO 3663 ...

Page 33: ...Stand Off 7 2 CWO 4326 Fixed Leg Wheel 8 2 CWO 4327 Adj Leg Wheel 9 4 FAS 0527 Soc Hd Cap 8 32 x 3 4 10 2 FAS 0557 Soc Hd Cap 1 4 20 x 3 4 11 2 FAS 0559 Soc Hd Cap 1 4 20 x 1 12 1 GOF 3014 Drive Pinion w Key 13 2 WAS 0240 1 4 SAE Washer 14 1 CWO 1696 Motor Enclosure 15 1 BUG 9486 Panel Connector 2 T M 16 2 GOF 3036 QD Female 17 4 FAS 0504 Soc Hd Cap 4 40 x 3 8 18 4 FAS 0525 Soc Hd Cap 8 32 x 1 2 1...

Page 34: ... CWO 9065 T 3 Track 36 Lg 10 1 CWP 3356 Horiz P M Motor Bracket 970 Mod 11 6 FAS 1301 Hex Nut 1 2 13 12 2 WAS 0281 1 2 Split Lockwasher Zinc Plated 13 4 WAS 0280 1 2 SAE Flat 14 4 FAS 2591 SS Soc Hd Cap Scr 3 8 16 x 1 1 4 Stainless Steel 15 4 FAS 1444 SS Phil Pan Hd Scr 10 32 x 3 8 Stainless Steel 16 10 FAS 0359 SS Hex Hd Cap Scr 1 4 20 x 1 Stainless Steel 17 1 FAS 0399 Hex Hd Cap Scr 3 8 16 x 1 1...

Page 35: ...35 OPTIONAL MOTORIZED RACKING EQUIPMENT PRS 1100 EXPLODED VIEW WIRING DIAGRAM ...

Page 36: ...Hold Down Spring 1 10 BUG 1384 Relay Socket Spring 1 11 BUG 1383 Relay 4Pdt 3A 120V Plug In 1 BUG 1551 Relay 3A 240VAC 1 BUG 9636 Relay 48VAC 1 12 BUG 9902 Panel Connector 6 T F 1 13 CAS 1770 Speed Control Iron Rotor 2 14 BUG 9446 Cord Grip 1 15 BUG 9445 Power Cord 120VAC Shown 1 1 GOF 3115 Line Cord 240VAC 1 16 BUG 9628 Cap Chain Assembly 1 17 FAS 0124 8 32 X 3 8 Pan Hd Di Chrome 10 18 FAS 1320 H...

Page 37: ...363 EXPLODED VIEW PARTS LIST OPTIONAL MOTORIZED RACKING EQUIPMENT PRS 1075 EXPLODED VIEW PARTS LIST ITEM QTY PART NO DESCRIPTION 1 1 CWO 1687 Plate 2 4 CWO 4326 Wheel Leg Assembly Fixed 3 4 CWO 4327 Wheel Leg Assembly Adjustable 2 1 3 2 2 2 3 3 3 ...

Page 38: ...e 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...

Page 39: ...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...

Page 40: ...t 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 ...

Page 41: ...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 th...

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