Instructions AND Parts Manual: STW-2000 Programmable Stiffener Welder
Instructions AND Parts Manual: STW-2000 Programmable Stiffener Welder
Instructions AND Parts Manual: STW-2000 Programmable Stiffener Welder
AND
PARTS MANUAL
STW-2000
PROGRAMMABLE
STIFFENER
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-STW-2000-IPM-1216
EQUIPMENT DAMAGE
ELECTRIC SHOCK can kill. POSSIBLE.
2
HIGH FREQUENCY WARNINGS
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
STW-2000
PROGRAMMABLE STIFFENER WELDER
INSTRUCTIONS AND PARTS MANUAL
TABLE OF CONTENTS
4
INTRODUCTION
The Programmable Stiffener Welder mechanizes two wire feeders to weld various types of stiffeners on
one or both sides simultaneously. The unit features independent wire feeder controls for voltage, wire
feed speed, cold wire jog and gas purge. When intermittent stitch welding is required the unit features
programmable control of weld length and travel speed, skip length, reverse drive crater fill, pre-weld and
post-weld gas purge times. Please see the Technical Data information in this manual for unit capacities.
1. Center the unit over the work piece. Connect welding cables and wire feeder control cables for each
feeder to the welding power sources. Connect the welding gas hoses to each Flow Meter/Valve
Assembly. Plug the unit into an available 110 VAC 50/60 Hz power source.
2. Turn power “ON” to both welding power sources. Turn power “ON” to the control panel by toggling
the “ON/OFF” switch on the upper rear left hand side of the control box to the “ON” position. Turn
“ON” power to both feeders by toggling the feeder “ON/OFF” switches located on the front lower left
and right of the control box to the “ON” position.
NOTE: Ensure that the Emergency Stop Switch located on the top of the control box is in the
released position or no power will be supplied to the unit.
3. Adjust the Capture Wheel Assemblies so that they contact the side of the work. Swing the Drive
Unit into position against the work piece and engage the Drive Latch and tighten to ensure constant
pressure on the work piece between the Drive Assembly, Work Piece and Capture Wheel Assemblies.
NOTE: Move the unit forward and reverse using the Travel Manual Jog Switch located on the front
bottom center of the control box to ensure proper tension has been applied by the Drive Latch to
move the unit smoothly along the work piece.
4. Align the left and right Corner Followers and welding guns for the desired weld placement. The
Corner Followers can be adjusted up, down, in and out to achieve the placement you desire. The
Corner Followers are also equipped with a gun angle adjustment knob to achieve the desired torch
angle. Purge the shield gas to each welding gun by pressing the Shield Gas Purge button located
on the left and right sides of the control panel for each Flow Meter/Valve Assembly.
5. Set all welding parameters. Each wire feeder’s wire speed and voltage are set independently from
each other utilizing the controls to the left and right of the soft touch Programming Center located
on the control panel. All other welding parameters are set using the soft touch Programming Center.
Please refer to the controls section of the manual.
6. When you are ready to begin your weld cycle press the Weld Cycle Start button located on the
control panel below the soft touch Programming Center. To stop the weld cycle press the Weld
Cycle Stop button.
NOTE: In case of an emergency press the Emergency Stop switch located on the top of the control
box to kill all power to the unit including the weld cycle. Once the Emergency Stop switch is returned
to the released position you will need to press the Cycle Start button to resume your cycle.
5
CONTROLS (MAIN)
VOLTAGE CONTROL: Regulates welding voltage for the assigned feeder
WIRE SPEED CONTROL: Regulates the wire feed speed for the assigned feeder
WIRE JOG: Allows wire to be fed without closing the weld current contact
WIRE FEEDER POWER INDICATOR LIGHT: Illuminate when power is being supplied to the assigned
wire feeder
WIRE FEEDER ON/OFF SWITCH: Allows operator to turn power on or off to the assigned wire feeder.
SHIELD GAS PURGE: Allows operator to activate shield gas solenoid to purge welding gun and check
the gas rate on the units regulators
TRAVEL MANUAL JOG: Allows operator to move the unit forward or backward without welding
Emergency Stop
Programming Center
Voltage Voltage
Control (A) Control (A)
6
CONTROLS (PROGRAMMING CENTER)
DIGITAL DISPLAY: Visual display to supply welding motion information to operator
GAS PREFLOW DELAY: Programmable time for gas to purge lines before weld start
BACKUP DISTANCE: Distance the unit travels in reverse after completed weld length
GAS POSTFLOW DELAY: Programmable time for gas to shield weld at arc stop
INCREASE VALUE: Pressing this button increases the value shown in the digital display
DECREASE VALUE: Pressing this button decreases the value shown in the digital display
FUNCTION SELECT: Allows the user to cycle through the welding programming functions
SKIP/CONTINUOUS MODE SELECT: Allows the user to select skip mode or continuous mode for
the welding operation
SKIP INDICATOR LIGHT: When illuminated the machine will weld in skip mode
STRAIGHT LINE INDICATOR LIGHT: When illuminated the machine will weld in continuous mode
PUDDLE DELAY:
There are two internal settings in the Control Module that do not appear in the normal setting
selection on the control panel keypad/display. These are time delays at weld start and stop, when
the wire feed is on but travel is stopped, in order to allow for puddle buildup.
3. Release Stop button. (LED No.1 and 3 should light; and the display shows the start puddle
build time.)
5. Briefly push Function Select (cycle settings) button. LED No. 3 and 5 should light, and display
shows the end crater fill time.
7
CONTROLS (PROGRAMMING CENTER CONT’D.)
Digital Readout
Backup Distance
Weld Length
Travel Speed
Postflow
Skip Indicator
Decrease Value
Straight Indicator
Function Select
8
TECHNICAL DATA
Programmable Weld/Skip Travel Speed: 0"-36" ipm (0-914 mm/min)
Programmable Reverse Drive Crater Fill: 0"-1" (0-25 mm)
Programmable Pre-Weld/Post Weld Gas Purge: 0-10 seconds
Net Weight: 250 lbs. (113 kg)
Stiffener Size Range: Height 4"-18" (102-457 mm)
Width 4"-12" (102-305 mm)
Wire Spool Capacity: 10, 20, 60 lbs. each side
DIMENSIONS
36"
14" (914 mm)
(356 mm)
19.50"
(495 mm)
47" 24"
(1194 mm) (610 mm)
9
STW-2000 STIFFENER WELDER / MAJOR COMPONENTS
12
1
20
13
10
11
14
13 5
6 4
17
19
13
16
10
8
18
15
13 16
9 10
10
STW-2000 STIFFENER WELDER / PARTS LIST
11
WIRING DETAIL / LEFT WIRE FEEDER CONTROL
pg. 14
pg. 14
15
STW-2080 WIRE FEEDER / EXPLODED VIEW / PARTS LIST
12
7
13
2
3
8, 10
6
11
9
16
STW-2140-L CORNER FOLLOWER LEFT / EXPLODED VIEW /
PARTS LIST
12
13
22
9
8 21
14 15
4
11
20
16
5
10
18
17 2
19
3
6
ITEM QTY PART NO. DESCRIPTION 7
1 1 ARM-2358-4.1 Leg 4-1/8"
2 1 BGV-1215 Clamp Block Assembly
3 1 BUG-1857 Knob w/Set Screw
4 4 BUG-2593 Glide “Flat”
5 2 BUG-2841 Washer 5/8" O.D. x 5/16" I.D.
6 1 CON-1029 Washer 5/16" x .015" Thk.
7 1 FAS-0453 Set Scr 1/4-20 x 1/4" HDP
8 1 FAS-0535 Soc Hd Cap Scr 10-24 x 1/2"
9 1 FAS-0557 Soc Hd Cap Scr 1/4-20 x 3/4"
10 2 FAS-0654 Soc Hd Shd 5/16" x 3/8" x 1/4-20
11 2 FAS-0957 Flt Hd Soc 1/4-20 x 3/4"
12 1 MUG-1515 Collar
13 1 PAN-1235 Slide Assembly
14 1 PAN-2125 Mounting Arm Assembly
15 1 PAN-2131-L Mounting Plate, Left
16 1 PAN-2133-L Slide Plate
17 1 PAN-2134 Screw Retainer
18 1 PAN-2135 Screw Block
19 1 PAN-2136 Adjusting Screw
20 1 PAN-2137 External Retaining Ring
21 1 WAS-0230 #10 SAE Washer
22 1 RPS-0179 Roll Pin
17
STW-2140-R CORNER FOLLOWER RIGHT / EXPLODED VIEW /
PARTS LIST
12
13
1
22
9
8
21
15
14
4
11
20 3
16
17
5
10 6
7
19
18
2
ITEM QTY PART NO. DESCRIPTION
1 1 ARM-2358-4.1 Leg 4-1/8"
2 1 BGV-1215 Clamp Block Assembly
3 1 BUG-1857 Knob w/Set Screw
4 4 BUG-2593 Glide “Flat”
5 2 BUG-2841 Washer 5/8" O.D. x 5/16" I.D.
6 1 CON-1029 Washer 5/16" x .015" Thk
7 1 FAS-0453 Set Scr 1/4-20 x 1/4" HDP
8 1 FAS-0535 Soc Hd Cap Scr 10-24 x 1/2"
9 1 FAS-0557 Soc Hd Cap Scr 1/4-20 x 3/4"
10 2 FAS-0654 Soc Hd Shd 5/16" x 3/8" x 1/4-20
11 2 FAS-0957 Flt Hd Soc 1/4-20 x 3/4"
12 1 MUG-1515 Collar
13 1 PAN-1235 Slide Assembly
14 1 PAN-2125 Mounting Arm Assembly
15 1 PAN-2131-R Mounting Plate, Left
16 1 PAN-2133-R Slide Plate
17 1 PAN-2134 Screw Retainer
18 1 PAN-2135 Screw Block
19 1 PAN-2136 Adjusting Screw
20 1 PAN-2137 External Retaining Ring
21 1 WAS-0230 #10 SAE Washer
22 1 RPS-0179 Roll Pin
18
STW-2150-L GUN HINGE LEFT / EXPLODED VIEW / PARTS LIST
13 10
15
12
9
2
16
4 8
7 6
1 11
14
13
19
STW-2150-R GUN HINGE RIGHT / EXPLODED VIEW / PARTS LIST
10 13
15
12
2
9
16
5 4
6 7
11 1
3
14
13
20
STW-2170-A CAPTURE WHEEL ASSEMBLY “A” / EXPLODED VIEW /
PARTS LIST
2
10
1
12
3
4
5 13
7
11
6
21
STW-2170-B CAPTURE WHEEL ASSEMBLY “B” / EXPLODED VIEW /
PARTS LIST
10
1
12
3 4
13
5
6
11
9
22
STW-2115 DRIVE LATCH / EXPLODED VIEW / PARTS LIST
5
1
23
STW-2060 FLOW-METER & VALVE ASSEMBLY / EXPLODED VIEW /
PARTS LIST
15
3
14
1
10
7 13
11
4 5 6 12
25
STW-2120 DRIVE UNIT ASSEMBLY / EXPLODED VIEW
11
7 8
11
15
22
20 12
17 21
16
13 19
4 6
3
10
18
14
26
STW-2120 DRIVE UNIT ASSEMBLY / PARTS LIST
27
STW-2195 SPOOL SUPPORT BRACKET / EXPLODED VIEW /
PARTS LIST
3
2
4
5
1 4
28
CSM-1100 500 AMP AIR-COOLED GUN / EXPLODED VIEW /
PARTS LIST
4
5
3
18 9
12
19 11
20
10
7
6
13 5
14
15
16 2
17
1 4
5
3
Order #STW-2100
Comes in quantities of 1.
Order #WFU-1041
Comes in quantities of 1.
Order #BUG-3293
Comes in quantities of 1.
31
WARRANTY
Model ______________________________
Limited 3-Year Warranty* 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 consequen-
tial 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.
*Bug-O System’s warranty applies to Bug-O components only. Where other brands of power sources, wire feeders or sub
components are a part of Bug-O Equipment, please refer to that specific Manufacturer’s manual for warranty specifications
on their components.
32