Frequently Asked Questions
Answers to some questions about the BORTECH welding systems.
Q. How do I know how to set the control box parameters?
A. Initial control setting includes four major parameters, listed in order of importance.

1. Rotation Speed; this setting is obtained by utilizing the chart in the manual for a coarse adjust. It is generally recommended to have a torch travel speed, at the surface of the bore, of 18 to 22 Inches per Minute (IPM). To enhance accuracy, timing the spindle rotation enables the operator to know exactly how fast his travel speed is. How to calculate your times for the specific bore size is by this simple equation. Diameter x 3.14 x 60 / IPM Desired (20 IPM) = Seconds per Rotation.

2. Wire Speed; Amperage! Ammeter is helpful in bore welding. Rule of thumb, 125 amps @ 20 IMP equals about .125 thousandths step. The BoreWelder current limit is not to exceed 175 amperes. 2 on the wire Speed dial is approximately 100 amps with .035 wire. 3 on the Wire Speed dial is approximately 150 amps with .035 wire.

3. Step varies directly with wire speed. Higher amperage means higher step. Step varies inversely with rotation speed, faster rotation speed means less step. We are looking for the wire to be pointing at the junction of the previous bead and the bae metal or slightly above.

4. Voltage; Generally, the welding voltage is approximately 17 volts depending on amperage. Starting voltage can be 18 volts and trimmed for best run after the welding process is stabilized.
Q. What is the proper operation of the 306-P BoreWelder?
A. The 306-P BoreWelder is designed for safety and ease of use, but as with the operation of any machinery, safety depends on the operator. The BoreWelder requires thoughtful, careful operation to produce both optimum results and safety.

The 306-P BoreWelder is an automated welding device. It uses a rotating and axially stepping torch in conjunction with the MIG process to build up the surface of a bore by depositing contiguous weld beads around the bore's circumference. Differences in bore diameter are accommodated by torch selection, and/or adjustment of an Offset Head. During the set-up phase, the operator must align the BoreWelder to the bore, determine the proper torch/bore clearance, and make the initial control settings.

During welding, the operator can start and stop the machine if necessary, and he needs to watch the welding process continuously in order to make minor adjustments in the rotational speed, voltage, and wire speed necessary to maintain good weld quality.
Q. What maintenance should I perform?
A. The BoreWelder is relatively maintenance free, but the most important maintenance is on a daily basis and is mostly just common sense.

Daily maintenance consists primarily of keeping the BoreWelder clean and protected. The BoreWelder has been designed to survive in industrial environments that are usually dusty and gritty, but the BoreWelder is a machine tool with close-fitting parts. Like most machine tools, it will last longer if it's taken care of. Follow these steps for best results:

  • Wipe off the BoreWelder after each use, particularly sliding parts like the quill and the offset head.
  • Lightly coat these parts with a dry lubricant such as WD-40™, wiping off any excess lubricant with a clean cloth. This will keep the quill and offset head sliding freely while protecting them.
  • Avoid using an excessive amount of a sticky lubricant, which may trap dirt and cause limit switch failure with resultant machine damage.
  • If the BoreWelder is in some sort of permanent set-up, wipe it down frequently, and cover it when not in use.

For longer-term maintenance, we recommend these tasks:

  • Clean or replace the liners.
  • Inspect the control cables for wear.
  • Occasionally, inspect the torch and extension ends where they mate for "dings" and burrs. These parts require good surfaces for a gas seal.