Hercules Deluxe User manual

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Deluxe Hot Wire Table
#8500 DHWT
Manual

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Thank you for your purchase!
Please read the enclosed safety and operating instructions
before you use the Hercules® Deluxe Hot Wire Table #8500 DHWT
for the first time, in order to ensure safe and proper handling.
With the Hercules® #8500 Deluxe Hot Wire Table you can cut low
density foam, polystyrene, Styrofoam in a clean and safe way.
The standard equipment includes a spool with cutting wire
(Φ0.18mm, length 5m), an adjustable angle stop with an
extension rail, circle cutting attachment & foot pedal switch.
WARNING
Some fumes or gases created by soldering, welding or cutting
when using these products can contain chemicals known to the
State of California to cause cancer, birth defects or other
reproductive harm. Some examples of these chemicals are:
●Lead form lead-based soldering wire,
●Flame retardants from flame resistant insulation Styrofoam.
You risk from these exposure varies, depending on how often
you do this type of work. To reduce your exposure to these
chemicals: work in a well-ventilated area, and work with
approved safety equipment. For more information go to
www.P65Warnings.ca.gov.

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Overall view (Fig. 1):
1. Foot Pedal control/ switch
2. –ON, ՕOFF, =FOOT PEDAL Mode
3. Temperature Level adjustment knob
4. Standby LED
5. Knurled screw for clamping the cutting wire
6. Circle cutting attachment
7. Overarm
8. Screw for wire spool
9. Wire spool (Replacement wire #6555)
10. Screw for spool carrier
11. Spool carrier
12. Guide slot
13. Guide Wire
14. Lower wire guide
15. Slot for angle stop
16. Extension rail
17. Angle/ Miter gauge
18. Miter angle adjustment screw
19. Rail adjustment screw
20. Slide adjustment screw
Fig.1

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Technical data
Voltage: Primary 115 Volt, 60Hz
Secondary max.10.5 Volt, 60Hz
Power rating: max. 25W
Secondary current: max.1.7 A
Dimensions of work surface: 14 ½”x 10 ¼” (370 x 260 mm)
Max. Cutting height: 5 ½” (140 mm)
Throat: 13 ¾” (350 mm)
Weight: 8lb (3.6kg)
For use in dry environments only
Protection class ll device
Additional safety instructions
1. Provide good ventilation, when using the device
2. Observe the material suppliers safety instructions when cutting
3. The cutting wire is hot. ** Risk of skin burn! **
4. DO NOT use the device near curtains or other combustible
materials.
5. DO NOT leave the device unattended when it is switched on.
6. Only use the supplied cutting wire or genuine Hercules® #8500
DHWT replacement wire (#6555), otherwise the transformer can
become overloaded and damage the unit.
7. Switch off the device after use.

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Assembling the Hercules® #8500 DHWT
1. Fit the overarm 1 (Fig. 2) underneath the device by using
the enclosed knurled screw. Fasten the cable 2to the overarm
with the screw 3. Tighten the screw well to ensure good
electrical contact (10.5 volt low voltage). Slide the spool carrier
11 (Fig. 1) on to the arm and fasten it with the screw 10 (Fig. 1).
Fig.2
2. Install Cutting Wire. After installing Overarm & Spool Carrier,
turn-over machine to install cutting wire. MAKE SURE MACHINE
IS UNPLUGGED FROM POWER SOURCE. Unwind wire from the
spool approx. 8” (20cm). Open Lower Wire Guide 14 (Fig. 1)by
loosening the Knurled Screw 1(Fig. 1). Lightly push overarm
downward & thread the wire approx. 2” into Lower Wire Guide.
Clamp the wire by tightening the Knurled Screw.

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DO NOT overtighten Knurled Screw, this will break the wire.
Release the overarm & adjust wire for tension by sliding the spool
carrier.
3. The Level/ temperature table on the front of the device serves
as a guide. The best way to find the ideal temperature is to try
different temperatures yourself. For example, straightforward
cuts you use a high temperature, for complicated shapes use a
lower temperature. Please note that too high temperatures will
cause untidy edges & burn material.
4. When cutting, move the workpiece through the wire with a
light pressure and even speed. Be aware that too high pressure
in the direction of the cut when cutting complicated shapes will
tend to bend the wire.
Note: It is normal that the wire extends somewhat after being
heated for the first time. Stretch the wire slightly by the first
heating and tension it again. The wire will now retain its length.
Foot Pedal Controller
The use of the Foot Pedal Controller 1(Fig. 1) is optional.
The Foot Pedal controls ONLY the on/ off (power)of the unit,
NOT the temperature level of the wire. It is used to heat the
cutting wire for intermittent cutting, circle/ conical cutting &
complex designs.
To use Foot Pedal Controller: Plug in Foot Pedal Controller on
front of device.
Power switch must be in =FOOT PEDAL Mode, on front of
machine. Press pedal to operate power to heat the cutting
wire. Depress pedal to power off the machine.
When you are done cutting, switch Power to ՕOFF to turn off
the device completely. Unplug foot pedal when not in use.

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Cutting Types
1. Miter Cutting
Miter cutting can be done in two ways with the Hercules®
Deluxe Hot Wire Table: by adjusting the spool carrier on the
overarm or with the adjustable angle/ miter gauge.
Adjusting the spool carrier: loosen the screws 1 and 2 (Fig. 3) and
select the required angle by sliding the spool carrier. Tighten the
screw 1again and tension the wire as usual.
Note: Adjusting the spool carrier will lengthen the heated part of
the wire and thus increase the electrical resistance. The
temperature must be adjusted accordingly.
Fig.3
Working with the angle/ miter gauge:Loosen Angle adjustment
screw 1(Fig. 4) Select the desired angle on the miter gauge 17
(Fig. 1), and tighten the Angle adjustment screw. Loosen Rail
adjustment screw 4 (Fig. 5) and move the extension rail 2 (Fig. 5)
so that you can pass the cutting wire without difficulty. Tighten
Rail adjustment screw. Press the workpiece against the rail and
guide the stop along the slot.

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Fig.4
2. Parallel Cutting
The angle/ miter gauge can be fixed for parallel cutting. Turn the
screw 3 (Fig. 5) to clamp the gauge in the slot. Guide the
workpiece past the cutting wire along the rail.
Fig. 5

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3. Small sections of long profiles
Small sections of long profiles can best be cut by laying a waste
piece 1 (Fig. 6) between the rail the work piece and then cutting
against the stop. The cutting wire then cuts into the waste piece
and the edges remain clean.
Fig. 6

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4. Cylindrical Cutting and Conical Cutting
You can fit circle cutting attachment 2 (Fig. 7)on the extension
rail 2(Fig. 5) to cut out the cylinder or the cone. By controlling
foot pedal switch 1 (Fig.7 & 8) and then releasing your hands
to turn the workpiece, the cylinder or cone can be cut out
accurately.
Fig. 7
Fig. 8

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Important hints:
-When cutting double miter (e.g. roof), don't remove the cut off
part after the first cutting. Use it as an underlay for the second
cut.
- The wire has a higher temperature at the exit side of the
workpiece, which may cause surface melting. To prevent this,
the wire can be cooled by blowing on it.
- The cutting wire normally breaks above the guide bushing.
Insert the wire a few inches further in the lower wire guide and
fasten it again at regular intervals to prevent the wire from
breaking.
Maintenance & Cleaning
CAUTION: MAKE SURE MACHINE IS UNPLUGGED FROM POWER
SOURCE prior to every adjustment, maintenance, cleaning,
measure or repair!
Cleaning the Machine: Clean the wire and bushing around
Lower Wire Guide to prevent unnecessary build-up of
polystyrene residue.
Maintenance:Check & adjust wire tension before any cuts. A
loose wire will make uneven cuts, burn material or possibly cause
injury. Keep tabletop, extension rail and guide slots free of build-
up & debris to prevent any errors with your material.
Note: Every device is dirtied when working. Cleaning is therefore
essential. To ensure a long service life, however, the machine
should be cleaned with a soft cloth or brush after each use. Mild
soap or other suitable cleaning agent may be used in this
context. Solvents or cleaning agents containing alcohol (e.g.
petrol, cleaning alcohols, etc.) should be avoided, since these
can attack plastic casings and markings on the device.

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Deluxe Hot Wire Cutting Table
Part: #8500 – DHWT
01 Housing/ Cutting Table
02 Overarm
03 Circle cutting attachment
04 Extension Rail
05 Knurled screw long
06 Washer
07 Cutting wire (PN6555)
(Φ0.18mm, length 5m)
08 Knurled screw-short
09 Slider
10 Knurled screw for overarm
11 Contact screw
12 Rubber foot
13 Miter Angle gauge
14 Clamp spring
15 Knurled screw for wire
16 Level/ Temperature
adjustment knob
17 Switch
18 Socket for foot pedal
19 Clamping
20 Washer for clamping
21 Screw for clamping
22 Foot pedal
23 Circuit board
24 Lower housing cover
25 Screw for lower
housing cover
26 Screw for transformer
27 Transformer
28 Strain relief
29 Screw for strain relief
30 Power cord

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Deluxe Hot Wire Cutting Table
Part: #8500 – DHWT