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OM-HWP-50E-02-2014
OPERATION MANUAL
for HWP-50E
Hot Wire Process
Effective with Serial Number 130542
February 2014
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: sales@jetline.com
HWP-50E Hot Wire Process
ii
HWP-50E Hot Wire Process
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
HWP-50E Hot Wire Process
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
HWP-50E Hot Wire Process
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
J.
California Proposition 65 Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Section II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Section III . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
A.
HWP-200E-1-220-A1000 Hot Wire Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
B.
HWP-200E-1-A1000 Hot Wire Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
C.
9302C Hot Wire Voltage Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
D.
WF-50 Wire Feedhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
E.
9629HW Wire Speed Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
F.
Hot Wire Torch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
G.
Wire Positioner Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Section IV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Installation and Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
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HWP-50E Hot Wire Process
Section V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Section VI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Section VII . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Section VIII . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
PCB Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
A.
HWP-200-6-1 Voltage Reference Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
B.
PCM4 Analog Isolator Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
C.
Transformer Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Section IX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
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HWP-50E Hot Wire Process
Section I
Safety Precautions
WARNING
A. 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.
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.
Have all installation, operation, maintenance
and repair work performed only by qualified
people.
B. 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.
Do not touch live electrical parts.
2.
Wear dry, hole-free insulating gloves and
appropriate body protection.
1
3.
Disconnect input power before installing
o r s e r v i c i n g t h i s e q u i p me n t .
Lockout/tagout input power according to
OSHA 29 CFR 1910.147 (see Safety
Standards).
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.
6.
When making input connections, attach
proper grounding conductor first double-check connections.
7.
Frequently inspect input power cord for
damage or bare wiring. Replace cord
immediately if damaged - bare wiring can
kill.
8.
Turn off all equipment when not in use.
9.
If earth grounding of the workpiece is
required, ground it directly with a
separate cable - do not use work clamp or
work cable.
10.
Do not touch electrode if you are in
contact with the work, ground, or another
electrode from a different machine.
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.
HWP-50E Hot Wire Process
13.
Keep all panels and covers securely in
place.
2.
If inside, ventilate the area and/or use
exhaust at the arc to remove welding
fumes and gases.
14.
Clamp work cable with good metal-tometal contact to workpiece or worktable
as near the weld as practical.
3.
If ventilation is poor, use an approved airsupplied respirator.
C. Arc Rays
4.
Arc rays can burn eyes and skin; noise can
damage hearing; flying slag or sparks can injure
eyes.
Read the Material Safety Data Sheets
(MSDS) and the manufacturer's
instruction for metals, consumables,
coatings, cleaners, and degreasers.
5.
Work in a confined space only if it is well
ventilated, or while wearing an airsupplied respirator. Always have a trained
watch person nearby.
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.
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.
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.
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.
3.
Wear approved safety glasses with side
shields.
4.
Use protective screens or barriers to
protect others from flash and glare; warn
others not to watch the arc.
5.
E. Cylinders
Cylinders can explode if damaged.
Wear protective clothing made from
durable, flame-resistant material (wool
and leather) and foot protection where
necessary.
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.
D. Fumes and Gases
1.
Protect compressed gas cylinders from
excessive heat, mechanical shocks, slag,
open flames, sparks, and arcs.
2.
Install cylinders in an upright position by
securing to a stationary support or
cylinder rack to prevent falling or tipping.
Fumes and gases can be hazardous to your
health.
Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
1.
Keep your head out of the fumes. Do not
breathe the fumes.
2
HWP-50E Hot Wire Process
3.
Keep cylinders away from any welding or
other electrical circuits.
5.
Watch for fire, and keep a fire
extinguisher nearby.
4.
Never weld on a pressurized cylinder explosion will result.
6.
5.
Use only correct shielding gas cylinders,
regulators, hoses and fittings designed for
the specific application; maintain them
and associated parts in good condition.
Do not weld on closed containers such as
tanks, drums, or pipes, unless they are
properly prepared according to AWSF4.1
(see safety Standards).
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.
Wear oil-free protective garments such as
leather gloves, heavy shirt, cuffless
trousers, high shoes, and a cap.
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.
8.
8.
Read and follow instructions on
compressed gas cylinders, associated
equipment, and CGA publication P-1
listed in Safety Standards.
G. Moving Parts
F.
Moving parts, such as fans, rotors, and belts can
cut fingers and hands and catch loose clothing.
Welding
1.
Keep all doors, panels, covers, and guards
closed and securely in place.
2.
Have only qualified people remove
guards or covers for maintenance and
troubleshooting as necessary.
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.
1.
Protect yourself and others from flying
sparks and hot metal.
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.
H. EMF Information
Considerations About Welding and the
Effects of Low Frequency Electric and
Magnetic Fields
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-BPE-53 (Washington, DC: U.S. Government
Printing Office, May 1989):
".... 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
Be alert that welding sparks and hot
materials from welding can easily go
through small cracks and openings to
adjacent areas.
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HWP-50E Hot Wire Process
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
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."
Safe Handling of Compressed Gases in
Cylinders, CGA Pamphlet P-1, from
Compressed Gas Association, 1235 Jefferson
Davis Highway, Suite 501, Arlington, VA
22202
To reduce magnetic fields in the work place, use
the following procedures:
1.
Keep cables close together by twisting or
taping them.
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.
5.
Connect work clamp to workpiece as
close to the weld as possible.
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
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
About Pacemakers:
The above procedures are among those also
normally recommended for pacemaker wearers.
Consult your doctor for complete information.
I.
J.
Principal 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
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
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HWP-50E Hot Wire Process
Section II
Introduction
The HWP-50E consists of the following parts:
The hot wire welding process produces a high
quality weld with a high deposition rate of the
filler material. It differs from the more common
cold wire process in that the filler wire is
electrically preheated and enters the weld pool
at a temperature close to its melting point. This
prevents the wire from chilling the weld pool
and allows the filler metal to flow out across the
puddle, solidifying in a smooth, rounded bead.
Deposition rates up to 18 lb/hr (8 kg/hr) are
achievable under the right circumstances.
HWP-200E Contoured Wave Power Supply
This is a unique AC power supply in which the
AC output waveform is electronically generated
to closely simulate a sine wave form. The use
of sinusoidal AC voltage greatly improves the
flow of the hot wire into the weld pool. The AC
frequency is adjustable from 50 to 200 Hz. The
power supply is rated at 200 amps at 100% duty
cycle and the nominal output voltage is
adjustable from 2 to 15 VAC through the 9302C
control.
One of the more important benefits of the hot
wire process is the virtual elimination of
porosity from the weld deposit. Experiments
have shown that the I2R heating of the filler
wire as it approaches the weld puddle drives off
most of the volatile surface contamination.
Since hydrogen or hydrogen containing
compounds entrapped on the surface of the filler
metal are a primary cause of porosity in high
performance materials, use of the hot wire
process can be expected to remove this potential
source of difficulty.
There are two power supply models available:
HWP-200E-1-F7 is the 360/480 VAC model;
HWP-200E-1-220-F7 is the 220 VAC model.
WF-50 Wire Feed Head
The wire feed head has four gear-driven rolls
driven by a high capacity, DC motor. It is
supplied with wire feed kits for 0.045” (1.2 mm)
and 1/16” (1.6 mm) diameter wires and can feed
at speeds from 12 to 600 IPM (30 to 1,525
mm/min).
The hot wire welding process is ideally suited to
welds that have high quality requirements, such
as nuclear or pressure vessel applications.
These welds normally require radiographic or
ultrasonic inspection.
9629HW Speed Control
The control of wire feed speed is effected
through the 9629HW microprocessor controller.
The control sets and maintains the desired wire
feed speed and provides control of wire inching,
speed ramp up at the start of the wire feed and
wire retract distance at the end of the wire feed
sequence.
The process is suitable for a wide range of
materials including carbon and low alloy steels,
stainless steels, nickel alloys and combinations
of them all. Aluminum and copper alloys are
not suited for the process because of their low
resistance to the electrical heating current.
Hot Wire Torch
The torch guides the wire into the weld pool and
is equipped with a contact tip which transfers
the hot wire current through the wire and
provides a protective gas shield to the heated
wire. It is gas-cooled and rated at 200 amps AC
at 100% duty cycle.
In addition to its use for joining, the hot wire
process is an excellent choice for cladding
operations. It produces an overlay with a clean
weld surface, free of spatter, and lower porosity
levels than MIG, FCAW or SAW.
5
HWP-50E Hot Wire Process
Wire Positioner Assembly
This unit mounts to any conventional GTAW
(TIG) or Plasma (PAW) torch. It permits the
hot wire torch angle to be set and provides
manual cross-seam and vertical adjustment of
wire position.
6
HWP-50E Hot Wire Process
HWP-50E SYSTEM INTERCONNECTION
7
HWP-50E Hot Wire Process
8
HWP-50E Hot Wire Process
Section III
Specifications
A. HWP-200E-1-220-A1000
Hot Wire Power Supply
Input
Voltage:
Phases:
Frequency:
Power:
SCC:
General
220 V ±10%
Three
50/60 Hz
3 KVA
10 KA
Weight:
Environment
Indoor use only
Ambient Temp:
Storage Temp:
Max Humidity:
Altitude:
Output
Voltage:
Phases:
Frequency:
Amps:
Duty Cycle:
Waveform:
110 lb (50 Kg)
2.5 to 15 VAC (Adjustable)
Single
50 to 200 Hz (Adjustable)
200 A
100%
Electrically-generated
sinusoidal
9
-10/C to 40/C
-20/C to 60/C
95% RH non cond
1000 M or lower; up to
3000 M with derating
HWP-50E Hot Wire Process
B. HWP-200E-1-A1000 Hot
Wire Power Supply
Input
Voltage:
Phases:
Frequency:
Power:
SCC:
General
380/415/440-480 V ±5%
Three
50/60 Hz
3 KVA
10 KA
Weight:
Environment
Indoor use only
Ambient Temp:
Storage Temp:
Max Humidity:
Altitude:
Output
Voltage:
Phases:
Frequency:
Amps:
Duty Cycle:
Waveform:
110 lb (50 Kg)
2.5 to 15 VAC (Adjustable)
Single
50 to 200 Hz (Adjustable)
200 A
100%
Electrically-generated
sinusoidal
10
-10/C to 40/C
-20/C to 60/C
95% RH non cond
1000 M or lower; up to
3000 M with derating
HWP-50E Hot Wire Process
C. 9302C Hot Wire Voltage
Control
Input
Connections
Input requirements delivered through S11.
S11:
S13:
S14:
Controls and Indicators
Meters:
Adjustment:
Switch:
Pushbutton:
Hot Wire volts and amps
Hot wire voltage
Hot, Cold or Setup
Gas Purge
To hot wire power supply
To remote contactor
To 9629HW wire feed control
General
Weight:
11
10 lb (4.5 kg)
HWP-50E Hot Wire Process
D. WF-50 Wire Feedhead
General
Specifications
Wire Diameters:
No. Drive Rolls:
Speed Range:
Weight:
20 lb (9 kg)
Wire Spool:
12" (300 mm) diameter
Controlled by: 9629HW Microprocessor
Control
0.045" and 0.062"
(1.2 and 1.6 mm)
Four
12 to 600 IPM
(30 to 1,525 cm/min)
CLEAR PLASTIC
SPOOL COVER
DIA 13.25 in
(337 mm)
13.38 in
(340 mm)
0.38 in
(9 mm)
4X DIA 0.344 in
(9 mm)
MOUNTING HOLES
5.25 in
(133 mm)
8.0 in
(204 mm)
1.38 in
(35 mm)
2.50 in
(62 mm)
22.0 in
(559 mm)
6.0 in
(152 mm)
12
HWP-50E Hot Wire Process
E. 9629HW Wire Speed
Control
General
Input
Voltage:
Phases:
Frequency:
Weight:
110/220 Volts
Single
50/60 Hz
16 lb (7 kg)
Connections
S1:
S2:
S3:
Pulse lockout input and output
Remote Control
Wire Feedhead motor
(And tach-generator if fitted)
4X DIA 0.3125 in
(8 mm)
MOUNTING HOLES
UP
8.75 in
(222 mm)
CRS
S3
WIRE SPEED
245.0 ipm
ADJUST
DOWN
8 in
(203 mm)
S2
Series 9600 CONTROL
EMERGENCY
STOP
S1
LEFT RIGHT
STOP
START
STOP
8 in
(203 mm)
CRS
0.5 in
(13 mm)
10 in
(254 mm)
13
0.875 in
(21 mm)
6 in
(152 mm)
HWP-50E Hot Wire Process
F.
Hot Wire Torch
G. Wire Positioner Assembly
14
HWP-50E Hot Wire Process
Section IV
Installation and Setup
On receipt of the HWP-50E Hot Wire Welding
system, carefully inspect the various parts of the
system for any damage which may have
occurred during shipping. In the event of
damage, contact the carrier immediately. In
these circumstances, do not use the system until
the damage has been corrected as operation in a
damaged condition could result in further
damage or injury.
Primary Power Connections
The HWP-200E series hot wire power supply
requires 3 phase primary input power. The
model HWP-200E-1-220-A1000 requires a 220
±10% Volt, 3 Phase, 50/60Hz, 3Kva supply.
The model HWP-200E-1-A1000 requires a
380/415/440-480 Volt ±5%, 3 Phase, 50/60Hz,
3Kva supply. The power supply is normally
shipped with the power cord installed and the
voltage preselected for the customer. If,
however, the primary voltage selection needs to
be changed, refer to the following:
Transformer T1 is the larger 3KVA transformer
that supplies the isolated 3 to 15VAC to the hot
wire process. T1 is inherently short circuit
proof.
Transformer T2 is the 250VA transformer that
supplies the 120VAC and 24VAC control
voltages for internal use only, in the power
supply.
HWP-200E-1-220-A1000
For either model of hot wire power supply, the
two transformers, T1 and T2 must be configured
for input voltage changeover:
See also Dwg HWP-200E-1-220-A1000
Connect the 220 volt (208-240VAC) 3 phase
power cable to L1, L2, L3 on the TB1 terminal
block. Connect the ground wire to the input
ground stud bolt on the inside of the rear panel.
There is no neutral wire connection on this unit.
T1 Connections – On transformer T1 (P/N
9749B) jump terminals 1-2 and also 3-4 with
12ga wire on the primary windings. Connect
wire #8 to terminal 4 and wire #9 to terminal 1
of the T1 transformer. This sets the primary for
208-240 VAC. There is never any change in
connections to the T1 secondary.
Maximum Winding Temperature: 65/C
15
HWP-50E Hot Wire Process
T2 Connections – On transformer T2 (P/N
9751) connect wire #5 to terminal 1 of the T2
transformer primary. Connect wire #4 to one of
the other primary terminals as follows:
Wire #4 to T2, terminal 2 for 208-240VAC
operation. There is never any change in
connections to the T2 secondary.
Maximum Winding Temperature: 65/C
HWP-200E-1-A1000-CE
See also Dwg HWP-200E-1-A1000-CE
T2 Connections – On transformer T2 (P/N
9751) connect wire #5 to terminal 1 of the T2
transformer primary. Connect wire #4 to one of
the other primary terminals as follows:
Connect the 3 phase power cable to L1, L2, L3
on the TB1 terminal block. Connect the ground
wire to the input ground stud bolt on the inside
of the rear panel. There is no neutral wire
connection on this unit.
Wire #4 to T2, terminal 3 for 380 VAC
Wire #4 to T2, terminal 4 for 415 VAC
Wire #4 to T2, terminal 5 for 440-480 VAC
There is never any change in connections to the
T2 secondary.
Maximum Winding Temperature: 65/C
System Start Contact
The HWP-50E system is most commonly
started from a remote contact closure provided
by the user. This can be a dry contact or toggle
switch. With this method, use the 9629-S29302-P14 interconnecting cable. (This is the
standard supplied cable.) See the HWP-50E
layout drawing for further details.
T1 Connections – On transformer T1 (P/N
9749B) jump terminals 2 and 3 with 12ga wire
on the primary windings. Connect wire #8 to
terminal 4 and wire #9 to terminal 1 of the T1
transformer. This sets the primary for 380480VAC operation. There is never any change
in connections to the T1 secondary.
The contact closure should be applied at S13,
Pins A and B on the 9302C control or,
alternately, can be applied to RC1 (2 prong
Hubbell) on the HWP-200E power supply
enclosure. Either place may be used with the
same results. The choice is usually determined
by the physical location of the remote start relay
contact.
Maximum Winding Temperature: 65/C
When the contact closure is applied, the wire
feeder will always start. The hot wire power
supply will also start if the toggle switch on the
16
HWP-50E Hot Wire Process
3106A-20-33P mating connector with 97-30571012-1 cable clamp. Connect remote signals as
follows:
9302C control unit is in the “HOT” position.
The contact closure must be maintained and
opened when the hot wire process is to be
stopped.
Apply start contact to Pins E and F.
The 9629HW wire feed controller is slaved to
the system. Pushing the 9629HW start button
will not start the hot wire power supply, it is
used for maintained jog. The Em Stop button on
the 9629HW will stop the wire without retract
but will not stop the HWP-200E power unit.
NOTE: When starting from S2, no start signal
is required at S13 or RC1.
Jump Pins K and L to enable the remote voltage
function. The K-L jumper energizes relay CR4
which switches the voltage control function
from the 93302B control to the S2 connector.
The voltage control pot on the 9302C is inactive
while the jumper is present. Apply 0-10vdc
voltage control signal to Pins A and B. Pin A
should be Hi, referenced to Pin B. 0 volt
reference is approximately 2 vac output, 10 volt
reference will produce approximately 15 vac
output.
System Start From 9629
The system may alternately be started from the
9629HW Start button by using the 9629-S29032-P13 interconnecting cable. See drawings
HWP-50E and 9629-S2-9032-P13 for further
details. When using this method, the Start Delay
for the wire feeder is not active, so the wire
feeder and the hot wire power supply will start
simultaneously with pressing the 9629HW Start
button.
Gas can be controlled remotely by applying a
contact closure to Pins H and J. This function
can be used by itself without controlling voltage
remotely (no jumper between Pins K and L).
When using this input, the hot wire shield gas
can be started before striking the welding arc so
as not to disturb the GTAW or PAW shield gas
as the hot wire process turns on.
Pressing the 9629HW Stop button will stop the
hot wire power supply immediately but wire
will continue if there is time programmed for
the wire feed Stop Delay. Normally, 0 sec Stop
Delay time is used.
Pressing the 9629HW Estop button will stop
both the wire feed and the hot wire power
supply immediately.
Remote Functions Connector S2, 9629HW
If using the remote connector on the HWP-200E
power supply, the remote connector, S2, on the
9629HW wire feed control may also be used for
remote sequencing. Please refer also to the 9629
manual for further details. In this case the
interconnecting cables, 9629-S2-9032-P13 or
P14, will not be required.
Manual Start
To run the system manually without a start
signal, first switch the mode toggle switch on
the 9302C to Setup, then press the Start
pushbutton on the 9629 wire feed control.
Apply a wire feed start contact to S2, Pins A
and B of the 9629HW control. Closing this
contact will start the wire feed sequence,
opening the contact will stop the wire feed
sequence. 9629 Start and Stop Delays will be
active.
To stop, first press the Stop button on the 9629,
then switch the mode switch to Cold (or Hot).
Remote Functions Connector S2, HWP-200E
(Please refer also to HWP-200E Interconnection
Diagram.)
Additionally, the wire feed speed may be
controlled remotely by applying a 0-10vdc
signal to S2, Pins M and N (M is high and N is
low). Note: the “R1" option may have to be
The HWP-50E system can be more completely
controlled remotely by using the S2 remote
connector on the HWP-200E enclosure. Use a
17
HWP-50E Hot Wire Process
purchased to activate this feature on the 9629
control. Part number is 9629HW-R1.
9302C Hot Wire Control
This should be mounted close to the operating
position in such a way that the meters can be
clearly seen during operation.
There is a 0-10vdc feedback signal available at
Pins C and D only when the HWP-200-38®
feedback option is purchased. This is a DC
voltage representative of the AC output voltage.
It can be used for display and/or closed looping
applications.
The unit receives its electrical power from the
HWP-200E power supply through the HWP-200
cable.
HWP-200E Power Supply
9629HW Wire Speed Control
For satisfactory operation of the hot wire power
supply, it is necessary to allow at least 12” (300
mm) of space at the rear of the unit for adequate
ventilation purposes.
This unit is designed to be mounted to a vertical
surface and should be located close to the
9302C control.
The control requires a source of 110 or 220
volts, single phase AC power. See 9629
operation manual for input voltage selection.
The primary electrical connection primary
electrical connection should be made using 14
AWG or larger conductor. Check that the unit
is set up for the correct primary input voltage.
Hot Wire Torch and Positioner Assembly
The wire positioner assembly is designed to be
mounted to the welding torch and is equipped
with a clamping system which accommodates
torches with diameters from 3/4” to 1 ½” (19 to
38 mm). The hot wire torch mounts in the
positioner and should be securely clamped. For
ideal operation, the hot wire enters the weld
pool from the back and the positioner should
therefore be orientated to achieve this.
Secondary connections Secondary connections
to the power supply can be made with #1 AWG
cables, maximum recommended lengths are
100ft (30 m). Where possible, run the torch and
work cables closely together to avoid magnetic
fields.
Connect the gas connection to a supply of argon
gas at a pressure not to exceed 50 psig (3.5 bar).
The torch is connected to the feedhead using the
supplied wire conduit. Select the correct one for
the wire size to be used.
WF-50 Wire Feed Head
This should be firmly mounted to your welding
fixture within 6ft (2 m) of the welding torch and
at such an angle that the wire feed conduit
(when connected) has a smooth curve to aid in
the feeding of the wire. It is preferable for the
unit to be mounted to a vertical surface. Use
5/16” (8 mm) diameter mounting bolts.
The feedhead receives its electrical power from
the 9629HW hot wire speed control through the
cable supplied with the WF-50.
Fit the appropriate drive rolls and wire guides
for the wire size to be used.
18
HWP-50E Hot Wire Process
Section V
Operation
imparts the electrical current to the wire, is set
back ½” (12 mm) inside the gas diffuser. Check
that the correct contact tip and insulator are
being used for the selected wire size.
Prior to the commencement of welding, it is
necessary to position the hot wire torch to feed
the wire into the correct part of the weld puddle
and to achieve the desired preheating of the
wire.
The torch should be set in the wire guide
positioner in such a way that there is a wire
stick-out of about ½” to 3/4” (12 to 19 mm)
from the end of the nozzle to the work piece.
For optimum results, the wire should enter the
puddle approximately 1/8 to 3/8” (3 to 10 mm)
behind the tungsten electrode or the center of
the plasma stream in the event that plasma
welding is being employed. The actual distance
depends upon the welding current being used.
Higher currents and slower travel speeds allow
the wire to enter the puddle further from the
tungsten.
This electrical stick-out is important for process
control. For a set wire feed speed, a shorter
stick-out will require an increased hot wire
voltage setting while a longer stick-out will
require a decreased hot wire voltage setting to
achieve the desired wire melt condition. Precise
documentation of the stick-out distance, as well
as welding parameters, is important for
producing consistent results from weld to weld.
As the welding current is increased, the arc cone
increases and a larger “dimple” is created in the
weld puddle by the forces in the arc. As the part
travels, the dimple creates a ridge on the back
side of the puddle, just outside the arc cone. It
is important that the wire position be set such
that the wire enters the weld puddle on the top
of the ridge, just outside the arc cone.
The normal gas used to protect the heated wire
from oxidation is Argon. Weld pool size and
welding speeds are normally increased
compared to those without hot wire. Therefore,
it is beneficial to have this additional source of
shielding gas to aid in protecting the trailing
edge of the solidifying weld. Typically, gas
flow rates of 5 - 20 cfh (2.3 to 9.4 l/m) are used.
Note that the gas flow should be established
prior to starting the welding arc to avoid
interference during arc initiation.
In operation, the wire is preheated to a state just
short of melting. In this state, the wire is very
soft and can easily droop. For this reason the
angle at which the wire enters the weld puddle
should be as steep as possible. For best results,
a starting torch angle of 45 to 50 degrees should
be considered. This is mainly for controlling
the desired entry point into the weld pool. If the
wire enters the weld pool at too low an angle,
fluctuations in weld pool height may cause wire
entry point to vary. Increased entry angles also
reduce the effects of preheating the wire
(softening) and wire cast which can combine to
produce changes in the entry point.
For deep groove welding, it is sometimes
necessary to remove the gas nozzle from the hot
wire torch. In these circumstances the flow of
gas to the hot wire torch can be cut off as the
main welding gas flow protects the hot wire as
well as the weld puddle.
The starting sequence of the hot wire weld is
critical as defects can be caused if this is not
done correctly. A correct sequence would be:
As the wire is heated electrically, it is necessary
to have a set wire extension (stick-out) to
produce the resistance heating. Within the
Jetline HWC-200 torch, the contact tip, which
Start the welding current and upslope the weld
to establish a satisfactory weld puddle.
19
HWP-50E Hot Wire Process
At approximately two thirds of the full welding
current, start the wire using the speed ramping
facility in the 9629HW control. The wire speed
should be set to ramp up to the desired speed in
about 3 to 4 seconds. This allows the wire
heating to be gradually established to ensure
that the wire does not enter the weld puddle
while it is still too cold.
During welding, the wire should be close to
melting as it enters the weld puddle. This will
achieve the condition where 90% of the heat
required to melt the filler wire comes from
resistance heating. Thus, the majority of the
welding current is used to produce the weld and
is not wasted in melting of the wire.
If the hot wire current is too high, the wire
separates from the weld puddle and melts back,
forming a ball on the end of the wire. This
destroys the connection between the wire and
the weld puddle and no hot wire current can
flow. The result is a cooling of the wire which
then enters the weld puddle in too cool a
condition. This condition can be recognized by
an audible buzzing and snapping noise and the
wire balls up and then re-enters the weld
puddle.
This is an undesirable condition as the wire is
too cold when it enters the weld puddle and
could cause defects in the weld. For ideal hot
wire welding, the wire should flow freely and
smoothly into the weld puddle.
Hot wire welding allows higher wire deposition
rates than cold wire welding. This can result in
a larger weld puddle and, in order the maintain
a stable puddle, it may be necessary to increase
travel speeds relative to those which would be
used with cold wire techniques.
20
HWP-50E Hot Wire Process
Section VI
Maintenance
CAUTION
Always disconnect main input power before
servicing this equipment.
The following checks should be carried out on
a regular basis:
Daily:
Contact tips should be changed daily or more
often.
Weekly:
Blow out liners.
Monthly:
In addition to the weekly maintenance routine,
check the following:
Change liner
Blow out power source
Change ceramic nozzle
Annually:
In addition to the weekly and monthly
maintenance routines, check the following:
Change the drive rolls
21
HWP-50E Hot Wire Process
22
HWP-50E Hot Wire Process
Section VII
Parts List
The following pages provide a detailed parts list
of all the elements of the HWP-50E Hot Wire
System. They are arranged so the parts list on
the left hand page corresponds to the assembly
illustrated on the right 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.
The following parts lists are included in this
manual. Their appropriate page numbers are
listed:
HWP-200E - Front Panel . . . . . . . . . . . 24/25
HWP-200E - Rear Panel, Inside . . . . . . 26/27
HWP-200E - Inside Base . . . . . . . . . . . 28/29
9302C Control . . . . . . . . . . . . . . . . . . . 30/31
For details of the 9629HW control, please refer
to the separate manual for this product.
WF-50 Wire Feed Head . . . . . . . . . . . . 32/33
HWC-200 Torch . . . . . . . . . . . . . . . . . . 34/35
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:
HWCP-100 Wire Guide Positioner . . . 36/37
Accessory Kit . . . . . . . . . . . . . . . . . . . . . . . 38
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.
23
HWP-50E Hot Wire Process
HWP-200E-1-220-F7 OR HWP-200E-1-F7 POWER SUPPLY
FRONT PANEL - INTERIOR
24
HWP-50E Hot Wire Process
HWP-200E-1-A1000 POWER SUPPLY - 380/415/440-480V
AND
HWP-200E-1-220-A1000 POWER SUPPLY - 220V
FRONT PANEL - INTERIOR
Item
No.
1
2
3
4
5
6
7
Part
No.
Description
HWP-200E-2-ENC
M15859-3
M15859-3
F7U23P7
KD1-1
KD1-1
10F466
8
9
10
M-1432
HWP-200-6-1
PCM4
11
12
13
14
15
250CH-2
KBPC-2506
250CH-.5
37N1998
58V58
Qty
Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Work Receptacle . . . . . . . . . . . . . . . . . . . . . . . 1
Torch Receptacle . . . . . . . . . . . . . . . . . . . . . . . 1
Inverter, Ref PS1 . . . . . . . . . . . . . . . . . . . . . . . 1
Circuit Breaker, 1A, Ref CB4 . . . . . . . . . . . . . 1
Circuit Breaker, 1A, Ref CB3 . . . . . . . . . . . . . 1
Potentiometer, Frequency Cntrl, 1K, 1 turn, . . 1
Ref P1
Knob . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Printed Circuit Board, Ref. Voltage . . . . . . . . 1
Printed Circuit Board, Analog Output Isolator 1
(HWP-200-38, Optional)
Resistor, 2 Ohm, 250W, Ref R4 . . . . . . . . . . . 1
Bridge Rectifier, Ref BR1 . . . . . . . . . . . . . . . . 1
Resistor, 0.5 Ohm, 250W, Ref R2 . . . . . . . . . 1
Pilot Light, Red, Ref L1 . . . . . . . . . . . . . . . . . 1
Fitting, Gas Outlet . . . . . . . . . . . . . . . . . . . . . . 1
25
Recommended Spares
Level
Level
I
II
1
1
1
1
HWP-50E Hot Wire Process
HWP-200E-1 POWER SUPPLY
INTERIOR BASE VIEW
26
HWP-50E Hot Wire Process
HWP-200E POWER SUPPLY
INTERIOR BASE
Item
No.
1
2
3
4
5
6
7
8
9
Part
No.
Description
HWP-200E-2-ENC
802940URLLS
1492-DC2
65F1234
9749B-ECA
1769
9751-ECA
65F1237
1492-CD2
Qty
Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Current Transformer, 200A/5A, Ref CT1 . . . . 1
Terminal Block, 600V, Ref TB4 . . . . . . . . . . . 2
Terminal Block, 6 term, Ref TB3 . . . . . . . . . . 1
Transformer, 15V, 200A, Ref T1 . . . . . . . . . . 1
Current Transformer, 5A/500mA, Ref CT2 . . 1
Control Power Transformer, Ref T2 . . . . . . . . 1
Terminal Block, 14 term, Ref TB2 . . . . . . . . . 1
Terminal Block, 600V, Ref TB1 . . . . . . . . . . . 6
27
Recommended Spares
Level
Level
I
II
HWP-50E Hot Wire Process
HWP-200E POWER SUPPLY
REAR PANEL - INTERIOR
28
HWP-50E Hot Wire Process
HWP-200E POWER SUPPLY
REAR PANEL - INTERIOR
Item
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
Part
No.
Description
Qty
HWP-200E-2-ENC Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
8262G22
Solenoid Valve, Ref SV1 . . . . . . . . . . . . . . . . . 1
KD1-2
Circuit Breaker, 2A, Ref CB1 . . . . . . . . . . . . . 1
KD1-2
Circuit Breaker, 2A, Ref CB2 . . . . . . . . . . . . . 1
TSDB-420
Timer, DOB, Ref TD1 . . . . . . . . . . . . . . . . . . . 1
5258
Outlet, Single, 115VAC, Ref RC2 . . . . . . . . . . 1
Not used for CE
KD1-1
Circuit Breaker, 1A, Ref CB5 . . . . . . . . . . . . . 1
FLTR-2NW
Amphenol Connector, Filtered, Ref S1 . . . . . . 1
3102A-20-33S
Amphenol Connector, 11 Pin, Ref S2 . . . . . . . 1
7468
Receptacle, Twistlock, Ref RC1 . . . . . . . . . . . 1
RH1B-UT-24VAC Relay, SPDT, 24VAC, Ref CR4 . . . . . . . . . . . 1
RH1B-UT-24VAC Relay, SPDT, 24VAC, Ref CR3 . . . . . . . . . . . 1
RR3B-US-24VAC Relay, 3PDT, 24VAC, Ref CR2 . . . . . . . . . . . 1
A-PA6AXFN
Fan, 120VAC, Ref FAN . . . . . . . . . . . . . . . . . . 1
HBL7810UD
Power Switch, 3PST, Ref SW1 . . . . . . . . . . . . 1
HPLB
Fuse holder, Ref F1 . . . . . . . . . . . . . . . . . . . . . 1
ATQ15
F1, Fuse, 15A, 500V . . . . . . . . . . . . . . . . . . . . 1
SHAWMUT, Time Delay
HPLB
Fuse holder, Ref F2 . . . . . . . . . . . . . . . . . . . . . 1
ATQ15
F2, Fuse, 15A, 500V . . . . . . . . . . . . . . . . . . . . 1
SHAWMUT, Time Delay
HPLB
Fuse holder, Ref F3 . . . . . . . . . . . . . . . . . . . . . 1
ATQ15
F3, Fuse, 15A, 500V . . . . . . . . . . . . . . . . . . . . 1
SHAWMUT, Time Delay
29
Recommended Spares
Level
Level
I
II
1
1
1
1
1
1
1
1
1
2
1
2
1
2
HWP-50E Hot Wire Process
9302C HOT WIRE CONTROL
30
HWP-50E Hot Wire Process
9302C HOT WIRE CONTROL
Item
No.
Part
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
9302A-11
Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3102A-22-19P
Amphenol Connector, 14 Pin, Ref S11 . . . . . . . 1
50-250-240HYRL Meter, 200A AC, Ref M1 . . . . . . . . . . . . . . . . . 1
250230NDND
Meter, 15VAC, Ref M2 . . . . . . . . . . . . . . . . . . 1
RR3B-US-24VAC Relay, 3PDT, 24VAC, Ref CR4 . . . . . . . . . . . . 1
9302A-2
Faceplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3102A-14S-01S Amphenol Connector, 3 Pin, Ref S13 . . . . . . . . 1
3102A-14S-06P Amphenol Connector, 6 Pin, Ref S14 . . . . . . . . 1
10F466
Potentiometer, 5k 1 turn, Ref R2 . . . . . . . . . . . . 1
M1432
Knob . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
23F237
Switch, DPDT, Ref SW2 . . . . . . . . . . . . . . . . . . 1
MPA-206R
Pushbutton Switch, DPDT, Ref SW1 . . . . . . . . 1
C-22-0
Knob . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
G-12-C
Guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Description
Qty
31
Recommended Spares
Level
Level
I
II
1
1
1
1
1
1
1
HWP-50E Hot Wire Process
WF-50 WIRE FEED HEAD
32
HWP-50E Hot Wire Process
WF-50 WIRE FEED HEAD
Item
No.
Part
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
WF-50-1
Wire Feed Head . . . . . . . . . . . . . . . . . . . . . . . . . 1
046779
Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
053842
Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
CWF-20B-140
Retainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
SC50
Setscrew Collar . . . . . . . . . . . . . . . . . . . . . . . . . 1
CWF-20B-100
Mounting Plate . . . . . . . . . . . . . . . . . . . . . . . . . . 1
CWF-20B-110
Mounting Bracket . . . . . . . . . . . . . . . . . . . . . . . 1
374831A
Spool Adaptor . . . . . . . . . . . . . . . . . . . . . . . . . . 1
CWF-20B-120
Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
053841
Drive Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
BMQ1100-15-3-42CZ Gear Reducer . . . . . . . . . . . . . . . . . . . . . . . . 1
D016
Motor, 1/6HP, 90VDC . . . . . . . . . . . . . . . . . . . . 1
CHWS-100
Wire Straightener (Not shown) . . . . . . . . . . . . . 1
TGK-2
Tach-Generator Kit . . . . . . . . . . . . . . . . . . . . . . 1
Description
Qty
33
Recommended Spares
Level
Level
I
II
1
1
HWP-50E Hot Wire Process
HWCP-100 WIRE GUIDE POSITIONER
34
HWP-50E Hot Wire Process
HWCP-100 WIRE GUIDE POSITIONER
Item
No.
Part
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
HWCP-100
HWCP-100-3
HWCP-100-10
VV-38
CL-1-KHS
HWCP-100-5
WGP-1-200
WGP-1-230
WGP-1-240
WGP-1-250
3025
CL-1B-PPK1T
HWCP-100-6
CL-3A-PPK2T
HWCP-100-7
CL-1-SB
S-803
CL-2-SW
CL-1-KN
Description
Qty
Wire Guide Positioner . . . . . . . . . . . . . . . . . . . . 1
Cam Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Retainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Compression Spring . . . . . . . . . . . . . . . . . . . . . . 1
Fulcrum Pin, 1/4” (6 mm) dia x 1” (25 mm) . . . 1
Knurled Head Screw . . . . . . . . . . . . . . . . . . . . . 1
Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
V-Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Knob . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Knob . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Guide Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Knob . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Swing Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Compression Spring . . . . . . . . . . . . . . . . . . . . . . 1
Spherical Washer . . . . . . . . . . . . . . . . . . . . . . . . 1
Knurled Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
35
Recommended Spares
Level
Level
I
II
1
1
2
2
1
HWP-50E Hot Wire Process
HWT-1 HOT WIRE TORCH
36
HWP-50E Hot Wire Process
HWT-1 HOT WIRE TORCH
Item
No.
Part
No.
1
2
3
4
T1035
T1045
N1C12Q
44115
44215
5
44N3545
44N116
Description
Qty
Main Body Assembly . . . . . . . . . . . . . . . . . . . . . 1
Contact Tip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
.035" (0.9 mm)
.045" (1.2 mm)
Nozzle Assembly . . . . . . . . . . . . . . . . . . . . . . . . 1
Liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
.035-.045" (0.9-1.2 mm)
.062" 91.6 mm)
Conduit (not shown) . . . . . . . . . . . . . . . . . . . . . . 1
.035-.045" (0.9-1.2 mm)
.062" 91.6 mm)
37
Recommended Spares
Level
Level
I
II
10
25
1
2
HWP-50E Hot Wire Process
HOT WIRE ACCESSORY KITS
Item
No.
Part
No.
20B6035HW
T1035
N1C12Q
44115
046781
OG-035-045
44N3545
20B6045HW
T1045
N1C12Q
44115
046782
OG-035-045
44N3545
20B6062HW
T1116
N1C12Q
44215
046789
OG-062
44N116
Description
Qty
Accessory Kit, 0.035” (0.9 mm) Wire . . . . . . . . 1
Includes:
Contact Tip, 0.035" (0.9 mm) Wire . . . . . . . . . . 1
Nozzle Assembly, 0.5" (12.7 mm) orifice . . . . . 1
Liner, .035-.045" (0.9-1.2 mm) . . . . . . . . . . . . . 1
Four-roll Feed Roll Kit, .035" (0.9 & 1.0 mm) wire
Outlet Guide, 0.035-0.045” (0.9-1.2 mm) Wire 1
Conduit, 0.035-0.045” (0.9-1.2 mm), 6ft (1.8 m) 1
Accessory Kit, 0.045” (1.2 mm) Wire . . . . . . . . 1
Includes:
Contact Tip, 0.045" (1.2 mm) Wire . . . . . . . . . . 1
Nozzle Assembly, 0.5" (12.7 mm) orifice . . . . . 1
Liner, .045-.062" (1.2-1.6 mm) . . . . . . . . . . . . . 1
Four-roll Feed Roll Kit, .045" (1.2 mm) wire . . 1
Outlet Guide, 0.035-0.045” (0.9-1.2 mm) Wire 1
Conduit, 0.035-0.045” (0.9-1.2 mm), 6ft (1.8 m) 1
Accessory Kit, 1/16” (1.6 mm) Wire . . . . . . . . . 1
Includes:
Contact Tip, 0.062" (1.6 mm) Wire . . . . . . . . . . 1
Nozzle Assembly, 0.5" (12.7 mm) orifice . . . . . 1
Liner, 0.062" (1.6 mm) . . . . . . . . . . . . . . . . . . . 1
Four-roll Feed Roll Kit, 0.062" (1.6 mm) wire . 1
Outlet Guide, 0.062" (1.6 mm) Wire . . . . . . . . . 1
Conduit, 0.062" (1.6 mm) Wire, 6ft (1.8 m) long 1
38
Recommended Spares
Level
Level
I
II
10
25
1
12
1
2
10
25
1
2
1
2
10
25
1
2
1
2
HWP-50E Hot Wire Process
Section VIII
PCB Descriptions
Pin 2 – Common. Reference common to
inverter, PS1.
A. HWP-200-6-1 Voltage
Reference Board
J5 - Start Output
Pin 1 – Collector. Isolated open collector output
to inverter, PS1. This signal starts the inverter,
to apply voltage to hot wire torch.
Please refer to the illustration on the next page
for details of the parts and test points.
CONNECTORS
Pin 2 – Emitter. Isolated open collector output
to inverter, PS1. This signal starts the inverter,
to apply voltage to hot wire torch.
J1 - Reference Voltage
Pin 1 – Pot drive voltage, 12vdc. To high side of
reference voltage pot in 9302C.
COMPONENTS
Pin 2 – Reference voltage in. From wiper of
9302C pot or, from Pin A, S2, if in remote
mode.
A1 – LM324N Operational Amplifier
Provides gain, conditioning and offset for
reference signal to inverter power supply, PS1.
Pin 3 – Reference voltage pot Low (common).
From low side of 9302C pot and Pin B of S2
U1 - CD40106B CMOS Inverting Schmitt
Trigger
J2 - Start Input
Conditions start (contactor) signal, drives Q1 to
turn on opto coupler output, U2.
Pin 1 – Common
Pin 2 – Start input. Pins 1 and 2 are enabled by
relay CR2. CR2 is energized from: S13 - 9302C
or, toggle switch - 9302C or, RC1 - HWP-200E
or, S2 remote - HWP-200E.
U2 - 4N25 Opto Coupler
J3 - Power Input
VR1 - 7812 Positive 12 Volt Regulator
Pin 1 – Positive voltage input. Unregulated
+17vdc from rectifier BR1.
Provides related +12vdc from input voltage
applied at J3.
Pin 2 – Common. Low voltage power supply
common.
VR2 - 7912 Negative 12 Volt Regulator
Isolates start signal to inverter power supply,
PS1.
Provides regulated -12vdc from input voltage
applied at J3.
Pin 3 – Negative voltage input. Unregulated 17vdc from rectifier BR1.
P1 - Gain Adjustment Pot
Pin 4 – No connection
Set to 10vdc reference output at J4 when
reference input at J1 is maximum. Monitor
output using TP3 (HI) and TP7 (Common).
J4 - Reference Signal Out
Pin 1 – 0 to 10vdc reference output to inverter,
PS1.
39
HWP-50E Hot Wire Process
P2 - Offset Adjustment Pot
TP7 - Circuit Common
Set to 0 vdc reference output at J4 when
reference input at J1 is minimum. Monitor
output using TP3 (HI) and TP7 (Common).
Circuit common.
TEST POINTS
Positive 12 volt power from on board regulator,
VR1. Check using TP7 as common. Tolerance
is ±5%.
TP8 - +12vdc
TP1 - Reference Input
Reference input after voltage division by
R1/R2. Use TP6 for common. R1 and C3
provide low pass filtering. This signal is at input
of first stage of A1.
TP9 - -12vdc
Negative 12 volt power from on board
regulator, VR2. Check using TP7 as common.
Tolerance is ±5%.
TP2 - Reference Signal, Intermediate
Reference signal after 2nd stage of conditioning.
This point is after gain adj pot and offset
summing point. Use TP7 for common.
Reference voltage polarity is inverted
TP3 - Reference Signal, Final
Reference signal after final stage of A1. Use
TP7 for common. Final stage provides unity
gain and polarity inversion. TP3 is the same
electrical point as output connector J4, Pin 1.
TP4 - Offset Voltage Pot
Voltage from the Offset adjustment, P2 can be
measured at this point. Use TP7 for common.
TP4 is the input voltage to A1 voltage follower
used for summing voltage to A1C (2nd stage).
TP5 - Start Output
TP5 is on the circuit side of the opto coupler for
the start output signal (U2). This point should
be approx +10vdc with no start signal and
approx 1 volt with start signal applied. Use TP7
for common.
TP6 - Reference Input Common
Common for external reference input voltage.
This is same electrical point as TP7 except for
100uh choke (L2) in series for filtering in
conjunction with C4.
40
HWP-50E Hot Wire Process
HWP-200-6-1
VOLTAGE REFERENCE BOARD
41
HWP-50E Hot Wire Process
P503 – Min
B. PCM4 Analog Isolator
Board
This is the minimum or offset adjustment. With
minimum input voltage applied, adjust until
output is in agreement, for best linearity.
Please refer to the illustration on the next page
for details of the parts and connection points.
SW501 – Input Type Selector
All switches on SW501 should be off (down, as
in illustration) to select for standard voltage
input. Do not change settings in this application
- damage could occur.
This optional board is used to provide the user
with a 0 to 10 vdc signal that is representative of
the AC output of the HWP-200E power supply.
The input is connected to a generated output
from the PS1 inverter. Output goes to the S2
Remote Connector (Pins C and D).PCM4 Analog Isolator Board
CONNECTORS
TB501— Input Terminal Block
Terminals 1, 2, 3, 4 are for 120vac input power.
power is applied to terms 1 and 4. terms 1 and 2
are jumped together as well as terms 3 and 4 to
configure for 120 vac input range.
Terminals 7 and 8 are for input signal voltage.
These terms are connected to the output
terminals of the PS1 inverter. Terminal 7 is
common, terminal 8 is signal (HI).
TB502 - Output Terminal Block
Terminals 1 and 2 are for isolated signal output
voltage. These terms are connected to the S2
remote connector. Terminal 1 is common
(isolated, LO), Terminal 2 is signal (HI).
COMPONENTS
P501 – Input
This is the input voltage divider adjustment. The
factory setting is not normally changed.
P502 – Max
This is the gain adjustment. This is normally set
to unity gain. It can also be adjusted to agree
with AC output voltage, as measured by the
user’s calibrated instrumentation, however this
device is not intended to give precise RMS
value reporting.
42
HWP-50E Hot Wire Process
PCM4
ANALOG ISOLATOR BOARD
43
HWP-50E Hot Wire Process
C. Transformer Ratings
Transformer T2 is the 250VA transformer that
supplies the 120VAC and 24VAC control
voltages for internal use only, in the power
supply. T2 is protected by CB1, CB2, CB5, see
Dwg HWP-200E-1-A1000.
Transformer T1 is the larger 3KVA transformer
that supplies the isolated 3 to 15VAC to the hot
wire process. T1 is inherently short circuit
proof.
The T2 primary is configured for different
primary voltages by moving wire #4 to one of
for different terminals on the transformer itself.
See Section IV, Primary Power Connections and
Dwg HWP-200E-1-A1000 for more details. The
secondary connections are never changed.
The secondary winding of T1 is connected to
the HWP-200E output terminals so the hot wire
torch can be connected via weld cables to the 3
to 15VAC output. The output frequency is
continuously variable from 50Hz to 200Hz. The
output current is rated up to 200 amps
continuous and varies with the output voltage
setting and the resistance of the secondary hot
wire torch circuit.
Maximum Winding Temperature: 65/C
The two primary windings must be configured
in series or parallel depending on the primary
voltage (see Section IV, Primary power
Connections and Dwg HWP-200E-1-A1000).
The secondary connections are never changed.
Maximum Winding Temperature: 65/C
44
HWP-50E Hot Wire Process
Section IX
Electrical Diagrams
The following pages include electrical diagrams
for the HWP-50E Hot Wire System.
Some drawings may be difficult to read due to
their reduction to a single page size. Full size
prints of any of the drawings are available on
application to our Electrical Engineering
Department.
Electrical Diagrams
The diagrams included in this manual are as
follows:
Interconnection Diagram . . . . Page 46
HWP-200E-1-A1000 Hot Wire
Power Supply, 380 to 480 Volt
Version
Interconnection Diagram . . . . . Page47
HWP-200E-1-220-A1000 Hot Wire
Power Supply, 220 Volt version
Interconnection Diagram . . . . . Page48
HWP-200E-1-220-A1000 Hot Wire
Power Supply, CE version
Wiring Diagram . . . . . . . . . . . Page 49
9302C Hot Wire Control
Cable Wiring Diagram . . . . . . Page 50
9629-S2-9302-P13
Cable Wiring Diagram . . . . . . Page 51
9629-S2-9302-P14
Wire Feeder Wiring Diagram . Page 52
WF-50-1W
45
HWP-50E Hot Wire Process
INTERCONNECTION DIAGRAM HWP-200E-1-A1000
46
HWP-50E Hot Wire Process
INTERCONNECTION DIAGRAM HWP-200E-1-220-A1000
47
HWP-50E Hot Wire Process
INTERCONNECTION DIAGRAM HWP-200E-1-A1000-CE
48
HWP-50E Hot Wire Process
WIRING DIAGRAM 9302C CONTROL
49
3106A-14S-1P
P13
A
B
G
H
9302B
9629HW
3106A-20-27P
P2
HWP
CONTROLLER
WIRE FEED
CONTROLLER
HWP-50E Hot Wire Process
CABLE WIRING DIAGRAM 9629-S2-9302P13
50
9629HW
WIRE FEED
CONTROLLER
51
B
B
B
A
P13
A
3106A-14S-6S
P14
A
3106A-20-27P
P2
9302B
HWP
CONTROLLER
HWP-50E Hot Wire Process
CABLE WIRING DIAGRAM 9629-S2-9302-P14
D
C
B
A
NOTES:
WF-50
CONDUIT BOX
P3
HWP-50E Hot Wire Process
WIRE FEEDER WIRING DIAGRAM WF-50-1W
52