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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
!
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Table of Contents
Summary of Contents for Jet Lline HWP-50E
- Page 1 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...
- Page 2 HWP-50E Hot Wire Process...
- Page 3 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.
- Page 4 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.
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Page 5: Table Of Contents
HWP-50E Hot Wire Process Table of Contents Section I ................1 Safety Precautions . - Page 6 HWP-50E Hot Wire Process Section V ................19 Operation .
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Page 7: Section I
HWP-50E Hot Wire Process Section I Safety Precautions Disconnect input power before installing WARNING 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... -
Page 8: Arc Rays
HWP-50E Hot Wire Process Keep all panels and covers securely in If inside, ventilate the area and/or use place. exhaust at the arc to remove welding fumes and gases. Clamp work cable with good metal-to- metal contact to workpiece or worktable If ventilation is poor, use an approved air- as near the weld as practical. -
Page 9: Welding
HWP-50E Hot Wire Process Keep cylinders away from any welding or Watch for fire, and keep a fire other electrical circuits. extinguisher nearby. Never weld on a pressurized cylinder - Do not weld on closed containers such as explosion will result. -
Page 10: Principal Safety Standards
HWP-50E Hot Wire Process results are complex. Current scientific Recommended Safe Practices understanding does not yet allow us to interpret Preparation for Welding and Cutting of the evidence in a single coherent framework. Containers That Have Held Hazardous Even more frustrating, it does not yet allow us... -
Page 11: Section Ii
Section II Introduction The hot wire welding process produces a high The HWP-50E consists of the following parts: quality weld with a high deposition rate of the HWP-200E Contoured Wave Power Supply filler material. It differs from the more common... - Page 12 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.
- Page 13 HWP-50E Hot Wire Process HWP-50E SYSTEM INTERCONNECTION...
- Page 14 HWP-50E Hot Wire Process...
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Page 15: Section Iii
HWP-50E Hot Wire Process Section III Specifications A. HWP-200E-1-220-A1000 Hot Wire Power Supply Input General Voltage: 220 V ±10% Weight: 110 lb (50 Kg) Phases: Three Frequency: 50/60 Hz Environment Power: 3 KVA SCC: 10 KA Indoor use only Ambient Temp: -10 / C to 40 / C... -
Page 16: Hwp-200E-1-A1000 Hot Wire Power Supply
HWP-50E Hot Wire Process B. HWP-200E-1-A1000 Hot Wire Power Supply Input General Voltage: 380/415/440-480 V ±5% Weight: 110 lb (50 Kg) Phases: Three Frequency: 50/60 Hz Environment Power: 3 KVA Indoor use only SCC: 10 KA Ambient Temp: -10 / C to 40 / C... -
Page 17: 9302C Hot Wire Voltage Control
HWP-50E Hot Wire Process C. 9302C Hot Wire Voltage Control Input Connections Input requirements delivered through S11. S11: To hot wire power supply S13: To remote contactor Controls and Indicators S14: To 9629HW wire feed control Meters: Hot Wire volts and amps... -
Page 18: Wire Feedhead
HWP-50E Hot Wire Process D. WF-50 Wire Feedhead General Specifications Weight: 20 lb (9 kg) Wire Diameters: 0.045" and 0.062" Wire Spool: 12" (300 mm) diameter (1.2 and 1.6 mm) Controlled by: 9629HW Microprocessor No. Drive Rolls: Four Control Speed Range:... -
Page 19: 9629Hw Wire Speed Control
HWP-50E Hot Wire Process E. 9629HW Wire Speed Control General Input Weight: 16 lb (7 kg) Voltage: 110/220 Volts Phases: Single Frequency: 50/60 Hz Connections Pulse lockout input and output Remote Control Wire Feedhead motor (And tach-generator if fitted) 4X DIA 0.3125 in... -
Page 20: Hot Wire Torch
HWP-50E Hot Wire Process F. Hot Wire Torch G. Wire Positioner Assembly... -
Page 21: Section Iv
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... - Page 22 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- T1 Connections –...
- Page 23 Diagram.) Additionally, the wire feed speed may be The HWP-50E system can be more completely controlled remotely by applying a 0-10vdc controlled remotely by using the S2 remote signal to S2, Pins M and N (M is high and N is connector on the HWP-200E enclosure.
- Page 24 HWP-50E Hot Wire Process purchased to activate this feature on the 9629 9302C Hot Wire Control control. Part number is 9629HW-R1. This should be mounted close to the operating There is a 0-10vdc feedback signal available at position in such a way that the meters can be Pins C and D only when the HWP-200-38®...
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Page 25: Section V
HWP-50E Hot Wire Process Section V Operation Prior to the commencement of welding, it is imparts the electrical current to the wire, is set necessary to position the hot wire torch to feed back ½” (12 mm) inside the gas diffuser. Check... - Page 26 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...
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Page 27: Maintenance
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. - Page 28 HWP-50E Hot Wire Process...
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Page 29: Section Vii
The following pages provide a detailed parts list The following parts lists are included in this of all the elements of the HWP-50E Hot Wire manual. Their appropriate page numbers are System. They are arranged so the parts list on... - Page 30 HWP-50E Hot Wire Process HWP-200E-1-220-F7 OR HWP-200E-1-F7 POWER SUPPLY FRONT PANEL - INTERIOR...
- Page 31 HWP-50E Hot Wire Process HWP-200E-1-A1000 POWER SUPPLY - 380/415/440-480V HWP-200E-1-220-A1000 POWER SUPPLY - 220V FRONT PANEL - INTERIOR Recommended Spares Item Part Level Level Description HWP-200E-2-ENC Enclosure ......1 M15859-3 Work Receptacle .
- Page 32 HWP-50E Hot Wire Process HWP-200E-1 POWER SUPPLY INTERIOR BASE VIEW...
- Page 33 HWP-50E Hot Wire Process HWP-200E POWER SUPPLY INTERIOR BASE Recommended Spares Item Part Level Level Description HWP-200E-2-ENC Enclosure ......1 802940URLLS Current Transformer, 200A/5A, Ref CT1 .
- Page 34 HWP-50E Hot Wire Process HWP-200E POWER SUPPLY REAR PANEL - INTERIOR...
- Page 35 HWP-50E Hot Wire Process HWP-200E POWER SUPPLY REAR PANEL - INTERIOR Recommended Spares Item Part Level Level Description HWP-200E-2-ENC Enclosure ......1 8262G22 Solenoid Valve, Ref SV1 .
- Page 36 HWP-50E Hot Wire Process 9302C HOT WIRE CONTROL...
- Page 37 HWP-50E Hot Wire Process 9302C HOT WIRE CONTROL Recommended Spares Item Part Level Level Description 9302A-11 Enclosure ......1 3102A-22-19P Amphenol Connector, 14 Pin, Ref S11 .
- Page 38 HWP-50E Hot Wire Process WF-50 WIRE FEED HEAD...
- Page 39 HWP-50E Hot Wire Process WF-50 WIRE FEED HEAD Recommended Spares Item Part Level Level Description WF-50-1 Wire Feed Head ......1 046779 Housing .
- Page 40 HWP-50E Hot Wire Process HWCP-100 WIRE GUIDE POSITIONER...
- Page 41 HWP-50E Hot Wire Process HWCP-100 WIRE GUIDE POSITIONER Recommended Spares Item Part Level Level Description HWCP-100 Wire Guide Positioner ....1 HWCP-100-3 Cam Plate .
- Page 42 HWP-50E Hot Wire Process HWT-1 HOT WIRE TORCH...
- Page 43 HWP-50E Hot Wire Process HWT-1 HOT WIRE TORCH Recommended Spares Item Part Level Level Description Main Body Assembly ..... 1 Contact Tip .
- Page 44 HWP-50E Hot Wire Process HOT WIRE ACCESSORY KITS Recommended Spares Item Part Level Level Description 20B6035HW Accessory Kit, 0.035” (0.9 mm) Wire ..1 Includes: T1035 Contact Tip, 0.035" (0.9 mm) Wire ..1 N1C12Q Nozzle Assembly, 0.5"...
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Page 45: Section Viii
HWP-50E Hot Wire Process Section VIII PCB Descriptions Pin 2 – Common. Reference common to A. HWP-200-6-1 Voltage inverter, PS1. Reference Board J5 - Start Output Pin 1 – Collector. Isolated open collector output Please refer to the illustration on the next page to inverter, PS1. - Page 46 HWP-50E Hot Wire Process P2 - Offset Adjustment Pot TP7 - Circuit Common Set to 0 vdc reference output at J4 when Circuit common. reference input at J1 is minimum. Monitor TP8 - +12vdc output using TP3 (HI) and TP7 (Common).
- Page 47 HWP-50E Hot Wire Process HWP-200-6-1 VOLTAGE REFERENCE BOARD...
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Page 48: Pcm4 Analog Isolator Board
HWP-50E Hot Wire Process P503 – Min B. PCM4 Analog Isolator This is the minimum or offset adjustment. With Board minimum input voltage applied, adjust until output is in agreement, for best linearity. Please refer to the illustration on the next page SW501 –... - Page 49 HWP-50E Hot Wire Process PCM4 ANALOG ISOLATOR BOARD...
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Page 50: Transformer Ratings
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... -
Page 51: Section Ix
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. -
Page 52: Interconnection Diagram
HWP-50E Hot Wire Process INTERCONNECTION DIAGRAM HWP-200E-1-A1000... -
Page 53: Interconnection Diagram
HWP-50E Hot Wire Process INTERCONNECTION DIAGRAM HWP-200E-1-220-A1000... -
Page 54: Interconnection Diagram
HWP-50E Hot Wire Process INTERCONNECTION DIAGRAM HWP-200E-1-A1000-CE... -
Page 55: Wiring Diagram
HWP-50E Hot Wire Process WIRING DIAGRAM 9302C CONTROL... -
Page 56: Cable Wiring Diagram
HWP-50E Hot Wire Process CABLE WIRING DIAGRAM 9629-S2-9302P13... -
Page 57: Cable Wiring Diagram
HWP-50E Hot Wire Process CABLE WIRING DIAGRAM 9629-S2-9302-P14... -
Page 58: Wire Feeder Wiring Diagram
HWP-50E Hot Wire Process WIRE FEEDER WIRING DIAGRAM WF-50-1W...
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