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OM-CWF-50-01-2014
OPERATION MANUAL
for
Model CWF-50
Cold Wire Feeder
Revised January 2014
Effective with Serial Number 070159
IMPORTANT
Read this manual carefully before installing,
commissioning or operating this product.
Jetline Engineering, 15 Goodyear Street, Irvine, CA 92618
Telephone: (949) 951-1515 • Fax: (949) 951-9237
Web Site: www.jetline.com • E-mail: [email protected]
Model CWF-50 Cold Wire Feeder
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Model CWF-50 Cold Wire Feeder
LIMITED WARRANTY
Jetline Engineering, of Irvine, California, U.S.A., warrants all new equipment to be free from defects
in material and workmanship for the period of one (1) year, provided that the equipment is installed
and operated according to instructions.
Jetline Engineering’s obligation under this warranty is expressly limited to replacing or repairing
any defective part or correcting any manufacturing defect without charge during the warranty period,
if Jetline’s inspection confirms the existence of such defects. Jetline’s option of repair or replacement
will be F.O.B. factory at Irvine, California, and therefore no compensation for transportation costs of
any kind will be allowed.
The warranty period begins on the date of sale to the original-purchase user of the equipment.
Jetline Engineering will not be liable for any loss or consequential damage or expense accruing
directly or indirectly from the use of equipment covered by this warranty.
This warranty supersedes all previous Jetline warranties and is exclusive with no other guarantees or warranties expressed or implied.
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Model CWF-50 Cold Wire Feeder
NOTICE
The installation, operation and maintenance guidelines set out in this manual will enable you to
maintain the equipment in peak condition and achieve maximum efficiency with your welding operation. Please read these instructions carefully to become aware of every advantage.
CAUTION
Only experienced personnel familiar with
the operation and safe practice of welding
equipment should install and/or use
this equipment.
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Model CWF-50 Cold Wire Feeder
Table of Contents
Section I.................................................................................................................................. 1
Safety Precautions................................................................................................................ 1
A.Arc Welding............................................................................................................... 1
B.
Electric Shock............................................................................................................ 1
C.
Arc Rays..................................................................................................................... 2
D.
Fumes and Gases........................................................................................................ 2
E.Cylinders.................................................................................................................... 2
F.Welding...................................................................................................................... 3
G.
Moving Parts.............................................................................................................. 3
H.
EMF Information....................................................................................................... 3
I.
Principal Safety Standards......................................................................................... 4
Section II.................................................................................................................................. 5
General Description.............................................................................................................. 5
Section III.................................................................................................................................. 7
Installation............................................................................................................................ 7
Section IV................................................................................................................................ 11
Operating Instructions........................................................................................................ 11
A.
B.Operation.................................................................................................................. 11
C.
Preparation for Welding........................................................................................... 11
Wire Guide Positioner.............................................................................................. 12
Section V................................................................................................................................ 15
Wire Feed Accessory Kits.................................................................................................. 15
Section VI................................................................................................................................ 17
Maintenance........................................................................................................................ 17
Section VII................................................................................................................................ 19
Optional Accessories.......................................................................................................... 19
A.
607B Spool Cover.................................................................................................... 19
B.
WGP-2ES Motorized Wire Guide Positioner.......................................................... 19
C.
WGP-3 Compact Wire Guide Positioner................................................................. 19
D.
CHWS-100 Wire Straightener................................................................................. 19
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Model CWF-50 Cold Wire Feeder
Section VIII................................................................................................................................ 21
Parts Lists........................................................................................................................... 21
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CWF-50 Cold Wire Feeder
Section I
Safety Precautions
2.
Wear dry, hole-free insulating gloves and
appropriate body protection.
WARNING
3.Disconnect input power before installing or
servicing this equipment. Lockout/tagout
input power according to OSHA 29 CFR
1910.147 (see Safety Standards).
CALIFORNIA PROPOSITION 65 WARNING
This product contains chemicals, including lead,
known to the state of California to cause cancer,
and birth defects or other reproductive harm.
Wash hands after use. §248224
A.
4.Properly install and ground this equipment
according to the operation manual and
national, state and local codes.
5.Always verify the supply ground-check and
be sure that input power cord ground wire
is properly connected to ground terminal
in disconnect box or that cord plug is connected to a properly grounded receptacle
outlet.
Arc Welding
Arc Welding can be hazardous. Protect yourself and others from possible serious injury or
death. Keep children away. Pacemaker wearers keep away until consulting your doctor.
6.When making input connections, attach
proper grounding conductor first - doublecheck connections.
In welding, as in most jobs, exposure to certain
hazards occurs. Welding is safe when precautions are taken. The safety information given
below is only a summary of the more complete
safety information that will be found in the
Safety Standards listed at the end of this section.
Read and follow all Safety Standards.
Frequently inspect input power cord for
7.
damage or bare wiring. Replace cord immediately if damaged - bare wiring can kill.
8.
9.If earth grounding of the workpiece is required,
ground it directly with a separate cable - do not
use work clamp or work cable.
Have all installation, operation, maintenance
and repair work performed only by qualified
people.
B.
10.Do not touch electrode if you are in contact
with the work, ground, or another electrode
from a different machine.
Electric Shock
Touching live electrical parts can cause fatal
shocks or severe burns. The electrode and work
circuit is electrically live whenever the output is
on. The input power circuit and machine internal
circuits are also live when power is on. When
using mechanized wire feed, the wire, wire reel,
drive roll housing and all metal parts touching
the welding wire are electrically live. Incorrectly
installed or improperly grounded equipment is
a hazard.
1.
Turn off all equipment when not in use.
11.Use only well-maintained equipment.
Repair or replace damaged parts at once.
Maintain unit according to manual.
12. Wear a safety harness if working above
floor level.
13.Keep all panels and covers securely in
place.
14.Clamp work cable with good metal-tometal contact to workpiece or worktable
as near the weld as practical.
Do not touch live electrical parts.
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CWF-50 Cold Wire Feeder
C.
4.Read the Material Safety Data Sheets
(MSDS) and the manufacturer’s instruction for metals, consumables, coatings,
cleaners, and degreasers.
Arc Rays
Arc rays can burn eyes and skin; noise can
damage hearing; flying slag or sparks can injure
eyes.
5.Work in a confined space only if it is well
ventilated, or while wearing an air-supplied respirator. Always have a trained
watch person nearby.
Arc rays from the welding process produce
intense visible and invisible (ultraviolet and
infrared) rays that can burn eyes and skin. Noise
from some processes can damage hearing. Chipping, grinding and weld cooling throw off pieces
of metal or slag.
6.Do not weld in locations near degreasing,
cleaning, or spraying operations. The
heat and rays of the arc can react with
vapors to form highly toxic and irritating
gases.
1.Use approved ear plugs or ear muffs if
noise level is high.
2.Use a welding helmet fitted with a proper
shade of filter to protect your face and
eyes when welding or watching.
7. Do not weld on coated metals, such as
galvanized, lead or cadmium plated steel,
unless the coating is removed from the
weld area, the area is well ventilated,
and if necessary, while wearing an airsupplied respirator. The coatings and any
metals containing these elements can give
off toxic fumes if welded.
3.Wear approved safety glasses with side
shields.
4.Use protective screens or barriers protect
others from flash and glare; warn others
not to watch the arc.
E.Cylinders
5.Wear protective clothing made from
durable, flame-resistant material (wool
and leather) and foot protection where
necessary.
D.
Cylinders can explode if damaged.
Shielding gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode.
Since gas cylinders are normally part of the
welding process, be sure to treat them carefully.
Fumes and Gases
Fumes and gases can be hazardous to your
health.
1.Protect compressed gas cylinders from
excessive heat, mechanical shocks, slag,
open flames, sparks, and arcs.
Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
2.Install cylinders in an upright position by
securing to a stationary support or cylinder rack to prevent falling or tipping.
1.Keep your head out of the fumes. Do not
breathe the fumes.
2.If inside, ventilate the area and/or use
exhaust at the arc to remove welding
fumes and gases.
3.Keep cylinders away from any welding
or other electrical circuits.
4.Never weld on a pressurized cylinder
- explosion will result.
3.If ventilation is poor, use an approved
air-supplied respirator.
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CWF-50 Cold Wire Feeder
5.Use only correct shielding gas cylinders,
regulators, hoses and fittings designed for
the specific application; maintain them
and associated parts in good condition.
6.Do not weld on closed containers such
as tanks, drums, or pipes, unless they are
properly prepared according to AWSF4.1
(see safety Standards).
6.Turn face away from valve outlet when
opening cylinder valve.
7. Keep protective cap in place over valve
except when cylinder is in use or connected for use.
7.Connect work cable to the work as close
to the welding area as practical to prevent
welding current traveling long, possibly
unknown paths and causing electric
shock and fire hazards.
8.Read and follow instructions on compressed gas cylinders, associated equipment, and CGA publication P-1 listed in
Safety Standards.
8.Wear oil-free protective garments such
as leather gloves, heavy shirt, cuffless
trousers, high shoes, and a cap.
G.
F.
Moving parts, such as fans, rotors, and belts can
cut fingers and hands and catch loose clothing.
Welding
Welding can cause fire or explosion.
Moving Parts
1.Keep all doors, panels, covers, and guards
closed and securely in place.
Welding on closed containers, such as tanks,
drums, or pipes, can cause them to blow up.
Sparks can fly off from the welding arc. The
flying sparks, hot workpiece, and hot equipment
can cause fires and burns. Accidental contact of
electrode to metal objects can cause sparks, explosion, overheating, or fire. Check and be sure
the area is safe before doing any welding.
2.Have only qualified people remove
guards or covers for maintenance and
troubleshooting as necessary.
H.
EMF Information
Considerations About Welding and the Effects of Low Frequency Electric and Magnetic
Fields
1. Protect yourself and others from flying
sparks and hot metal.
The following is a quotation from the General
Conclusions Section of the U.S. Congress, Office of Technology Assessment, Biological
Effects of Power Frequency Electric & Magnetic Fields - Background Paper, OTA-BP-E-53
(Washington, DC: U.S. Government Printing
Office, May 1989):
2.Do not weld where flying sparks can
strike flammable material.
3.Remove all flammables within 35 ft. (10.7
m) of the welding arc. If this is not possible, tightly cover them with approved
covers.
4.Be alert that welding sparks and hot materials from welding can easily go through
small cracks and openings to adjacent
areas.
5.Watch for fire, and keep a fire extinguisher nearby.
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CWF-50 Cold Wire Feeder
I.
“.... there is now a very large volume of scientific
findings based on experiments at the cellular
level and from studies with animals and people
which clearly establish that low frequency
magnetic fields can interact with, and produce
changes in, biological systems. While most of
this work is of very high quality, the results are
complex. Current scientific understanding does
not yet allow us to interpret the evidence in a
single coherent framework. Even more frustrating, it does not yet allow us to draw definite
conclusions abut questions of possible risk or to
offer clear science-based advice on strategies to
minimize or avoid potential risks.”
Principal Safety Standards
Reference as applicable
Safety in Welding and Cutting, ANSI Standard
Z49.1, from American Welding Society, 550
N.W. LeJeune Rd, Miami, FL 33126
Safety and Health Standards, OSHA 29 CFR
1910, from Superintendent of Documents, U.S.
Government Printing Office, Washington, D.C.
20402
National Electric Code, NFPA Standard 70 from
National Fire Protection Association, Batterymarch Park, Quincy, MA 02269
To reduce magnetic fields in the work place, use
the following procedures:
Recommended Safe Practices for the Preparation for Welding and Cutting of Containers That
Have Held Hazardous Substances, American
Welding Society Standard AWS F4.1, from
American Welding Society, 550 N.W. LeJeune
Rd, Miami, FL 33126
1.Keep cables close together by twisting or
taping them.
2.Arrange cables to one side and away from
the operator.
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, from Compressed Gas
Association, 1235 Jefferson Davis Highway,
Suite 501, Arlington, VA 22202
3.Do not coil or drape cables around the
body.
4.Keep welding power source and cables
as far away as practical.
Code for Safety in Welding and Cutting, CSA
Standard W117.2, from Canadian Standards
Association, Standards Sales, 178 Rexdale Boulevard, Rexdale, Ontario, Canada M9W 1R3
5.Connect work clamp to workpiece as
close to the weld as possible.
About Pacemakers:
Sales Practices for Occupation and Educational
Eye and Face Protection, ANSI Standard Z87.1,
from American National Standards Institute,
1430 Broadway, New York, NY 10018
The above procedures are among those also
normally recommended for pacemaker wearers.
Consult your doctor for complete information.
Cutting and Welding Processes, NFPA Standard
51B, from National Fire Protection Association,
Batterymarch Park, Quincy, MA 02269
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CWF-50 Cold Wire Feeder
Section II
Introduction
3.WGP-1 Wire Guide Positioner: guides
wire into puddle.
The cold wire feeder is designed to supply filler
metal to the weld puddle in a mechanized tungsten arc welding application. The system will
accurately feed 0.020”, 0.030”, 0.035”, 0.045”,
0.062” and 0.093” (0.5 to 2.4 mm) hard and soft
wires for mechanized TIG or plasma welding.
Note: The wire guide positioner can be
used either as a left hand or right hand
assembly. To change configuration as supplied by factory, reverse thumb knob, set
screw, and spring. (See WGP-1 drawing.
item numbers 13, 18, and 24.)
The wire feeder can be mounted as an assembly
or the components can be removed from the
mounting plate and installed in a number of
positions with respect to each other.
4.Spool adapter: holds 12” (305 mm) diameter wire spools.
The system consists of a 9629 control, D.C.
motor-driven four feed roll assembly, spool
adapter, and a wire guide positioner. The
positioner incorporates X-Y-Z movements of
the wire tip. The positioner includes a universal
torch mounting bracket.
5.Wire Feed Accessory Kit: conduit, feed
rolls, inlet guides, outlet guides, and tips
for 0.020”, 0.030”, 0.035”, 0.045”, 0.062”
and 0.093” (0.5 to 2.4 mm) hard and soft
wire. Order kits separately for desired
wire size.
The basic components of the wire feeder are:
(See Figure 1)
1.Wire drive unit: consists of motor, drive
housing, and wire spool assembly to feed
wire. (Part number CWF-50-DA.)
2.9629 Control: includes a keypad, display,
encoder control knob, start, stop, and
emergency stop switches. The SCR motor
controller is built into the control box and
provides a wire feed speed of 4 to 200 IPM
(10 to 508 CPM) with a speed holding
accuracy of +1% of base speed.
For operating details and function of controls, see 9629 Quick Start Guide.
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CWF-50 Cold Wire Feeder
6' CABLE
(1.8M)
UP
DOWN
ADJUST
etline
®
e n g in e e r in g
Series 9600 CONTROL
E-STOP
REV
POWER
START
FOR
STOP
CWF-50-DA
COLD WIRE FEEDER
9629
WIRE FEED CONTROL
etline
etline
®
®
e ngi ne e ring
e ngi ne e ring
MADE IN U.S.A.
MADE IN U.S.A.
6' POWER CORD
(1.8M)
607B
CLEAR SPOOL COVER (OPTIONAL)
WGP-1
WIRE GUIDE POSITIONER
CONDUIT
STANDARD LENGTH 6 FT
(1.8M)
Figure 1
CWF-50 Cold Wire Feeder
-6-
CWF-50 Cold Wire Feeder
Section III
Installation
As standard, the unit is provided with 6 ft. (1830
mm) of cable between the control and the wire
drive assembly. The control is typically mounted
near the feeder due to the length of the control
cable.
a.The inlet guide should be inserted
until the “set screw” properly aligns
with the notched section on the
guide. The closer the tapered tip is
to the feed rolls the better.
1.To mount the wire drive assembly, transfer mounting holes from the wire feeder’s
aluminum mounting plate to the mounting surface. (See Figure 2 for mounting
hole dimensions.)
b.The intermediate guide needs to be
inserted prior to the mounting of the
feed rollers. The intermediate guide
also has a “notched” section which
should align with the screw holding
it in position.
2.The 9629 control must be mounted in
a suitable manner providing adequate
ventilation. The control should not be
mounted in a high temperature environment.
c.The feed rolls need to be mounted
securely. If not tightened, they will
loosen and will eventually fall off.
d.The conduit assembly is then fitted
into the outlet guide assembly. This
step may need to be repeated in order to fit it correctly. First, the end
and inside of the conduit must be
deburred. The wire must slide freely
into the conduit.
3.Slip the wire guide positioner onto the
torch barrel and tighten the wing nuts.
You may choose from one of three sets
of mounting holes depending upon the
brand of the torch to be used.
The wire guide tip angle should be set
roughly by positioning the guide and
tightening the screw. The tip should be
approximately on the same level as the
tungsten.
Next the conduit should be chamfered. The conduit needs to be as
close as possible to the feed rolls
in order to avoid “bird-nesting”,
especially on soft wires. Putting a
chamfer on the conduit allows you
to get the conduit very close to the
feed rolls.
4.Select the wire feed accessory kit for the
size wire your application requires. The
kit will include inlet and outlet guides,
conduit, wire guide tip, and feed rolls. Be
sure all components match the wire size
to be used. (Refer to Figure 3)
At this point, slide the conduit
through the outlet guide. You
should extend the conduit beyond
the tapered end of the outlet guide
approximately 1/4” (6 mm). Tighten
the set screw securely, holding the
conduit properly in position.
Proper installation of the wire feed kit is
very critical to the successful operation
of the cold wire feed unit. Proper installation helps avoid “bird-nesting” at the
feed rolls and smooth wire feed delivery
into the weld puddle.
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CWF-50 Cold Wire Feeder
The wire guide tip is held in position by
a set screw. The tip can slide into the
clamping mechanism on the WGP-1 Wire
Guide Positioner.
e.Insert the outlet guide/conduit assembly into the drive roll assembly.
Position it so the chamfered conduit
is very close to the drive rolls. (Make
sure the end of the outlet guide is
clear of the drive rolls.) Tighten the
outlet guide securely by turning the
hand knob.
5.
Electrical Connections:
As standard, the feeder is shipped with
an electrical connector and 6 ft. (1380
mm) cord suitable for 115 volts 50/60 Hz
power supply. Operation for 220 volts is
configurable.
f.Run the conduit to the torch as required. Remember sharp twists and
turns affect the flow of the wire. Test
the path of the conduit with the torch
in its fully retracted and extended
positions.
If you need to start the wire feeder from
a remote signal, you must supply a normally open, maintained contact closure
to Connector S2, Pins A and B.
If the conduit is too long, cut the
end, making sure it is completely
deburred.
g.Strip 4” (100 mm) of the outer cover
on the conduit. Slide the bare conduit into the wire guide tip. Tighten
the set screw holding the conduit
securely into position.
Note: On a rare occasion, you may
have to pull this end of the conduit
from the tip when initially feeding
wire. Let the wire extend about 6”
to 8” (150 to 200 mm) beyond the
conduit and then feed the wire into
the tip until the conduit is back into
normal position.
-8-
CWF-50 Cold Wire Feeder
Figure 2
Mounting Plate Dimensions
-9-
CWF-50 Cold Wire Feeder
- 10 -
CWF-50 Cold Wire Feeder
Section IV
Operating Instructions
A.
tungsten. This action could also cause
adverse effects with the arc length control.
Preparation for Welding
Mount the spool of welding wire on the spool
adapter so the wire will be pulled from the low
side of the coil. Adjust the friction brake on the
wire spool by adjusting the screw in the center
of the spool. If adjusted properly, the spool will
feed smoothly and will not coast or continue to
spin when feeding stops.
When the wire is inched forward, this is
a good time to verify the wire’s position.
Adjust if necessary.
3.Retract wire to desired starting position
using the Reverse key.
4.Check wire and wire spool briefly. Verify there is enough wire for the next weld
and that the wire is not wrapped around
the spool holder.
Debur the end of the wire, then insert it into the
inlet guide through the feed rolls and the outlet
guide. (Refer to Figure 3).
Press the power switch to the “On” position
and feed the wire into the conduit by pressing “Forward” key. Continue to feed the wire
through the conduit and the wire guide tip until
a desired amount extends beyond the tip.
5.Check wire feed speed setting, the start
delay setting, and the stop retract setting.
These settings are critical to achieve the
desired weld.
6.At this point, the unit is ready to feed
wire. If the starting and stopping of the
wire is controlled remotely, the control
will go through the start delay. Once
this delay has timed out, the unit will
proceed to feed wire at the rate set on
the dial.
See the Quick Start Guide for various jog
modes.
B.Operation
9629 Control:
The operation of a CWF-50 is not difficult. The
following sequence is suggested:
When the remote start signal quits, the
unit will go through the stop delay, then
stop. The unit then proceeds to enter the
wire retract time, pulling the wire out of
the weld zone. This action prevents the
wire from sticking in the weld puddle at
the end of the weld.
1.Turn on power to unit.
2.Using the Forward key, inch the wire
forward a little. Trim the wire if there is
a ball on the end of the wire. This step is
especially necessary if feeding wire and
using an arc length control. A ball on the
end of the wire could touch the tungsten
when feeding initially. If the wire contacts the tungsten, you will get a “ball”
on the end of the tungsten. The operator
should stop the weld and resharpen the
Note: If the retract time is set too long,
the wire could retract up into the wire
tip. If this happens, the wire could, on
occasion, get stuck on the tip on the next
weld.
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CWF-50 Cold Wire Feeder
7.If the unit is used manually, the operator
will press the Start button when ready to
feed wire. The start delay will NOT be
activated when using this method. Wire
will feed immediately once in the Run
position.
When wire is no longer required the operator presses the Stop button. The unit
will stop feeding wire immediately and
go into the wire retract procedure.
C.
Wire Guide Positioner
Several adjustments are provided on the wire
guide positioner in order to permit the exact
position of the wire as it enters the puddle.
1.Lateral adjustment of 1/4” (1/8” adjustment of tip on each side of weld seam).
(6.4 mm total adjustment, 3.2 mm on
each side.)
2.Vertical adjustment of 1/4” (6.4 mm) tip
to work.
3.Coarse adjustment of guide tip angle, by
loosening screw and setting in approximate position.
The wire position should be checked at the beginning of the weld.
Jog the wire forward through the control and
make required adjustments on the positioner.
Wire typically enters the weld puddle at the
leading edge of the puddle. The wire should
contact the work piece about .04” (1 mm) in
front of the weld puddle and slide under the
center of the welding arc.
Check tension of drive roll spring. Too much
pressure will deform the wire and too little
pressure will cause wire slippage.
- 12 -
CWF-50 Cold Wire Feeder
Figure 3
Wire Feed Accessory Kit Components
- 13 -
CWF-50 Cold Wire Feeder
- 14 -
CWF-50 Cold Wire Feeder
Section V
Wire Feed Accessory Kits
Wire Size
0.020”
(0.5 mm)
0.030”
(0.8 mm)
0.035”
(0.9/1 mm)
0.045”
(1.2 mm)
0.062”
(1.6 mm)
0.093”
(2.4 mm)
*Complete Conduit - 6
Outlet
Inlet Guide Wire Guide Feed Rolls **Curved
Accessory
ft (2 m)
Guide
Tip
& Inlet
Wire Guide
Kit
Guide
Tip
20B6020K 42-23
OG-020
056192
WGT-020 053693
N/A
PT-40-NAT
20B6030K 44N3545
OG-035-45 056192
WFT-030
046780
CWGT-030
20B6035K
44N3545
OG-035-45 056192
WGT-035
046781
CWGT-035
20B6045K
44N3545
OG-035-45 056193
WGT-045
046782
CWGT-045
20B6062K
45N116
OG-062
056195
WGT-062
046784
N/A
20B6093K
18630F
OG-17
056196
WGT-093
046789
N/A
*Includes inlet and outlet guides, feed rolls, wire guide tip, and 6 ft (2 m) conduit.
**Requires WGP-3 wire guide positioner for curved tips.
Wire Feed Roll Kits, parts and optional items are sold separately.
- 15 -
CWF-50 Cold Wire Feeder
- 16 -
CWF-50 Cold Wire Feeder
Section VI
Maintenance
Periodically clean the drive rolls of dirt and
chips. Occasionally check the wear of liners,
tips, and guides.
Always replace fuse with one of equal value —
3 amp fast blow.
Periodically check, and replace if necessary,
the carbon brushes on the motor. Failure to replace worn brushes could cause severe damage
to motor control.
WARNING
Maintenance and electrical work must be
performed by experienced and trained personnel.
CAUTION
Whenever repairs are required, always turn
all power controls off and disconnect all electrical cables from power supply.
- 17 -
CWF-50 Cold Wire Feeder
- 18 -
CWF-50 Cold Wire Feeder
Section VII
Optional Accessories
Jetline offers the WGP-2ES motorized positioner
so the operator can adjust the position of the
wire from a remote location. The positioner includes the motorized wire positioner, the motor control, and a joystick pendant which the
operator uses to move the wire guide tip to the
desired position. Speed of motion is adjustable
to provide accurate positioning as desired by
the operator.
When you purchased your cold wire feeder,
you may not have been aware of optional enhancements for your unit. Jetline is pleased to
offer these enhancements which can be added
to your system in the field.
If you are interested in these features, please
do not hesitate to contact Jetline directly or the
nearest distributor for more information.
A.
607B Spool Cover
C.WGP-3 Compact Wire Guide
Positioner
The 607B is a clear plastic cover designed and
manufactured for Jetline’s wire feeders. The
cover mounts around the spool holder and encases the standard “30 lb/12 inch” wire spool
which fits onto the spool mounting adaptor. The
main purpose of the cover is to protect the wire
from dust and weld particle build-up. The clear
plastic allows the operator to see the spool effectively. Installing the spool cover is a simple,
perhaps 5 minute, job.
In some applications, the space envelope required by the standard WGP-1 is too large.
Jetline manufactures a wire guide positioner
which requires less space, yet still gives the
operator the ability to adjust the wire position.
The WGP-3 is designed to attach directly to
the torch, but includes a curved wire guide tip.
Wire is fed vertically until the moment where it
is angled into the weld puddle.
B.WGP-2ES Motorized Wire
Guide Positioner
D.CHWS-100 Wire Straightener
In some applications, minor deviations in wire
position are a result of the cast in the wire. The
wire straightener can help limit the twist by using a 3 roll action. Tension on the center roll
is adjustable. The unit mounts on the inlet side
of the drive roll assembly. The straightener is
designed to work on 0.035” and 0.045” (0.9/1.0
and 1.2 mm) wire.
The standard wire feed unit is provided with a
manually adjusted WGP-1 wire guide positioner.
In some applications, the operator cannot easily get to the positioner to make the desired alterations to the wire’s location as it enters the
weld puddle. Due to the cast and helix in some
wires, the need to adjust the wire’s position can
be required.
- 19 -
CWF-50 Cold Wire Feeder
- 20 -
CWF-50 Cold Wire Feeder
Section VIII
Parts Lists
The following parts lists are included in this
manual. Their appropriate page numbers are
listed.
The following pages provide a detailed parts
list of all the elements of the cold wire feed
unit. They are arranged so that the parts list
on the right hand page corresponds with the assembly illustrated on the left hand page. Item
numbers shown in the parts list refer to those
numbers contained in the balloons in the drawing. On each parts list, the quantities shown
are the number of items used in that particular
assembly.
Cold Wire Feeder Assembly................... 22/23
WGP-1 Wire Guide Positioner................ 24/25
WGP-2ES Wire Guide Positioner........... 26/27
WGP-3 Wire Guide Positioner................ 28/29
Two columns are included in the list to show
the spare parts which are recommended to be
stocked by the user. The two levels can be defined as follows:
Level 1These are the spares recommended
for US domestic users whose use of
the product does not exceed 2000
hours per year.
Level 2These are the spares recommended
for international use of the product or
for US domestic users who will use
the products in excess of 2000 hours
per year.
- 21 -
CWF-50 Cold Wire Feeder
- 22 -
CWF-50 Cold Wire Feeder
CWF-50-DA
Cold Wire Feeder Assembly
Recommended
ItemPartLevelLevel
No.No.
Description
Qty
I
II
2
CWF-20B-100
3
CWF-20B-110
4
CWF-20B-120
5
046779
053842
10-32x7/8
1/2-20x1 1/4
6
0467__
7
OG-030/045
8
44N3545
9
WGT-0__
10
CWF-10-WG-60
11
95611AO31
12
8527K134
13
14
15
053841
16
374831-A
17
MT3353-42CZ
18
6010
19
3106A-145-6P
20
CWF-10-4R-9
21
CWF-20B-140
22
8-32X5/8
23
8-32X5/16
24
1/4-20X1/2
25
1/4-20X5/8
26
3/8-16X1 1/4
27
3/8
Mounting Plate..........................................................1
Mounting Bracket.....................................................1
Cover Assembly........................................................1
Drive Housing, includes:..........................................1
Housing.....................................................................1
Gear...........................................................................42
Flat Head Screw......................................................12
Hex Head Screw.......................................................4
Gear Driven Roll Kit.................................................1
(See chart in Section V for complete part number)
Outlet Guide (See chart in Section V)......................1
Conduit and Liner (See chart in Section V)..............1
Wire Guide Tip..........................................................1
(See chart in Section V for complete part number)
Gear Reducer............................................................1
Insulating Washer......................................................1
Insulating Tube, 36” (914 mm) length......................1
Natural Hard Fiber Insulation...................................2
Natural Hard Fiber Insulation...................................2
Drive Gear.................................................................11
Spool Adapter............................................................1
Motor, DC Servo, with flange...................................1
Shielded Cable, 8 ft (2.5 m)......................................1
Cable Connection......................................................1
Set Screw Collar.......................................................1
Retainer.....................................................................1
Socket Head Screw...................................................1
Button Head Screw...................................................4
Socket Head Screw...................................................4
Flat Head Screw........................................................4
Hex Head Screw.......................................................2
Flat Washer...............................................................2
- 23 -
- 24 WGP-1
L
4/14/08
WIRE GUIDE POSITIONER
CWF-50 Cold Wire Feeder
CWF-50 Cold Wire Feeder
WGP-1 (Rev L)
Wire Guide Positioner
Recommended
ItemPartLevelLevel
No.No.
Description
Qty
I
II
2 WGP-1-230
Base...........................................................................1
3
WGP-1-100 (REV E) Cam Plate..................................................................1
4 WGP-1-200
Housing.....................................................................1
5
WGP-1-210 (REV E) Bar.............................................................................1
6 WGP-1-220
Clamp........................................................................1
7
WGP-XXX
Shown for Reference (part of Wire Feed Kit)
8 WGP-1-240
Stud...........................................................................2
9 WGP-1-250
V-Block.....................................................................21
10
Guide, Dowell...........................................................1
11
Fulcrum Pin, Dowell.................................................1
12
Hinge Pin, Dowell.....................................................1
13
CL-1-KHS
Knurled Head Screw.................................................111
14
CL-1-KN
Knurled Nut..............................................................111
15
CL-1-SB
Swing Bolt................................................................1
16
WGP-1-16
Lift Pin......................................................................1
17
6655K13
Thrust Bearing..........................................................1
18
VV-38
Compression Spring..................................................11
19
1/4-20x7/8
Socket Head Screw...................................................2
20
1/4-20x5/8
Socket Head Screw...................................................222
21
1/4
Flat Washer...............................................................1
22
11256
Compression Spring..................................................11
23
3025
Knob..........................................................................211
24
3/8-16-5/16
Nylock Set Screw......................................................1
25
WGP-1-260
V-Mount (Optional Item, Large Clamp Kit).............1
26
WGP-1-261
V-Clamp (Optional Item, Large Clamp Kit).............1
27
WGP-1-262
Stud (Optional Item, Large Clamp Kit)....................2
28
1/4-20-5/8
Socket Head Screw...................................................2
29
WGP-1-263
Base Extension (Optional Item, extended base).......1
Socket Head Screw (Optional Item, extended base).....2
30
1/4-20x3/4
31
6435K12
Collar, 1/4 diameter...................................................1
32
6391K143
Bronze Bearing, 1/4 x 1/2 x 1...................................1
- 25 -
- 26 WGP-2ES
E
4/10/08
COLD WIRE GUIDE POSITIONER,
SPECIAL MOTORIZED VERSION
CWF-50 Cold Wire Feeder
CWF-50 Cold Wire Feeder
WGP-2ES (Rev E)
Motorized Wire Guide Positioner
Recommended
ItemPartLevelLevel
No.No.
Description
Qty
I
II
2
WGP-1
5
WGP-2-5 (REV C)
6 WGP-2-6
7
WGP-2-7
8
WGP-2-10
9
1375K34
10
WGP-2-10
11
1679K86
12
WGP-2-9
13
4-40x1/4
14
DWM-202
15
#2-216
16
9045
17
Basic Wire Guide Assembly.....................................1
Motor Bracket, detail................................................1
Screw.........................................................................1
Motor Bracket, detail................................................1
Driven Pulley, detail..................................................1
Driven Pulley, detail..................................................2
Driven Pulley............................................................1
Belt............................................................................211
Motors and Cable Assembly, set...............................1
Socket Head Screw...................................................6
Cover.........................................................................2
O-ring seal.................................................................4
Control Assembly, for reference
Lift Pin, detail...........................................................1
- 27 -
- 28 WGP-3
D
4/10/08
COMPACT WIRE GUIDE POSITIONER,
FOR COLD WIRE FEEDERS
CWF-50 Cold Wire Feeder
CWF-50 Cold Wire Feeder
WGP-3
Compact Wire Guide Positioner
Recommended
ItemPartLevelLevel
No.No.
Description
Qty
I
II
2
WGP-3-2
3
WGP-3-3
4
WGP-3-4
5
WGP-3-5
6
WGP-1-250
7 WGP-1-240
8
WGP-3-8
9
WGP-3-9
10
WGP-3-10
11
WGP-3-11
12
13
XX-68
14
L-35
15
2813
16
CL-1-KHS
17
CL-6-KHS
18
CL-2-SLB
19
1/4-20x3/4
20
1/4
21
1/420
22
1/4-20x2 1/4
23
1/8x3/4
24
CWGT
25
3025
Base Detail................................................................1
Yoke Detail...............................................................1
Slide Detail................................................................1
Rotor Detail...............................................................1
V-Block Detail..........................................................21
Stud...........................................................................2
Pin Detail..................................................................1
Clamp Detail.............................................................1
Tube Detail................................................................1
Spacer Detail.............................................................1
Fender Washer...........................................................1
Compresion Pin.........................................................11
Compresion Pin.........................................................11
Compresion Pin.........................................................1
Knurled Head Screw.................................................111
Knurled Head Screw.................................................111
Button, radius loc......................................................1
Socket Head Screw...................................................322
Flat Washer...............................................................1
Hex Nut.....................................................................1
Hex Head Screw.......................................................1
Roll Pin.....................................................................1
Curved Wire Guide Tip Detail..................................1
Knob..........................................................................211
- 29 -