Miller JETLINE HWP-50F HOT WIRE PROCESS Owner's manual

OM-HWP-50F-01-2015

2-12-V

February 2015

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]

OPERATION MANUAL

HWP-50F

Hot Wire Process

IMPORTANT

II.

III.

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.

When contacting the factory, please have the serial number and job number of your machine available

in order to reference the original factory configuration.

LIMITED WARRANTY

IV.

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.

Only experienced personnel familiar with

the operation and safe practice of welding

equipment should install and/or use this

equipment.

NOTICE

CAUTION

V.

TABLE OF CONTENTS

Section I Safety Precautions 1

Section II Introduction

4

Section III Specifications

7

A. HWP-200E-1-220-A1000 Hot Wire Power Supply 7

D. WF-50 Wire Feedhead 9

E. 9700W Wire Speed Control 11

F. Hot Wire Torch 12

G. Wire Positioner Assembly 12

Section IV 13

Installation and Setup

13

Section V Operation

16

Section VI Maintenance

18

Section VII Parts List

19

Section VIII PCB Descriptions

32

Section IX Electrical Diagrams

37

Page 1

Section I Safety Precautions

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 part 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 part or worktable as near the weld as

practical.

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

Page 2

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.

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 part, 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.

Page 3

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 about 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 part 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.

I. Principal Safety Standards

Reference as applicable

Safety in Welding and Cutting, ANSI Standard Z49.1,

from American Welding Society, 550 N.W. LeJeune

Rd, Miami, FL 33126

Safety and Health Standards, OSHA 29 CFR 1910,

from Superintendent of Documents, U.S. Government

Printing Office, Washington, D.C. 20402

National Electric Code, NFPA Standard 70 from

National Fire Protection Association, Batterymarch

Park, Quincy, MA 02269

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

J. 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. §2482

Page 4

Section II Introduction

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.

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 I

2

R 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.

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.

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.

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.

The HWP-50E consists of the following parts:

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.

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).

9700W Speed Control

The control of wire feed speed is effected through the 9700W 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.

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.

Page 5

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.

Page 6

HWP-50F SYSTEM INTERCONNECTION

Page 7

Section III Specifications

A. HWP-200E-1-220-A1000

Hot Wire Power Supply

Input

Voltage: 220 V 10%

Phases: Three

Frequency: 50/60 Hz

Power: 3 KVA

SCC: 10 KA

Output

Voltage: 2.5 to 15 VAC (Adjustable)

Phases: Single

Frequency: 50 to 200 Hz (Adjustable)

Amps: 200 A

Duty Cycle: 100%

Waveform: Electrically-generated

sinusoidal

General

Weight: 110 lb (50 Kg)

Environment

Indoor use only

Ambient Temp: -10°C to 40°C

Storage Temp: -20°C to 60°C

Max Humidity: 95% RH non cond

Altitude: 1000 M or lower; up to

3000 M with derating

B. HWP-200E-1-A1000 Hot

Wire Power Supply

Input

Voltage: 380/415/440-480 V 5%

Other specifications same as A above.

Page 8

C. 9302C Hot Wire Voltage Control

Input

Input requirements delivered through S11.

Controls and Indicators

Meters: Hot Wire volts and amps

Adjustment: Hot wire voltage

Switch: Hot, Cold or Setup

Pushbutton: Gas Purge

Connections

S11: To hot wire power supply

S13: To remote contactor

S14: To 9629HW wire feed control

General

Weight: 10 lb (4.5 kg)

Page 9

D. WF-50 Wire Feedhead

Specifications

Wire Diameters: 0.045" and 0.062"

(1.2 and 1.6 mm)

No. Drive Rolls: Four

Speed Range: 12 to 600 IPM

(30 to 1,525 cm/min

General

Weight: 20 lb (9 kg)

Wire Spool: 12" (300 mm) diameter

Controlled by: 9700W Microprocessor Control

Page

11

E. 9700W Wire Speed Control

Input

Voltage: 110/220 Volts

Phases: Single

Frequency: 50/60 Hz

Connections

S1: Pulse lockout input and output

S2: Remote Control

S3: Wire Feedhead motor

(And tach-generator if fitted)

General

Weight: 16 lb (7 kg)

See 9700W manual for operation and set up.

Page

12

F. Hot Wire Torch

G. Wire Positioner Assembly

Page

13

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

Volt, 3 Phase, 50/60Hz, 3Kva supply. The model

HWP-200E-1-A1000 requires a 380/415/440-480

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:

For either model of hot wire power supply, the

two transformers, T1 and T2 must be configured

for input voltage changeover:

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

See also Dwg HWP-200E-1-A1000-CE

Page

14

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.

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 380-480VAC operation.

There is never any change in connections to the

T1 secondary.

Maximum Winding Temperature: 65°C

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 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-S2-9302-P14

interconnecting cable. (This is the standard

supplied cable.) See the HWP-50E layout

drawing for further details.

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.

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

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.

The 9700W wire feed controller is slaved to the

system. Pushing the 9700W start button will not

start the hot wire power supply, it is used for

maintained jog.

System Start From 9700W

The system may alternately be started from the

9700W Start button by using the 9629-S2-9032-

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 9700W Start

button.

Pressing the 9700W Stop button will stop the hot

wire power supply immediately.

Make sure that in the HWP sub menu on the

9700 that it is enabled and the start and stop

delay times are set to 0.0. If HWP is disabled the

hot wire power supply will not turn on. If HWP

start delay is not 0.0 then the hot wire power

supply will not come on at the same time as the

wire, but come on after that time delay. If the

HWP stop delay is not 0.0 then the hot wire

power supply will stay on for that amount of time

after the wire has stopped.

Note that the HWP sub menu is set up in AUX1

Program Sub Menu of 9700W. Normally this is

done at factory prior to shipment if defined at time

of order.

Page

15

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

9700W wire feed control.

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.)

The HWP-50E system can be more completely

controlled remotely by using the S2 remote

connector on the HWP-200E enclosure. Use a

3106A-20-33P mating connector with 97-3057-

1012-1 cable clamp. Connect remote signals as

follows:

Apply start contact to Pins E and F.

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.

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.

Remote Functions Connector S2, 9700W

If using the remote connector on the HWP-200E

power supply, the remote connector, S2, on the

9700W wire feed control may also be used for

remote sequencing. Please refer also to the

9700W manual for further details. In this case the

interconnecting cables, 9629-S2-9032-P13 or

P14, will not be required.

Apply a wire feed start contact to S2, Pins A and

B of the 9700W control. Closing this contact will

start the wire feed sequence, opening the contact

will stop the wire feed sequence. 9700W Start

and Stop Delays will be active.

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 purchased

to activate this feature on the 9700W control. Part

number is 9629HW-R1.

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.

HWP-200E Power Supply

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.

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.

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 close 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).

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 9700W hot wire speed control through the

cable supplied with the WF-50.

Page

16

Fit the appropriate drive rolls and wire guides for

the wire size to be used.

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.

The unit receives its electrical power from the

HWP-200E power supply through the HWP-200

cable.

9700W Wire Speed Control

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 9700W operation

manual for input voltage selection.

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.

The torch is connected to the feedhead using the

supplied wire conduit. Select the correct one for

the wire size to be used.

Section V Operation

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.

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.

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.

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.

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

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.

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.

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

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Miller JETLINE HWP-50F HOT WIRE PROCESS Owner's manual

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Miller JETLINE HWP-50F HOT WIRE PROCESS Owner's manual

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