Miller JETLINE CWF-20C PRECISION WIRE FEEDER Owner's manual

Brand: Miller

Model: JETLINE CWF-20C PRECISION WIRE FEEDER

Category: Welding System

Type: Owner's manual

This manual is also suitable for

MH000000

OPERATION MANUAL

for CWF-20C

Cold Wire Feeder

OM-CWF-20C-01-2013

January 2013

IMPORTANT

Read this manual carefully before installing,

commissioning or operating this product.

Jetline Engineering, 15 Goodyear Street, Irvine, CA 92618

Telephone: (949) 951-1515 ! Fax: (949) 951-9237

Web site: www.jetline.com

! E-mail: [email protected]

CWF-20C Cold Wire Feeder

iii

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.

CWF-20C Cold Wire Feeder

NOTICE

The installation, operation and maintenance guidelines set out in this manual will enable you to maintain

the equipment in peak condition and achieve maximum efficiency with your welding operation. Please read these

instructions carefully to become aware of every advantage.

CAUTION

Only experienced personnel familiar with the operation

and safe practice of welding equipment should install

and/or use this equipment.

CWF-20C Cold Wire Feeder

Table of Contents

Section I ...............................................................................1

Safety Precautions ..................................................................1

A. Arc Welding ............................................................1

B. Electric Shock...........................................................1

C. Arc Rays ...............................................................2

D. Fumes and Gases ........................................................2

E. Cylinders...............................................................2

F. Welding................................................................3

G. Moving Parts............................................................3

H. EMF Information ........................................................3

I. Principal Safety Standards .................................................4

Section II ..............................................................................5

Introduction .......................................................................5

Section III..............................................................................6

Installation........................................................................6

Section IV .............................................................................7

Operation.........................................................................7

Section V ..............................................................................8

Maintenance.......................................................................8

A. Calibration Procedure.....................................................8

Section VI .............................................................................9

Wire Feed Accessory Kits ............................................................9

Section VII............................................................................11

CWF-20C Cold Wire Feeder

Parts Lists .......................................................................11

CWF-20C Cold Wire Feeder

WARNING

Section I

Safety Precautions

CALIFORNIA PROPOSITION 65

WARNING

This product contains chemicals, including lead,

known to the state of California to cause cancer,

and birth defects or other reproductive harm.

Wash hands after use. §248224

A. 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.

3. Disconnect input power before installing or

servicing this equipment. 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.

13. Keep all panels and covers securely in place.

14. Clamp work cable with good metal-to-metal

contact to workpiece or worktable as near the

weld as practical.

CWF-20C Cold Wire Feeder

C. Arc Rays

Arc rays can burn eyes and skin; noise can damage

hearing; flying slag or sparks can injure eyes.

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. Wear protective clothing made from durable,

flame-resistant material (wool and leather)

and foot protection where necessary.

D. Fumes and Gases

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. If inside, ventilate the area and/or use exhaust

at the arc to remove welding fumes and gases.

3. If ventilation is poor, use an approved air-

supplied respirator.

4. 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 air-supplied

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 air-supplied

respirator. The coatings and any metals

containing these elements can give off toxic

fumes if welded.

E. Cylinders

Cylinders can explode if damaged.

Shielding gas cylinders contain gas under high

pressure. If damaged, a cylinder can explode. Since

gas cylinders are normally part of the welding

process, be sure to treat them carefully.

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.

3. Keep cylinders away from any welding or

other electrical circuits.

4. Never weld on a pressurized cylinder -

explosion will result.

5. Use only correct shielding gas cylinders,

regulators, hoses and fittings designed for the

specific application; maintain them and

associated parts in good condition.

6. 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. Read and follow instructions on compressed

gas cylinders, associated equipment, and

CGA publication P-1 listed in Safety

Standards.

CWF-20C Cold Wire Feeder

F. Welding

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. Be alert that welding sparks and hot materials

from welding can easily go through small

cracks and openings to adjacent areas.

5. Watch for fire, and keep a fire extinguisher

nearby.

6. Do not weld on closed containers such as

tanks, drums, or pipes, unless they are

properly prepared according to AWSF4.1 (see

safety Standards).

7. Connect work cable to the work as close to

the welding area as practical to prevent

welding current traveling long, possibly

unknown paths and causing electric shock

and fire hazards.

8. Wear oil-free protective garments such as

leather gloves, heavy shirt, cuffless trousers,

high shoes, and a cap.

G. Moving Parts

Moving parts, such as fans, rotors, and belts can cut

fingers and hands and catch loose clothing.

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.

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-BP-E-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 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."

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.

About Pacemakers:

The above procedures are among those also

normally recommended for pacemaker wearers.

Consult your doctor for complete information.

CWF-20C Cold Wire Feeder

I. Principal Safety Standards

Reference as applicable

Safety in Welding and Cuttin

g, 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

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

Safe Handling of Compressed Gases in Cylinders,

CGA Pamphlet P-1, from Compressed Gas

Association, 1235 Jefferson Davis Highway, Suite

501, Arlington, VA 22202

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

CWF-20C Cold Wire Feeder

Section II

Introduction

The cold wire feeder is designed to supply filler

metal to the weld puddle in a mechanized tungsten

arc welding application.

The wire feeder can be mounted as an assembly or

the components can be removed from the mounting

plate and installed in a number of positions with

respect to each other.

The CWF-20C Cold Wire Feeder comes with a

motor/tach generator cable, but no motor control. It

is specifically designed for connection to an MCM-1

motor control module, as part of the 9500 System

Controller. However, it can be used with any DC

motor controller capable of delivering 0 to 90 volts

DC at 1/10 hp. The tach generator output is

approximately 0 to 25 volts DC.

The Cold Wire Feeder system will accurately feed

0.020, 0.030, 0.045, 0.062 and 3/32 (0.5 to 2.4 mm)

hard and soft wires for mechanized TIG or plasma

welding. The system consists of a DC motor-driven

four feed roll assembly, spool adapter and a wire

guide positioner. The positioner incorporates X-Y-Z

movements of the wire tip. The positioner includes

a universal torch mounting bracket.

The basic components of the CWF-20C are:

1. The wire drive unit consisting of the motor

and the drive housing to feed the wire.

2. The wire guide positioner attachment guides

the wire into the puddle.

3. The spool adapter holds 8" to 10" (200 to 254

mm) diameter wire spools.

4. A spool cover is supplied to keep the wire

clean.

If using the MCM-3X optional control:

5. The MCM-3X control includes a power

on/off switch, a fuse assembly, and a power

indicating light. Also contained in the MCM-

3X enclosure is a DC servo drive that, when

coupled to the 9500 Controller, is capable of

driving the filler wire at a maximum speed of

300 IPM (7620 mm) with a 500:1 speed range

and a speed holding accuracy of 0.5%.

The drive is a closed loop servo incorporating

a motor with an integral tach-generator for

velocity feed-back. This tach-generator

signal also goes to the 9500 Controller

enabling the 9500 to display actual wire feed

speed and to further close the velocity loop

ensuring that the actual value agrees with the

set value (if there is a non-zero number

entered in the “Sensitivity” field in the 9500

configuration screen - see the 9500 manual).

All jog and run functions for the wire feeder

are controlled by the 9500. The MCM-3X

unit will not control the filler wire unless

interfaced to the 9500 Controller. See the

9500 manual for operation and calibration of

the CWF-20C wire feeder assembly.

CWF-20C Cold Wire Feeder

Section III

Installation

1. The wire feeder gearbox is filled with oil at

the factory. It is necessary to replace the

shipping plug in the gearbox with the vent

plug attached to the wire feeder. The vent

plug should be mounted in the highest

position on the gearbox.

2. Wire Feeder - Transfer mounting holes from

aluminum mounting plate if the unit is to be

mounted as an assembly. Optional mounting

brackets are available from the factory.

If the components are to be mounted

separately, the spool adapter hub must be

mounted so that the wire feeds in a straight

line into the inlet guide.

3. If using the MCM-3X, the control should be

mounted in a suitable manner providing

adequate ventilation. The control has a built-

in fan to distribute the heat from the hot spots

in the control to the enclosure walls and relies

on both convection and radiation to dissipate

the heat from the walls of the enclosure.

There are no ventilation louvers.

The MCM-3X is shipped with electrical cord

and connections set for 115 volt, 50/60 Hz

power supply (5 amps).

4. Slip the wire guide positioner onto the torch

barrel and tighten wing nuts. You may

choose from one of three sets of mounting

holes depending upon the brand of the torch

to be used. The wire guide tip angle should

be set roughly by positioning the wire guide

tip and tightening screw. The tip should be

on approximately the same level as the

tungsten (see WGP-1 drawing).

5. Select the inlet guides, conduit, wire guide

tip, and feed rolls required for a given wire

size. Be sure all the components match the

wire to be used.

Slip the conduit into the outlet guide and

tighten the securing knob. Insert the opposite

end into the wire guide tip and tighten the

screw. If the conduit, as supplied, is too long,

the assembly can be shortened to any desired

length. It is essential that the end be deburred

after cutting.

Install the feed rolls on the drive housing with

the screws supplied. The feed rolls are

interchangeable from top to bottom and are

reversible if one side should wear. Install the

inlet guide in its receptacle on the drive

housing and install the intermediate guide

between the feed rolls.

6. Remove the spool lid and mount the spool of

welding wire on the spool adapter so that the

wire will be pulled from the low side of the

coil. When the spool is in place, replace the

spool retaining ring. Adjust friction brake on

the wire spool by adjusting the screw in the

center of the spool. Replace the lid on the

spool cover. Insert the deburred end of the

wire into the inlet guide through the feed roll

and the outlet guide. Jog the wire into the

conduit using the 9500 wire jog function.

Continue to feed the wire through the conduit

and guide tip until the desired amount extends

beyond the tip.

CWF-20C Cold Wire Feeder

Section IV

Operation

Refer to the 9500 System Controller manual for

operation and programming of the CWF-20C wire

feeder.

CAUTION

Whenever repairs are required, always turn all

power controls off and disconnect all electrical

cables from power supply.

Several adjustments are provided on the wire

positioner in order to permit the exact position of the

wire as it enters the puddle.

1. Lateral adjustment of 1/4" (6 mm), 1/8" (3

mm) adjustment of tip on each side of weld

seam.

2. Vertical adjustment of 1/4" (6 mm) tip to

work.

3. Coarse adjustment of guide tip angle.

Check tension of the drive roll springs. Too much

pressure will deform the wire and too little pressure

will cause wire slippage.

CWF-20C Cold Wire Feeder

Section V

Maintenance

Periodically clean the drive rolls of dirt and chips.

Occasionally check wear of liners, tips, and guides.

Always replace the fuse with one of equal value (3

amp fast blow).

Periodically clean the control enclosure. Dust and

dirt will hamper the cooling efficiency. Check

inside the enclosure for dust. Remove with a

vacuum and brush if excessive.

WARNING

Maintenance and electrical work must be

performed by experienced and trained personnel.

A. Calibration Procedure

The wire feed system calibration is done at the 9500

Controller. The wire feed speed is checked with

time/distance measurements at the low end and high

end speeds. If calibration is outside the system

limits, software calibration numbers are changed in

the 9500 calibration screens to correct the error. See

the 9500 System Controller manual and 9500

Software Calibration Guide for further calibration

information.

CWF-20C Cold Wire Feeder

Section VI

Wire Feed Accessory Kits

Wire Size *Complete

Accessory

Kit

Conduit - 6

ft. only

Outlet Guide Inlet Guide Wire Guide

Tip

Feed Rolls

& Inlet

Guide

**Curved

Wire Tip

0.020

(0.5 mm)

20B6020K 42-23

PT-40-NAT

OG-020 056192 WGT-020 053693

(Order 4)

0.030

(0.8 mm)

20B6030K 44N3545 OG-033-45 056192 WGT-030 046780 CWGT-030

0.035

(1.0/0.9 mm)

20B6035K 44N3545 OG-035-45 056192 WGT-035 046781 CWGT-035

0.045

(1.2 mm)

20B6045K 44N3545 OG-035-45 056193 WGT-045 046782 CWGT-045

0.062

(1.6 mm)

20B6062K 45N116 OG-062 056195 WGT-062 046783

0.093

(2.4 mm)

20B6093K 18630F OG-17 056196 WGT-093 046789

* Includes Inlet/Outlet guides, feed rolls, wire guide tip, and 6 ft. (1800 mm) conduit.

**Requires wire guide positioner for curved tips, P/N WGP-3.

Wire Feed Roll Kits and parts sold separately.

Optional Items Sold Separately

607B Wire Spool Cover, clear

CWF-20C Cold Wire Feeder

Section VII

Parts Lists

The following pages provide a detailed parts list of all

the elements of the CWF-20C Cold Wire Feeder.

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.

Two columns are included in the list to show the

spare parts which are recommended to be stocked by

the user. The two levels can be defined as follows:

Level 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.

The following parts lists are included in this manual.

Their appropriate page numbers are listed:

Cold Wire Feeder Assembly ............ 12/13

Wire Guide Positioner ................. 14/15

Precision Wire Feed Control ............ 16/17

CWF-20C Cold Wire Feeder

COLD WIRE FEEDER ASSEMBLY

CWF-20C

Recommended Spares

Item Part Level Level

No. No. Description Qty I II

2 CWF-20B-100 Mounting Plate Detail ....................... 1

3 CWF-20B-110 Mounting Bracket Details .................... 1

4 CWF-20B-120 Cover Assembly ............................ 1

5 Drive Housing ............................. 1

6 Feed Roll & Inlet Guide Assy (See chart Section VI) 1

10 F710-50-B4-J Gear Reducer .............................. 1

11 MT3353-42CZ Motor & Tach Assembly ..................... 1 1

15 053841 Drive Gear ................................ 1

16 374831-A Spool Adapter ............................. 1

20 SC50 Set Screw Collar............................ 1

21 CWF-20B-140 Retainer Detail ............................. 1

22 8-32X5/8 Socket Head Screw ......................... 1

23 8-32X5/16 Button Head Screw ......................... 4

24 1/4-20X1/2 Socket Head Screw ......................... 4

25 1/4-20X5/8 Flat Head Screw............................ 4

26 3/8-16X1 1/4 Hex Head Screw............................ 2

27 3/8 Flat Washer ............................... 2

29 95611A031 Insulating Washer .......................... 2

30 8527K134 Insulating Tube ............................ 2

31 1/32X6X5 Insulation ................................. 1

32 1/32X6X5 Insulation ................................. 1

33 1/4-20X7/8 Hex Head Screw............................ 4

34 1/4 Lock Washer .............................. 4

CWF-20C Cold Wire Feeder

WIRE GUIDE POSITIONER

WGP-1 (Rev L)

Recommended Spares

Item Part Level Level

No. No. Description Qty I II

2 WGP-1-230 Base ..................................... 1

3 WGP-1-100 (REV E) Cam Plate ............................... 1

4 WGP-1-200 Housing .................................. 1

5 WGP-1-210 (REV E) Bar ..................................... 1

6 WGP-1-220 Clamp.................................... 1

7 WGP-XXX Shown for Reference (part of Wire Feed Kit)

8 WGP-1-240 Stud ..................................... 2

9 WGP-1-250 V-Block .................................. 2 1

10 Guide, Dowell ............................. 1

11 Fulcrum Pin, Dowell ........................ 1

12 Hinge Pin, Dowell .......................... 1

13 CL-1-KHS Knurled Head Screw ........................ 1 1 1

14 CL-1-KN Knurled Nut ............................... 1 1 1

15 CL-1-SB Swing Bolt ................................ 1

16 WGP-1-16 Lift Pin ................................... 1

17 6655K13 Thrust Bearing ............................. 1

18 VV-38 Compression Spring ......................... 1 1

19 1/4-20x7/8 Socket Head Screw ......................... 2

20 1/4-20x5/8 Socket Head Screw ......................... 2 2 2

21 1/4 Flat Washer ............................... 1

22 11256 Compression Spring ......................... 1 1

23 3025 Knob ..................................... 2 1 1

24 3/8-16-5/16 Nylock Set Screw........................... 1

25 WGP-1-260 V-Mount (Optional Item, Large Clamp Kit) ...... 1

26 WGP-1-261 V-Clamp (Optional Item, Large Clamp Kit) ...... 1

27 WGP-1-262 Stud (Optional Item, Large Clamp Kit) .......... 2

28 1/4-20-5/8 Socket Head Screw ......................... 2

29 WGP-1-263 Base Extension (Optional Item, extended base) .... 1

30 1/4-20x3/4 Socket Head Screw (Optional Item, extended base) . . 2

31 6435K12 Collar, 1/4 diameter ......................... 1

32 6391K143 Bronze Bearing, 1/4 x 1/2 x 1 ................. 1

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Miller JETLINE CWF-20C PRECISION WIRE FEEDER Owner's manual

Brand: Miller

Model: JETLINE CWF-20C PRECISION WIRE FEEDER

Category: Welding System

Type: Owner's manual

This manual is also suitable for

MH000000

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Miller JETLINE CWF-20C PRECISION WIRE FEEDER Owner's manual

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