OM-CWF-23E-01-2013 OPERATION MANUAL for CWF-23E-9900 Dabber-Type Wire Feeder January 2013 Preliminary Manual 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] CWF-23E Dabber-Type Wire Feeder - ii - CWF-23E Dabber-Type 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. - iii - CWF-23E Dabber-Type 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. - iv - CWF-23E Dabber-Type 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 Introduction............................................................................................................................. 5 A. Description of Dabber-type Wire Feed Action............................................................. 5 Section III..................................................................................................................................... 7 Specifications........................................................................................................................... 7 A. System Components..................................................................................................... 7 B. Operating Specifications............................................................................................... 7 Section V ���������������������������������������������������������������������������������������������������������������������������������������11 Maintenance........................................................................................................................... 11 Section VI ���������������������������������������������������������������������������������������������������������������������������������������13 Parts Lists.............................................................................................................................. 13 -v- CWF-23E Dabber-Type Wire Feeder - vi - CWF-23E Dabber Type 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. -1- CWF-23E Dabber Type 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. -2- CWF-23E Dabber Type 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.Welding Moving parts, such as fans, rotors, and belts can cut fingers and hands and catch loose clothing. 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. -3- CWF-23E Dabber Type 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: 1.Keep cables close together by twisting or taping them. 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 2.Arrange cables to one side and away from the operator. 3.Do not coil or drape cables around the body. 4.Keep welding power source and cables as far away as practical. Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, from Compressed Gas Association, 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202 5.Connect work clamp to workpiece as close to the weld as possible. About Pacemakers: 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 The above procedures are among those also normally recommended for pacemaker wearers. Consult your doctor for complete information. 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 Cutting and Welding Processes, NFPA Standard 51B, from National Fire Protection Association, Batterymarch Park, Quincy, MA 02269 -4- CWF-23E Dabber Type Wire Feeder Section II Introduction Figure 3: The Jetline CWF-23E dabber type wire feeder is designed to be controlled by the 9900 Controller and can be used with the GTAW or PAW process. At the moment when the welding current goes “Low”, the wire feed speed is reversed and the wire is retracted away from the welding puddle at the Pullback Speed, programmed in the Configuration screen. The Retract distance is programmed in the Weld Program Editor screens. Please refer to the 9900 Controller manual for more programming details. A. Description of Dabber-type Wire Feed Action Figure 4: The dabber-type wire feed can be described as a 4-step process when the action is synchronized with the weld current pulse. The figures on the following page will help to understand it more clearly. During the “Low” portion of the weld current, the pulse wire is in the retracted position and not moving. On the next pulse of the weld current, the entire process is repeated which results in controlled wire feed only during the “High” portion of the weld current pulse. Figure 1: Wire is retracted from the weld puddle. At the moment when the weld current goes “High”, wire is advanced towards the welding puddle at the programmed Pullback Speed, or at ½ this speed if the Digital Wire Feed configuration is in Config 1. If in Config 0, the wire advances at the same speed as the Pullback Speed (see below). Figure 2: After reaching the welding puddle, the wire feed speed is changed to a programmed value and wire is fed into the weld during the “High” time of the welding current pulse. For example, at a frequency of 3 Hz and a duty cycle of 50%, this time will be approximately 160 msec. -5- CWF-23E Dabber Type Wire Feeder DABBER WIRE FEEDER OPERATION -6- CWF-23E Dabber Type Wire Feeder Section III Specifications A. B. System Components The CWF-23 Dabber type wire feeder 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. The system consists of a D.C. motor-driven two 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. The basic components of the wire feeder are: 1.Wire drive unit: consists of motor, drive housing, and wire spool assembly to feed wire. (Part number CWF-10A-130.) 2.WGP-3 or WGP-1 Wire Guide Positioner: guides wire into puddle. Note: The WGP-1wire guide positioner (available as an alternate) 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.) 4.Spool adapter: holds 12” (305 mm) diameter wire spools. 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. -7- Operating Specifications Wire Feed Speed: 2 to 150 IPM 51 to 3810 mm/min Pulsing Frequency: 0.5 to 12 pulses/second CWF-23E Dabber Type Wire Feeder Spoolholder 0.31 (8) 5.25 (133) 2 (51) 13.375 (340) 8 (203) 0.375 (9.5) 22 (560) 6 (152) TWO ROLL DRIVE HOUSING Dimensions are in inches (millimeters) -8- CWF-23E Dabber Type Wire Feeder Section IV 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 10A6020K 42-23 OG-020 056192 WGT-020 087131 N/A PT-40-NAT 10A6030K 44N3545 OG-035-45 056192 WFT-030 079594 CWGT-030 10A6035K 44N3545 OG-035-45 056192 WGT-035 079595 CWGT-035 10A6045K 44N3545 OG-035-45 056193 WGT-045 079956 CWGT-045 10A6062K 45N116 OG-062 056195 WGT-062 079598 N/A 10A6093K 18630F OG-17 056196 WGT-093 079603 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. -9- CWF-23E Dabber Type Wire Feeder - 10 - CWF-23E Dabber Type Wire Feeder Section V 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. - 11 - CWF-23E Dabber Type Wire Feeder - 12 - CWF-23E Dabber Type Wire Feeder Section VI 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 CWF-23E. They are arranged so the parts list on the right hand page corresponds to the assembly illustrated on the left hand page. Item numbers shown in the parts list refer to those numbers contained in the balloon in the drawing. The quantities shown are the number of items used in that particular assembly. CWF-23E...............................................14-15 9900-MCMD-1......................................16-17 WGP-3...................................................18-19 WGP-1...................................................20-21 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 product in excess of 2000 hours per year. - 13 - CWF-23E Dabber Type Wire Feeder - 14 - CWF-23E Dabber Type Wire Feeder CWF-23E Dabber-Type Wire Feeder Assembly Recommended ItemPartLevelLevel No.No. Description Qty I II 2 3 7/16-14x11/4 4 7/16 5 HWF-17-131 6 CWF-23D-6 7 455502 8 CWF-23D-8 9 10 11 CWF-23D-11 12 5/16-18x3/4 13 CWF-23-13 14 CWF-23-14 15 TLY-A220 16 1/4-20x1/2 17 1/4 18 1/4 19 9376K147 20 5/16-18x11/4 21 5/16 22 5/16 23 CWF-23D-23 24 CWF-23D-100 Drive Housing...........................................................1 Hex. Head Screw......................................................2 Lock Washer.............................................................2 Shaft detail................................................................1 Spacer Detail.............................................................1 Bearing......................................................................1 Half Coupling detail..................................................1 Polyurethane Insert...................................................1 Drive Bracket detail..................................................1 Button Head Screw...................................................2 Base detail.................................................................1 Coupling Spacer detail..............................................2 Motor........................................................................1 Hex. Head Screw......................................................1 Lock Washer.............................................................1 Flat Washer...............................................................1 Rubber Stud Bumper.................................................8 Socket Head Screw...................................................8 Flat Washer...............................................................8 Lock Washer.............................................................8 Rubber Bumper Support...........................................1 Mounting Plate detail................................................1 - 15 - CWF-23E Dabber Type Wire Feeder - 16 - CWF-23E Dabber Type Wire Feeder 9900-MCMD-1 Motor Control Module Recommended PartLevelLevel No. Description Qty III 9900-10-U EL-50T PSA15LN3-050 PBA10F-24 23F230 AGC-10 20VK1 37N1998 2098-DSD-010 Interface Board with CPU.........................................111 Fiber Optic Media Converter....................................111 Power Supply, 5VDC................................................111 Ref. Desig. PS1 Power Supply, 24 VDC.............................................111 Ref. Desig. PS2 Switch, Toggle, SPST...............................................1 Ref. Desig. SW1 Fuse, 1 1/4”, 10 Amp, 250V.....................................133 Ref. Desig. F1 RF Filter, 250V, 20 Amp...........................................1 Ref. Desig. RF1 Pilot Light, 120V, Red..............................................111 Ref. Desig. PL1 Brushless Servo Drive...............................................111 Ref. Desig. MC1 - 17 - - 18 WGP-3 D 4/10/08 COMPACT WIRE GUIDE POSITIONER, FOR COLD WIRE FEEDERS CWF-23E Dabber Type Wire Feeder CWF-23E Dabber Type 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 - 19 - - 20 - 4/14/08 L WGP-1 WIRE GUIDE POSITIONER CWF-23E Dabber Type Wire Feeder CWF-23E Dabber Type Wire Feeder WGP-1 (Rev L) Wire Guide Positioner - (Available as an alternate) 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 - 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