Product Overview

The Bortech Corporation’s Model 1202 Borewelder increases productivity by reducing downtime in the field and opening up floor space in the shop. The 1202 builds up Bores, Pins, Conical surfaces and Faces on a variety of circumferential applications. Very heavy parts are no longer lifted onto a turntable, but kept on the floor, thereby creating a safer shop environment. The 1202 breaks away from the industry standard by rotating the welding apparatus around the part.

Keeping the diverse applications of every changing day in mind, the 1202 has surpassed customers needs in a variety of applications, including mine service, steel mill repair, crusher repair, shredder repair and cladding of nuclear steam vessels. Unmanageable field buildup, or cladding, is now within the reach of service companies interested in time savings and job diversification. While weighing in at only 300 lbs., the Model 1202 MIG welds up to 450 amperes with a 1/16" wire. Bortech Corporation, providing a range of systems for conical seat, pin, bore and face buildup, is proud to offer the 1202 system for under $30K with capabilities from 1’ to 12’.

Features

Every 1202 consists of a Head Assembly [A2202]. The head supplies the stability and orbital rotation for the welding operation. To this head is added a Line Bar, [20043-20046] which is used to mount equipment on and possibly to reach into the bore. This Line Bar may be a full-length bar or a stub length just long enough to mount the equipment.

To the Line Bar is clamped the Radial Rod Mount [A2034]. This adapter holds a Radial Rod [20036-20039 or 20224-20229] that is used to span the distance from the center of the bore to the bore surface. The Radial Rod Mount also holds a small electrical box with 3 AMP connectors for 3 separate control circuits. These circuits may be used to power devices such as a Wire Feeder and a Step Assembly.

The preceding describes standard 1202 configurations. In the discussion that follows, the components may be placed in a variety of places, but generally the BoreWelder will need the following additional components to function:

• Wire Reel Bracket [20228 or 20231]
• Wire Feeder Assembly [A2041]
• 2 Accessory Mounts [20199 or 20201]
• Auxiliary Stepping Unit [A2035]
• Auxiliary Torch Adjuster [A2029]
• Torch [A2008]

The Auxiliary Stepping Unit [A2035] is used to provide the required stepping action either through a bore or radially across a face (or any angle in between). The Step Assembly is electrically connected to the control box. By way of a rack and pinion, the Step Assembly climbs along an Auxiliary Slide Guide[A2036 - A2040]. The Guide assembly can be obtained in 5 lengths with travel lengths between 10" and 50". For radial face buildup, these guide rods can be mounted directly in the Radial Rod Mount [A2034] or coupled to a Radial Rod [20036-20039] for added reach. In this configuration, the Step Assembly would travel in a direction parallel to a face or flange.

For bore build up, a Radial Rod is secured in the Radial Rod Mount [A2034] and then a 90 degree Adapter Block [20207 or 20210]is used to hold an Auxiliary Slide Guide [A2036 - A2040] in a position parallel to the axis of the bore. In this configuration, the Step Assembly would travel in such a way as to build up a bore surface. The Adapter Block comes in two flavors: one with plain bores [20207] and one with a keyway in one of the bores [20210]. The keyway allows the Stepping Assembly's Guide Rod to be slipped entirely through the Adapter Block. This may be desirable at times if the exact length of Guide Rod is not available. However, it should be noted that the travel limits of the Stepping Assembly, being activated by detecting the end of the rack, may run into the Adapter Block if the Guide Rod is slid far into this keyway equipped Adapter Block and the operator is not paying attention.

Mounting of the Wire Reel Bracket [20228 or 20231] is facilitated with an Accessory Mount [20199 or 20201] component. This component contains a 1/2-13 tapped hole for securing the Wire Reel Bracket and it clamps onto either the 1.5" Radial Rod [20199] or the 2.0" Line Bar [20201]. Thus the Wire Reel can be mounted anywhere on either the 1.5" Radial Rod or the 2.0" Line Bar. This provides great flexibility.

Mounting of the Wire Feeder Assembly [A2041] to the unit is done identically to that of the Wire Reel and so can be mounted most anywhere on the Radial Rod or the Line Bar. (If needed, a wire guiding conduit can be used between the Wire Reel and the Wire Feeder.) The Wire Feeder can be run in either direction by toggling a switch located on the electrical box of the Radial Rod Mount. Thus the welding wire conduit can be placed on either end of the wire feeder — whichever is convenient — and the wire feeding direction to be changed to suit.

In order to adjust torch tip distance to the work surface the Auxiliary Torch Adjuster [A2029] is used. This device is usually perpendicular to the surface to be built up. This is also a direction which is generally at a right angle to the Step Assembly's Guide Rod.

There are several additional components that can be used to mount the Torch Adjuster to the Step Assembly and the Torch to the Torch Adjuster. These additional components can be used in a great variety of configurations, several of which are illustrated in the Applications section.

Setup, leveling and centering instructions are provided in the manual.

• Build up or clad bores from 12" to 144" (30 cm to 366 cm)
• Portable
• Rotation of part not required
• Continuous torch rotation
• Simple setup
• High deposition rates
• 100% duty cycle

Specifications

• Welding Process: Metal - inert - gas (MIG) (short arc, pulse, or spray)
• Wire Diameter Range: .045" to .062" diameter (1.2 mm to 1.6 mm)
• Max. Wire Spool Size: 2" (5 cm) I.D. by 14" (36 cm) O.D.
• Welding Current: 400 amps
• Axial Stroke: 13"(33 cm)
• Axial Travel:
  • 18" (46 cm) with 3' (.9 m) Line Bar
  • 30" (76 cm) with 4' (1.2 m) Line Bar
  • 54" (137 cm) with 6' (1.8 m) Line Bar
  • 78" (198 cm) with 8' (2.4 m) Line Bar
• Diameter Range:
  • 12" to 28" (30 cm to 71 cm) with #1 Radial Rod and Compact Torch
  • 24" to 43" (61 cm to 109 cm) with #2 Radial Rod and Compact Torch
  • 39" to 78" (99 cm to 198 cm) with #3 Radial Rod and Compact Torch
  • 61" to 120" (155 cm to 305 cm) with #4 Radial Rod and Compact Torch
  • Combine Radial Rods for more than 120" (305 cm)
• Alignment: Mounting Plate adjusts for parallelism and centrality

Package Includes

• Borewelder
• Control Box
• Adjustable Base
• Mounting Rod
• Mounting Rod Extender
• Radial Mount
• Radial Mount - Opposite
• Control Cables
• Power Cord
• Wrenches
• Interfacing Wire Feeder Conduit (Customer must advise make and model of wire feeder to be used)
• Torches:
• #0, #1, #2, #3 (Range of 1.8 - 9")
• Combination Torch (Range of 1.75 - 13")
• Extensions, 1 ea: 3", 6", 12", 18"
• Liner - 16'
• Carrying Case
• Manual Packet
• Weldcalc (Build up time program)