Miller | MH000000 | Owner Manual | Miller JETLINE 9900-CWF-23 DABBER TYPE WIRE FEEDER User manual

Miller JETLINE 9900-CWF-23 DABBER TYPE WIRE FEEDER  User manual
OM-CWF-23E-01-2013
OPERATION MANUAL
for
CWF-23E-9900
Dabber-Type Wire Feeder
January 2013
IMPORTANT
Read this manual carefully before installing,
commissioning or operating this product.
Miller Welding Automation, 281 E. Lies Rd., Carol
Stream, Il 60188
Telephone: (949) 951-1515 • Fax: (949) 951-9237
Web Site: www.jetline.com • E-mail: sales@jetline.com
CWF-23E Dabber-Type Wire Feeder
LIMITED WARRANTY
Components or parts manufactured directly by Miller Electric Mfg. Co. are subject to Miller’s True Blue® Warranty set forth
at www.millerwelds.com/support/warranty. Seller does not make any warranties for components or parts not
manufactured directly by Jetline Engineering, Miller Welding Automation, and Panasonic Welding Systems Company; such
components or parts are subject to the warranty terms of the respective manufacturer. Components and parts
manufactured by Jetline Engineering, Miller Welding Automation, and Panasonic Welding Systems Company are subject to
the following warranty terms. Terms and Conditions of Sale Seller warrants to Purchaser that the components or parts
manufactured by Seller or Panasonic Welding Systems Company shall be free from defects in material and workmanship,
and shall conform to the Seller’s specifications for the following periods:
a. 12 months from the date of shipment of the Products for components and equipment manufactured by
Panasonic Welding Systems Company including robot manipulator, controller and connecting cables; external axis
components (external axis base unit, servo amplifiers, motors, connecting cables and pre-engineered positioners);
peripheral devices (high voltage touch sensors, thru arc seam trackers); welding power sources (internally built
into the robot controller cabinet); wire feeders (separated design or integrated design, i.e. Active Wire
Torch/Feeder); or
b. 12 months from date of shipment of the Products for equipment manufactured by Jetline Engineering or Miller
Welding Automation.
In the event of a breach of the warranties set forth above, Seller will, at Seller’s option and as Seller’s sole liability and
Purchaser’s sole remedy, repair, replace or credit Purchaser’s account for, any Product that fails to conform to the above
warranty, provided that (i) during the applicable warranty period Seller is promptly notified in writing upon discovery of
such failure with a detailed explanation of any alleged deficiencies; (ii) Seller is given a reasonable opportunity to
investigate all claims; and (iii) Seller’s examination of such Product confirms the alleged deficiencies and that the
deficiencies were not caused by accident, misuse, neglect, improper installment, unauthorized alteration or repair or
improper testing. No Products may be returned to Seller until inspection and approval by Seller. All warranty work
performed shall be FOB Seller’s facility (Incoterms 2010) and freight for returned Products shall be paid for by Purchaser.
The above warranty against defects does not apply to: (1) consumable components or ordinary wear items including but
not limited to torches; or (2) defects due to (i) failure to install and perform maintenance set forth in Product
documentation, (ii) the use of components, parts, peripherals, attachments, accessories, or perishable tooling not
approved by Seller, (iii) accident, misuse, neglect, abuse, mishandling, misapplication, modification, alteration, acts of God,
or (iv) improper installation, service or maintenance. Purchaser and/or the operator of the Products are in full control of
the weld process. Seller makes no warranty regarding the quality or the success of the welds on the Products due to
factors under Purchaser’s and/or operator’s control including but not limited to welding procedures, material types,
material coatings, joint/part fit, part geometry, metallurgy, welding gases, proper machine/process maintenance, and
operator skill. EXCEPT AS SET FORTH ABOVE, SELLER MAKES NO WARRANTY OR REPRESENTATION OF ANY KIND, EXPRESS
OR IMPLIED (INCLUDING NO WARRANTY OF MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE).
- See more at: https://www.millerwelds.com/automation-terms-of-sale#sthash.l5oRebWB.dpuf
- ii -
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.
- iii -
CWF-23E Dabber-Type Wire Feeder
CONTENTS
Section I .................................................................................................................................................................... 1
SAFETY PRECAUTIONS – READ BEFORE USING (som 2013-09) .................................................................... 1
1.1 Symbol Usage ................................................................................................................................................. 1
1.2 Arc Welding Hazards ...................................................................................................................................... 1
1.3 Additional Symbols for Installation, Operation, And Maintenance ............................................................... 4
1.4 California Proposition 65 Warnings ................................................................................................................ 6
1.5 Principal Safety Standards .............................................................................................................................. 6
1.6 EMF Information............................................................................................................................................. 6
Section II ................................................................................................................................................................... 7
Introduction .............................................................................................................................................................. 7
Description of Dabber-type Wire Feed Action ..................................................................................................... 7
Section III .................................................................................................................................................................. 9
Specifications ......................................................................................................................................................... 9
System Components ............................................................................................................................................. 9
Operating Specifications....................................................................................................................................... 9
Section IV ................................................................................................................................................................ 11
Wire Feed Accessory Kits........................................................................................................................................ 11
Section V ................................................................................................................................................................. 12
Maintenance........................................................................................................................................................... 12
Section VI ................................................................................................................................................................ 13
Parts Lists ................................................................................................................................................................ 13
4
CWF-23E Dabber-Type Wire Feeder
-1-
SECTION I
SAFETY PRECAUTIONS – READ BEFORE USING
(som 2013-09)
Protect yourself and others from injury – read, follow and save these important safety precautions and operating instructions.
1.1 Symbol Usage
DANGER! − Indicates a hazardous situation which, if not avoided, will result in death or serious injury. The possible hazards are shown in the
adjoining symbols or explained in the text.
Indicates a hazardous situation which, if not avoided, could result in death or serious injury. The possible hazards are shown in the adjoining symbols or
explained in the text.
NOTICE − Indicates statements not related to personal injury.
 Indicates special instructions.
This group of symbols means: Warning! Watch Out! ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.
Consult symbols and related instructions below for necessary actions to avoid the hazards.
1.2 Arc Welding Hazards
The symbols shown below are used throughout this manual to call attention to and identify possible hazards. When you see the symbol,
watch out, and follow the related instructions to avoid the hazard. The safety information given below is only a summary of the more
complete safety information found in the Safety Standards listed in Section 1-5. Read and follow all Safety Standards.
Only qualified persons should install, operate, maintain, and repair this unit.
During operation, keep everybody, especially children, away.
ELECTRIC SHOCK can kill.
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. In semiautomatic or automatic wire welding, 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.
•
Do not touch live electrical parts.
•
Wear dry, hole-free insulating gloves and body protection.
•
Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work
or ground.
•
Do not use AC output in damp areas, if movement is confined, or if there is a danger of falling.
•
Use AC output ONLY if required for the welding process.
•
If AC output is required, use remote output control if present on unit.
•
Additional safety precautions are required when any of the following electrically hazardous conditions are present: in damp locations
or while wearing wet clothing; on metal structures such as floors, gratings, or scaffolds; when in cramped positions such as sitting,
kneeling, or lying; or when there is a high risk of unavoidable or accidental contact with the work piece or ground. For these
conditions, use the following equipment in order presented: 1) a semiautomatic DC constant voltage (wire) welder, 2) a DC manual
(stick) welder, or 3) an AC welder with reduced open-circuit voltage. In most situations, use of a DC, constant voltage wire welder is
recommended. And, do not work alone!
•
Disconnect input power or stop engine before installing or servicing this equipment. Lockout/tagout input power according to OSHA
29 CFR 1910.147 (see Safety Standards).
•
Properly install, ground, and operate this equipment according to its Owner’s Manual and national, state, and local codes.
•
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.
•
When making input connections, attach proper grounding conductor first − double-check connections.
•
Keep cords dry, free of oil and grease, and protected from hot metal and sparks.
•
Frequently inspect input power cord and ground conductor for damage or bare wiring – replace immediately if damaged – bare
wiring can kill.
•
Turn off all equipment when not in use.
-1•
Do not use worn, damaged, undersized, or repaired cables.
•
Do not drape cables over your body.
CWF-23E Dabber-Type Wire Feeder
•
•
•
•
•
•
•
•
•
•
If earth grounding of the workpiece is required, ground it directly with a separate cable.
Do not touch electrode if you are in contact with the work, ground, or another electrode from a different machine.
Do not touch electrode holders connected to two welding machines at the same time since double open-circuit voltage will be
present.
Use only well-maintained equipment. Repair or replace damaged parts at once. Maintain unit according to manual.
Wear a safety harness if working above floor level.
Keep all panels and covers securely in place.
Clamp work cable with good metal-to-metal contact to workpiece or worktable as near the weld as practical.
Insulate work clamp when not connected to workpiece to prevent contact with any metal object.
Do not connect more than one electrode or work cable to any single weld output terminal. Disconnect cable for process not in use.
Use GFCI protection when operating auxiliary equipment in damp or wet locations.
SIGNIFICANT DC VOLTAGE exists in inverter welding power sources AFTER removal of input power.
•
Turn Off inverter, disconnect input power, and discharge input capacitors according to instructions in Maintenance Section before
touching any parts.
HOT PARTS can burn.
•
•
•
Do not touch hot parts bare handed.
Allow cooling period before working on equipment.
To handle hot parts, use proper tools and/or wear heavy, insulated welding gloves and clothing to prevent burns.
FUMES AND GASES can be hazardous.
Welding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health.
•
Keep your head out of the fumes. Do not breathe the fumes.
•
If inside, ventilate the area and/or use local forced ventilation at the arc to remove welding fumes and gases. The recommended way
to determine adequate ventilation is to sample for the composition and quantity of fumes and gases to which personnel are
exposed.
•
If ventilation is poor, wear an approved air-supplied respirator.
•
Read and understand the Safety Data Sheets (SDSs) and the manufacturer’s instructions for adhesives, coatings, cleaners,
consumables, coolants, degreasers, fluxes, and metals.
•
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. Welding fumes and gases can displace air and lower the oxygen level causing injury or death. Be sure the breathing air is
safe.
•
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.
•
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 while wearing an air-supplied respirator. The coatings and any metals containing these elements can
give off toxic fumes if welded.
ARC RAYS can burn eyes and skin.
Arc rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin. Sparks fly off
from the weld.
•
Wear an approved welding helmet fitted with a proper shade of filter lenses to protect your face and eyes from arc rays and sparks
when welding or watching (see ANSI Z49.1 and Z87.1 listed in Safety Standards).
•
Wear approved safety glasses with side shields under your helmet.
•
Use protective screens or barriers to protect others from flash,glare and sparks; warn others not to watch the arc.
•
Wear body protection made from durable, flame−resistant material (leather, heavy cotton, wool). Body protection includes oil-free
clothing such as leather gloves, heavy shirt, cuffless trousers, high shoes, and a cap.
2
WELDING can cause fire or explosion.
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.
•
Remove all flammables within 35 ft (10.7 m) of the welding arc. If this is not possible, tightly cover them with approved covers.
•
Do not weld where flying sparks can strike flammable material.
•
Protect yourself and others from flying sparks and hot metal.
•
Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas.
•
Watch for fire, and keep a fire extinguisher nearby.
•
Be aware that welding on a ceiling, floor, bulkhead, or partition can cause fire on the hidden side.
•
Do not weld on containers that have held combustibles, or on closed containers such as tanks, drums, or pipes unless they are
properly prepared according to AWS F4.1 and AWS A6.0 (see Safety Standards).
•
Do not weld where the atmosphere may contain flammable dust, gas, or liquid vapors (such as gasoline).
•
Connect work cable to the work as close to the welding area as practical to prevent welding current from traveling long, possibly
unknown paths and causing electric shock, sparks, and fire hazards.
•
Do not use welder to thaw frozen pipes.
•
Remove stick electrode from holder or cut off welding wire at contact tip when not in use.
•
Wear body protection made from durable, flame−resistant material (leather, heavy cotton, wool). Body protection includes oil-free
clothing such as leather gloves, heavy shirt, cuffless trousers, high shoes, and a cap.
•
Remove any combustibles, such as a butane lighter or matches, from your person before doing any welding.
•
After completion of work, inspect area to ensure it is free of sparks, glowing embers, and flames.
•
Use only correct fuses or circuit breakers. Do not oversize or bypass them.
•
Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B for hot work and have a fire watcher and extinguisher nearby.
FLYING METAL or DIRT can injure eyes.
Read and understand the Safety Data Sheets (SDSs) and the manufacturer’s instructions for adhesives, coatings, cleaners, consumables,
coolants, degreasers, fluxes, and metals.
•
Welding, chipping, wire brushing, and grinding cause sparks and flying metal. As welds cool, they can throw off slag.
•
Wear approved safety glasses with side shields even under your welding helmet.
BUILDUP OF GAS can injure or kill.
•
•
Shut off compressed gas supply when not in use.
Always ventilate confined spaces or use approved air-supplied respirator.
ELECTRIC AND MAGNETIC FIELDS (EMF) can affect Implanted Medical Devices.
•
•
Wearers of Pacemakers and other Implanted Medical Devices should keep away.
Implanted Medical Device wearers should consult their doctor and the device manufacturer before going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating operations.
NOISE can damage hearing.
•
•
Noise from some processes or equipment can damage hearing.
Wear approved ear protection if noise level is high.
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CWF-23E Dabber-Type Wire Feeder
CYLINDERS can explode if damaged.
Compressed 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.
•
•
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Protect compressed gas cylinders from excessive heat, mechanical shocks, physical damage, slag, open flames, sparks, and arcs.
Install cylinders in an upright position by securing to a stationary support or cylinder rack to prevent falling or tipping.
Keep cylinders away from any welding or other electrical circuits.
Never drape a welding torch over a gas cylinder.
Never allow a welding electrode to touch any cylinder.
Never weld on a pressurized cylinder − explosion will result.
Use only correct compressed gas cylinders, regulators, hoses, and fittings designed for the specific application; maintain them and
associated parts in good condition.
Turn face away from valve outlet when opening cylinder valve. Do not stand in front of or behind the regulator when opening the
valve.
Keep protective cap in place over valve except when cylinder is in use or connected for use.
Use the right equipment, correct procedures, and sufficient number of persons to lift and move cylinders.
Read and follow instructions on compressed gas cylinders, associated equipment, and Compressed Gas Association (CGA) publication
P-1 listed in Safety Standards.
1.3 Additional Symbols for Installation, Operation, And Maintenance
FIRE OR EXPLOSION hazard.
•
•
•
Do not install or place unit on, over, or near combustible surfaces.
Do not install unit near flammables.
Do not overload building wiring − be sure power supply system is properly sized, rated, and protected to handle this unit.
FALLING EQUIPMENT can injure.
•
•
•
•
•
Use lifting eye to lift unit only, NOT running gear, gas cylinders, or any other accessories.
Use equipment of adequate capacity to lift and support unit.
If using lift forks to move unit, be sure forks are long enough to extend beyond opposite side of unit.
Keep equipment (cables and cords) away from moving vehicles when working from an aerial location.
Follow the guidelines in the Applications Manual for the Revised NIOSH Lifting Equation (Publication No. 94−110) when manually
lifting heavy parts or equipment.
OVERUSE can cause OVERHEATING
•
•
•
Allow cooling period; follow rated duty cycle.
Reduce current or reduce duty cycle before starting to weld again.
Do not block or filter airflow to unit.
FLYING SPARKS can injure.
•
•
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Wear a face shield to protect eyes and face.
Shape tungsten electrode only on grinder with proper guards in a safe location wearing proper face, hand, and body protection.
Sparks can cause fires — keep flammables away.
STATIC (ESD) can damage PC boards.
•
•
Put on grounded wrist strap BEFORE handling boards or parts.
Use proper static-proof bags and boxes to store, move, or ship PC boards.
MOVING PARTS can injure.
4
•
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Keep away from moving parts.
Keep away from pinch points such as drive rolls.
WELDING WIRE can injure.
•
•
Do not press gun trigger until instructed to do so.
Do not point gun toward any part of the body, other people, or any metal when threading welding wire.
BATTERY EXPLOSION can injure.
•
Do not use welder to charge batteries or jump start vehicles unless it has a battery charging feature designed for this purpose.
MOVING PARTS can injure.
•
•
•
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Keep away from moving parts such as fans.
Keep all doors, panels, covers, and guards closed and securely in place.
Have only qualified persons remove doors, panels, covers, or guards for maintenance and troubleshooting as necessary.
Reinstall doors, panels, covers, or guards when maintenance is finished and before reconnecting input power.
READ INSTRUCTIONS.
•
•
•
Read and follow all labels and the Owner’s Manual carefully before installing, operating, or servicing unit. Read the safety
information at the beginning of the manual and in each section.
Use only genuine replacement parts from the manufacturer.
Perform maintenance and service according to the Owner’s Manuals, industry standards, and national, state, and local codes.
H.F. RADIATION can cause interference.
•
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High-frequency (H.F.) can interfere with radio navigation, safety services, computers, and communications equipment.
Have only qualified persons familiar with electronic equipment perform this installation.
The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation.
If notified by the FCC about interference, stop using the equipment at once.
Have the installation regularly checked and maintained.
Keep high-frequency source doors and panels tightly shut, keep spark gaps at correct setting, and use grounding and shielding to
minimize the possibility of interference.
ARC WELDING can cause interference.
•
•
•
•
•
•
Electromagnetic energy can interfere with sensitive electronic equipment such as computers and computer-driven equipment such
as robots.
Be sure all equipment in the welding area is electromagnetically compatible.
To reduce possible interference, keep weld cables as short as possible, close together, and down low, such as on the floor.
Locate welding operation 100 meters from any sensitive electronic equipment.
Be sure this welding machine is installed and grounded according to this manual.
If interference still occurs, the user must take extra measures such as moving the welding machine, using shielded cables, using line
filters, or shielding the work area.
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CWF-23E Dabber-Type Wire Feeder
1.4 California Proposition 65 Warnings
Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to cause birth defects
and, in some cases, cancer. (California Health & Safety Code Section 25249.5 et seq.)
This product contains chemicals, including lead, known to the state of California to cause cancer, birth defects, or other reproductive
harm. Wash hands after use.
1.5 Principal Safety Standards
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, is available as a free download from the American Welding Society at
http://www.aws.org or purchased from Global Engineering Documents (phone: 1-877-413-5184, website: www.global.ihs.com).
Safe Practices for the Preparation of Containers and Piping for Welding and Cutting, American Welding Society Standard AWS F4.1, from Global
Engineering Documents (phone: 1-877-413-5184, website: www.global.ihs.com).
Safe Practices for Welding and Cutting Containers that have Held Combustibles, American Welding Society Standard AWS A6.0, from Global
EngineeringDocuments (phone: 1-877-413-5184, website: www.global.ihs.com).
National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Quincy, MA 02269 (phone: 1-800-344-3555, website:
www.nfpa.org and www. sparky.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, from Compressed Gas Association, 14501 George Carter Way, Suite 103,
Chantilly, VA 20151 (phone: 703-788-2700, website:www.cganet.com).
Safety in Welding, Cutting, and Allied Processes, CSA Standard W117.2, from Canadian Standards Association, Standards Sales, 5060 Spectrum Way,
Suite 100, Ontario, Canada L4W 5NS (phone: 800-463-6727, website: www.csa-international.org).
Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute, 25 West
43rd Street, New York, NY 10036 (phone: 212-642-4900, web-site: www.ansi.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot Work, NFPA Standard 51B, from National Fire Protection Association, Quincy,
MA 02269 (phone: 1-800-344-3555, website: www.nfpa.org.
OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q, and Part
1926, Subpart J, from U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954 (phone: 1-866512-1800) (there are 10 OSHA Regional Offices— phone for Region 5, Chicago, is 312-353-2220, website: www.osha.gov).
Applications Manual for the Revised NIOSH Lifting Equation, The National Institute for Occupational Safety and Health (NIOSH), 1600 Clifton Rd,
Atlanta, GA 30333 (phone: 1-800-232-4636, website: www.cdc.gov/NIOSH).
1.6 EMF Information
Electric current flowing through any conductor causes localized electric and magnetic fields (EMF). The current from arc welding (and allied processes
including spot welding, gouging, plasma arc cutting, and induction heating operations) creates an EMF field around the welding circuit. EMF fields
may interfere with some medical implants, e.g. pacemakers. Protective measures for persons wearing medical implants have to be taken. For
example, restrict access for passers−by or conduct individual risk assessment for welders. All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:
1. Keep cables close together by twisting or taping them, or using a cable cover.
2. Do not place your body between welding cables. Arrange cables to one side and away from the operator.
3. Do not coil or drape cables around your body.
4. Keep head and trunk as far away from the equipment in the welding circuit as possible.
5. Connect work clamp to workpiece as close to the weld as possible.
6. Do not work next to, sit or lean on the welding power source.
7. Do not weld whilst carrying the welding power source or wire feeder.
About Implanted Medical Devices:
Implanted Medical Device wearers should consult their doctor and the device manufacturer before performing or going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating operations. If cleared by your doctor, then following the above procedures is recommended.
6
SECTION II
INTRODUCTION
The Miller Welding Automation CWF-23E
dabber type wire feeder is designed to be
controlled by the 9900 Con- troller and can be
used with the GTAW or PAW process.
Please refer to the 9900 Controller manual for
more programming details.
Description of Dabber-type Wire
Feed Action
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.
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
-7-
50%, this time will be approximately 160
msec.
Figure 3:
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.
Figure 4:
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.
CWF-23E Dabber Type Wire Feeder
DABBER WIRE FEEDER OPERATION
-8-
SECTION III
SPECIFICATIONS
System Components
Operating Specifications
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.
2.
Wire drive unit: consists of motor, drive
housing, and wire spool assembly to
feed wire. (Part number CWF-10A-130.)
WGP-3 or WGP-1 Wire Guide Positioner:
guides wire into puddle.
Note: The WGP-1 wire 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.
5.
Spool adapter: holds 12” (305 mm) diameter wire spools.
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.
-9-
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)
2
(51)
13.375
(340)
5.25
8
(133)
(203)
0.375
(9.5)
22
6
(152)
(560)
- 10 -
SECTION IV
WIRE FEED ACCESSORY KITS
Wire Size
0.020”
*Complete Conduit - 6
Outlet
Guide
Accessory
ft (2 m)
Kit
10A6020K 42-23
OG-020
(0.5 mm)
0.030”
Inlet Guide Wire Guide Feed Rolls
Tip
& Inlet
Guide
056192
WGT-020
087131
**Curved
Wire Guide
Tip
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
(0.8 mm)
0.035”
(0.9/1 mm)
0.045”
(1.2 mm)
0.062”
(1.6 mm)
0.093”
(2.4 mm)
*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.
- 11 -
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.
- 12 -
SECTION VI
PARTS LISTS
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.
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
de- fined as follows:
Level 1 These are the spares recommended
for US domestic users whose use
of the product does not exceed
2000 hours per year.
Level 2 These 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 -
The following parts lists are included in this
manual. Their appropriate page numbers are
listed:
CWF-23E ................................................14-15
9900-MCMD-1 ......................................16-17
WGP-3 ...................................................18-19
WGP-1 ...................................................20-21
CWF-23E Dabber Type Wire Feeder
- 14 -
CWF-23E
Dabber-Type Wire Feeder Assembly
Item
No.
Part
No.
2
Description
Qty
Drive Housing .......................................................... 1
3
7/16-14x11/4
Hex. Head Screw ..................................................... 2
4
5
6
7/16
HWF-17-131
CWF-23D-6
Lock Washer .................................................................. 2
Shaft detail .............................................................. 1
Spacer Detail ........................................................... 1
7
455502
Bearing .................................................................... 1
8
CWF-23D-8
Half Coupling detail ................................................. 1
Polyurethane Insert ................................................ 1
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
CWF-23D-11
5/16-18x3/4
CWF-23-13
CWF-23-14
TLY-A220
1/4-20x1/2
1/4
1/4
9376K147
5/16-18x11/4
5/16
5/16
CWF-23D-23
CWF-23D-100
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 -
Recommended
Level
Level
I
II
CWF-23E Dabber Type Wire Feeder
- 16 -
9900-MCMD-1
Motor Control Module
Recommended
Level
Level
Part
No.
9900-10-U
EL-50T
PSA15LN3-050
PBA10F-24
23F230
AGC-10
20VK1
37N1998
2098-DSD-010
Description
Qty
Interface Board with CPU........................................ 1
Fiber Optic Media Converter .................................. 1
Power Supply, 5VDC ................................................ 1
Ref. Desig. PS1
Power Supply, 24 VDC ............................................. 1
Ref. Desig. PS2
Switch, Toggle, SPST ................................................ 1
Ref. Desig. SW1
Fuse, 1 1/4”, 10 Amp, 250V .................................... 1
Ref. Desig. F1
RF Filter, 250V, 20 Amp ............................................ 1
Ref. Desig. RF1
Pilot Light, 120V, Red............................................... 1
Ref. Desig. PL1
Brushless Servo Drive .............................................. 1
Ref. Desig. MC1
- 17 -
I
II
1
1
1
1
1
1
1
1
3
3
1
1
1
1
COMPACT WIRE GUIDE POSITIONER,
FOR COLD WIRE FEEDERS
WGP-3
D
4/10/08
WGP-3
Compact Wire Guide Positioner
Item
Part
No.
No.
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
WGP-3-2
WGP-3-3
WGP-3-4
WGP-3-5
WGP-1-250
WGP-1-240
WGP-3-8
WGP-3-9
WGP-3-10
WGP-3-11
XX-68
L-35
2813
CL-1-KHS
CL-6-KHS
CL-2-SLB
1/4-20x3/4
1/4
1/420
1/4-20x2 1/4
1/8x3/4
CWGT
3025
Recommended
Level
Level
Description
Qty
I
II
Base Detail .............................................................. 1
Yoke Detail ............................................................... 1
Slide Detail .............................................................. 1
Rotor Detail ............................................................. 1
V-Block Detail .......................................................... 2
Stud ......................................................................... 2
Pin Detail ................................................................. 1
Clamp Detail ............................................................ 1
Tube Detail .............................................................. 1
Spacer Detail ........................................................... 1
Fender Washer .............................................................. 1
Compression Pin ..................................................... 1
Compression Pin ..................................................... 1
Compression Pin ..................................................... 1
Knurled Head Screw ................................................ 1
Knurled Head Screw ................................................ 1
Button, radius loc .................................................... 1
Socket Head Screw .................................................. 3
Flat Washer.................................................................... 1
Hex Nut ................................................................... 1
Hex Head Screw ...................................................... 1
Roll Pin .................................................................... 1
Curved Wire Guide Tip Detail .................................. 1
Knob ........................................................................ 2
- 19 -
1
1
1
1
1
1
1
2
2
1
1
WIRE GUIDE POSITIONER
WGP-1
20
L
4/14/0
CWF-23E Dabber Type Wire Feeder
WGP-1 (Rev L)
Wire Guide Positioner - (Available as an alternate)
Item
Part
No.
No.
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
WGP-1-230
WGP-1-100 (REV E)
WGP-1-200
WGP-1-210 (REV E)
WGP-1-220
WGP-XXX
WGP-1-240
WGP-1-250
CL-1-KHS
CL-1-KN
CL-1-SB
WGP-1-16
6655K13
VV-38
1/4-20x7/8
1/4-20x5/8
1/4
11256
3025
3/8-16-5/16
WGP-1-260
WGP-1-261
WGP-1-262
1/4-20-5/8
WGP-1-263
1/4-20x3/4
6435K12
6391K143
Recommended
Level
Level
Description
Qty
I
II
Base ......................................................................... 1
Cam Plate ................................................................ 1
Housing ................................................................... 1
Bar ........................................................................... 1
Clamp ...................................................................... 1
Shown for Reference (part of Wire Feed Kit)
Stud ......................................................................... 2
V-Block ........................................................................... 2
Guide, Dowell .......................................................... 1
Fulcrum Pin, Dowell ................................................ 1
Hinge Pin, Dowell .................................................... 1
Knurled Head Screw ................................................ 1
Knurled Nut ............................................................. 1
Swing Bolt ............................................................... 1
Lift Pin ..................................................................... 1
Thrust Bearing ......................................................... 1
Compression Spring ................................................ 1
Socket Head Screw .................................................. 2
Socket Head Screw .................................................. 2
Flat Washer.................................................................... 1
Compression Spring ................................................ 1
Knob ........................................................................ 2
Nylock Set Screw ..................................................... 1
V-Mount (Optional Item, Large Clamp Kit) ............. 1
V-Clamp (Optional Item, Large Clamp Kit) .............. 1
Stud (Optional Item, Large Clamp Kit) .................... 2
Socket Head Screw .................................................. 2
Base Extension (Optional Item, extended base)..... 1
Socket Head Screw (Optional Item, extended base) . 2
Collar, 1/4 diameter ................................................ 1
Bronze Bearing, 1/4 x 1/2 x 1 .................................. 1
- 21 -
1
1
1
1
1
1
2
2
1
1
1
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