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- Page 1 LightWELD Wire Feeder SETUP GUIDE Part Number: CFHUGMPS0002ENUS | Rev: A | DCO: D6587 Copyright © 2024 IPG Photonics Corporation. All rights reserved.
- Page 2 IPG grants no license, directly or indirectly, under any patent or other intellectual property rights from use of the information provided herein. IPG, IPG Photonics and the IPG Logo are registered trademarks of IPG Photonics Corporation. IPG has identified words that are considered trademarks. Neither the presence nor absence of trademark identifications affects the legal status of any trademarks.
- Page 3 Preface Preface Please take time to read this Setup Guide and familiarize yourself with its contents before you use the product. This guide contains the following: Descriptions of the parts included in the LightWELD Wire Feeder Kit • Descriptions of the Hard Wire and Soft Wire configurations •...
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Page 5: Table Of Contents
Table of Contents Table of Contents Getting Started ....................11 Configuration Options ..........................11 1.1.1 Hard Wire Configuration ......................11 1.1.2 Soft Wire Configuration ......................13 1.1.3 Drive Rolls ............................ 14 1.1.4 Assembling the Wire Feeder Attachment ................15 1.1.5 Setting Up the Wire Feeder Unit .................... - Page 6 THIS PAGE IS INTENTIONALLY BLANK.
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Page 7: List Of Figures
List of Figures List of Figures Figure 1: Example of a Stainless Steel Filler Weld with 0.045” (1.1mm) Hard Wire ............12 Figure 2: Example of an Aluminum 5XXX filler Weld with 0.047” (1.2mm) Soft Wire ............14 Figure 3: Markings that Indicate the Groove Sizes on 0.045”... - Page 8 List of Figures Figure 50: The 0.030” - 0.035” V-DRIVE ROLLS ........................37 Figure 51: The 0.030” - 0.035” V-DRIVE ROLLS ........................37 Figure 52: The Liners ................................. 38 Figure 53: The 0.030” - 0.035” U-DRIVE ROLLS ........................39 Figure 54: The 0.047''-0.063'' U-DRIVE ROLLS .........................
- Page 9 List of Tables List of Tables Table 1: Components for the Hard Wire Configuration ....................11 Table 2: Components for the Soft Wire Configuration ...................... 13 Table 3: Drive Rolls for Hard Wire Configurations and Soft Wire Configurations ............14 Table 4: Suggested Settings for the Wire Feed Speed Parameters ..................
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Page 11: Getting Started
Getting Started 1 Getting Started VIDEO: Part 1 - Getting Started 1.1 Configuration Options Refer to Section 1.1.1 (below) to determine the appropriate components for a Hard Wire configuration. Refer to Section 1.1.2 on page 13 to determine the appropriate components for a Soft Wire configuration. -
Page 12: Figure 1: Example Of A Stainless Steel Filler Weld With 0.045" (1.1Mm) Hard Wire
Getting Started For example, to do a Stainless Steel filler weld with 0.045” (1.1mm) hard wire, use • the 0.045”-0.063” (1.1- 1.6mm) V-Drive Roll, the 0.030”-0.045” (0.8-1.1mm) Steel Liner, • the 0.047” (1.2mm) Contact Tip, and • • the 0.4'' (10mm) Extension. See Figure 1 (below). -
Page 13: Soft Wire Configuration
Getting Started 1.1.2 Soft Wire Configuration Use the Soft Wire configuration for welding with Aluminum wire or other very soft materials. The Soft Wire configuration requires U-Drive Rolls, Teflon Liners, and 0.28'' (7mm) Extension. To select the proper components, use the size that corresponds with the soft wire’s diameter. -
Page 14: Drive Rolls
Getting Started Figure 2: Example of an Aluminum 5XXX filler Weld with 0.047” (1.2mm) Soft Wire 1.1.3 Drive Rolls Table 3 (below) shows the Drive Rolls for Hard Wire configurations and the Drive Rolls for Soft Wire configurations. Table 3: Drive Rolls for Hard Wire Configurations and Soft Wire Configurations Part Number Corresponding Wire Diameter... -
Page 15: Assembling The Wire Feeder Attachment
Getting Started Each Drive Roll has two different-sized grooves to accommodate a range of wire diameters. Notice that the drive rolls are labeled on each side. Groove dimensions are indicated on the face opposite of the groove. When loading the Drive Rolls into the drive mechanism, ensure that the desired groove markings are facing out. -
Page 16: Figure 5: Insert The Liner Into The Conduit
Getting Started VIDEO: Part 2 - Assembly Do the following to assemble the Wire Feeder Attachment: 1. Prepare the Liner and Conduit. Insert the Liner into the Conduit and feed it through, until about an inch (25.4mm) of the Liner extends out from the tube. Figure 5: Insert the Liner into the Conduit 2. -
Page 17: Figure 8: Tighten The Wire Feeder Adapter On The Conduit
Getting Started a. Insert the Wire Feeder Adapter into the Conduit. b. The Liner is designed to be longer than the Conduit with the adapters attached. If a Teflon liner is installed, simply cut the liner to be flush with the Wire Feeder Adapter. -
Page 18: Setting Up The Wire Feeder Unit
Getting Started 1.1.5 Setting Up the Wire Feeder Unit Select the appropriate drive rolls based on the material being welded and the wire size. Refer to the following tables to select the appropriate drive roll: Table 1: Components for the Hard Wire Configuration on page 11 •... -
Page 19: Figure 11: Loosen The Set Screw
Getting Started 2. Connect the Wire Feeder Attachment to the Unit. a. Using a Phillips Head screwdriver, loosen the set screw on the Wire Feeder unit. Figure 11: Loosen the Set Screw b. Locate the Wire Feeder Attachment. Insert the Wire Feeder Adapter into the wire feeder unit as far as possible without it touching the drive roll. -
Page 20: Figure 13: Insufficient Amount Of Space
Getting Started There should be a slight amount of space between the adapter and drive roll to ensure that it does not get scratched and worn out. Figure 14: Sufficient Amount of Space Figure 13: Insufficient Amount of Space Using a Phillips Head screwdriver, tighten the set screw to secure the connection between the wire feeder attachment and Wire Feeder unit. -
Page 21: Figure 17: Insert The Corresponding Wire Spool For Your Application
Getting Started b. Insert the corresponding Wire Spool for your application. Ensure that the spool is installed so the wire will feed from the bottom. Figure 17: Insert the Corresponding Wire Spool for Your Application Screw the Spool Cap back on to secure the wire spool. Figure 18: Screw the Spool Cap Back On 4. -
Page 22: Figure 20: Remove The Start Of The Wire From The Spool
Getting Started b. Remove the start of the wire from the spool. The start of the wire is likely kinked from being secured to the outer panel of the spool. Use wire cutters to remove any kinks or casting. Figure 20: Remove the Start of the Wire from the Spool Manually feed the wire from the bottom of the spool into the drive housing mechanism, through both drive rolls and into the liner for a few inches. -
Page 23: Figure 22: Ensure That The Wire Is Pushed Into The Correct Grooves
Getting Started d. Ensure that the wire is pushed into the correct grooves, which are furthest from you. The outward face of the Drive Roll will have the size of the groove labeled on it. Figure 22: Ensure that the Wire is Pushed into the Correct Grooves e. -
Page 24: Figure 24: Feed The Wire
Getting Started 5. Feed the Wire. a. Plug the wire feeder unit into a standard 110V outlet and turn on the power. Figure 24: Feed the Wire b. Ensure that the Wire Feeder Attachment is as straight as possible to prevent the wire from kinking and getting stuck on this initial feed. -
Page 25: Figure 26: Unscrew The Contact Tip From The Weld Head Adapter
Getting Started Ensure that the Weld Head Adapter’s outlet is not directly pointing at yourself or others. Keep your hands and fingers out of the direct line of the wire’s path as there is a potential for the wire to puncture skin. Unscrew the Contact Tip from the Weld Head Adapter. -
Page 26: Figure 28: Screw The Contact Tip Back Into The Weld Head Adapter
Getting Started e. Continue to wire feed until about 2” (50.8 mm) of the wire is exposed. Then screw the Contact Tip back into the Weld Head Adapter. Figure 28: Screw the Contact Tip back into the Weld Head Adapter 6. -
Page 27: Figure 30: Connect The Synch Cable Wires To The 12-Pin I/O Connector
Getting Started Figure 30: Connect the Synch Cable Wires to the 12-pin I/O Connector Turn on the LightWELD unit using the Switch Key. more information about understanding and using the LightWELD panel, review the video LightWELD 1500 Initial System Overview. Figure 31: Turn on the LightWELD Unit Using the Switch Key 7. -
Page 28: Figure 33: Insert The Tube Into The Head And Secure It By Tightening The Chuck
Getting Started b. Insert the Tube into the head and secure it by tightening the chuck. Hand tighten only. Figure 33: Insert the Tube into the Head and Secure It by Tightening the Chuck Attach the Weld Head Adapter by sliding it onto the tube. Use a 3 mm Allen Wrench to begin tightening the screw. -
Page 29: Figure 36: Ensure That The Guide Beam Is Centered
Getting Started e. Ensure that the guide beam is centered. Press Trigger 1 on the Weld Head to activate the guide beam. If the guide beam is off center, it must be adjusted at the LightWELD Interface. See "Centering the Guide Beam" on page 31 for instructions. -
Page 30: Presets
Getting Started 1.2 Presets IPG has developed preset programs, and recommended wire feed rates, that depend on material, wire alloy, wire diameter, process gas, and material thickness. Refer to the Mode Table Chart attached to the LightWELD device for recommended wire feeder presets. 1.2.1 Wire Feeder Interface Overview Using the Mode Table Chart as a guide, set the wire feed speed for the welding job. -
Page 31: Lightweld Interface Overview
Getting Started 1.2.2 LightWELD Interface Overview The LightWELD program/mode should match the wire feed rate setting of the Wire Feeder. Refer to the Mode Table Chart on the LightWELD unit for recommended presets. You can find IPG-recommended wire welding programs on the Mode Table Chart attached to the LightWELD device. -
Page 32: Figure 41: Beam Is To The Left Of The Wire
Getting Started Use the Wobble Frequency Knob to adjust the beam until it is centered on the wire. Situation 1: Situation 2: Beam is to the left of the wire Beam is to the right of the wire Turn the Wobble Frequency Knob clockwise Turn the Wobble Frequency Knob coun- (+) to move the guide beam to the right. -
Page 33: Ready To Weld
Getting Started 1.4 Ready to Weld Once the Wire Feeder is set up and the desired settings are entered, the LightWELD is ready for use. 1.4.1 Weld Head Overview Please refer to the LightWELD User Guide for more details and safety descriptions. Figure 44: The Weld Head Table 5: Features of the Weld Head Feature... -
Page 34: Welding Process Overview
Getting Started 1.4.2 Welding Process Overview Before starting to weld, press and hold Trigger 1 to activate the gas. Touch the wire and nozzle to the workpiece to engage the safety interlock. This allows the laser to be activated. Press Trigger 2 to activate the laser and begin welding. -
Page 35: Replacement Parts
Replacement Parts 2 Replacement Parts Visit the IPG Web Shop to order parts 24/7: IPG Photonics Shop. 2.1 Wire Feeder Assembly Table 6: Parts of the Wire Feeder Assembly Item Part Number Part Name Quantity Number CFHUGMPS0002ENUS SETUP GUIDE CMMIXXX0005805PX... -
Page 36: Adapter Nozzle Assembly
Replacement Parts 2.2 Adapter Nozzle Assembly The following table shows the parts in the Adapter Nozzle Assembly. Table 7: Parts of the Adapter Nozzle Assembly Item Part Number Part Name Quantity Number CMUS0010223XXXXU WELD HEAD ADAPTER P40-009401 SCREW CMUS0008398002XU GROOVED NOZZLE TIP CMUS0010359XXXXU 0.28'' (7mm) EXTENSION CMUS0008377XXXXU... -
Page 37: Drive Rolls
Replacement Parts 2.4 Drive Rolls The following table shows the part numbers and part names of the Drive Rolls. Table 9: The Drive Rolls Item Part Number Part Name Quantity Number CMMIXXX0006092PX 0.030” - 0.035” (0.8 - 0.9mm) U-DRIVE ROLL CMMIXXX0006093PX 0.047'' - 0.063'' (1.2 - 1.6mm) U-DRIVE ROLL... -
Page 38: Liners
STEEL LINER Figure 52: The Liners 2.6 Accessories Kits Visit the IPG Web Shop to order parts 24/7: IPG Photonics Shop. The following table shows all of the items in the CEU00006623XXXXU- Accessories Kit, WF. Table 11: The CEU00006623XXXXU- Accessories Kit, WF... -
Page 39: Figure 53: The 0.030" - 0.035" U-Drive Rolls
Replacement Parts Item Part Number Part Name Quantity Number CMMIXXX0006095PX 0.030”-0.035” (0.8-0.9mm) V-DRIVE ROLL CMMIXXX0006096PX 0.045'' - 0.063'' (1.1 - 1.6mm) V-DRIVE ROLL CMUS0008377XXXXU 0.4'' (10mm) EXTENSION CMUS0010362X01XU ORANGE TEFLON LINER CMUS0010362X02XU TURQUOISE TEFLON LINER CMUS0010363X01XU 0.030'' - 0.045'' (0.8 - 1.1mm) STEEL LINER CMUS0010363X02XU 0.045'' - 0.063'' (1.1 - 1.6mm) -
Page 40: The 0.030" - 0.035" V-Drive Rolls Figure 56: The 0.030" - 0.035" V-Drive Rolls
Replacement Parts Figure 55: The 0.030” - 0.035” V-DRIVE ROLLS Figure 56: The 0.030” - 0.035” V-DRIVE ROLLS Figure 57: Parts of the Weld Head Assembly, Liner, Extension, Conduit, and Tube CFHUGMPS0002ENUS REV A... - Page 41 THIS PAGE IS INTENTIONALLY BLANK.
- Page 42 The user assumes all risks and liability whatsoever in connection with use of a product or its application. IPG, IPG Photonics, The Power to Transform and IPG Photonics™ logo are trademarks of IPG Photonics Corporation. © 2024 IPG Photonics Corporation. All rights reserved.
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