IPG Photonics LightWELD User manual

DOCCHUGMPSEN0005
Version:1.0
Release Date:2/16/2022
LightWELD Wire Feeder
SET-UPGUIDE

DISCLAIMER NOTICE
Copyright
© 2016-2021 IPG Photonics Corporation. All rights reserved. You may not copy, reproduce, transmit, store in a
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shall bear the same copyright and proprietary notices which were contained on the original version.
This Set-Up Guide is provided “as is” and is subject to change and revision without notice. IPG believes that the
information provided is accurate and reliable; however, IPG makes no warranty or representation, express or implied,
regarding this document, including without limitation any implied warranties of merchantability or fitness for a particular
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Safety and Support
Please refer to the original manufacturer’s instruction manual “WF-007A Wire filling machine (Argon arc welding wire
feeding machine)”, provided with the LightWELD system, for additional operating instructions and safety
For additional safety information, or to view instructional videos, you can reach IPGsupport using one of the following
methods:
LightWELD Wire Feeder Set-Up Guide:DOCCHUGMPSEN0005
ECO# Date History Rev #
7831 February,
2022
Replaces DOCCHRDMPSXX0034; updated
name, content, and addition of video links
1

Table of Contents
1 Getting Started
Configuration Options 1
Hard Wire Configuration 1
Soft Wire Configuration 2
Drive Rolls 3
Assembling the Wire Feeder Attachment 4
Step 1:Prepare the Liner and Housing Tube 4
Step 2:Connect the Weld Head Adapter and Components 5
Step 3:Connecting the Wire Feeder Adapter and Components 6
Setting up the Wire Feeder Unit 7
Step 1:Insert the Drive Rolls 7
Step 2: Connect the Wire Feeder Attachment to the Unit 9
Step 3:Install the Spool 11
Step 4: Adjust the Wire and Secure the Drive Rolls 12
Step 5: Feed the Wire 15
Step 6:Syncing the Wire Feeder Unit and the LightWELD 17
Step 7: Attach Adapter to Weld Head 18
Presets 21
Wire Feeder Interface Overview 21
LightWELD Interface Overview 22
Ready to Weld 24
Weld Head Overview 24
Welding Process Overview 25
2 Replacement Parts
Wire Feeder Assembly 26
Adapter Nozzle Assembly 27
Contact Tip 28
Drive Roll 28
Liner 29
Wire Configuration Kits 30
Hard Wire Kit - CEU00003657XXXXU 30
Soft Wire Kit - CEU00003658XXXXU 31
3 Reference Videos
Part 1 - Getting Started 32
Part 2 - Assembly 32
Part 3 - Process Development 32

1 Getting Started
This guide describes the parts included in theLightWELDWireFeeder Kit, descriptions about the hard wire and soft wire
configurations, how to install the wire into the feeder through the nozzle tip, and instruction to synch with the LightWELD.
VIDEO: Part 1 - Getting Started
Configuration Options
Refer to the sections below to determine the appropriate components for your application. This will affect steps later in
the set up process. This wire feeder accepts standard 8" (203 mm)or 12" (305 mm)spools.
Hard Wire Configuration
Use the hard wire configuration for welding
metals, such as Stainless Steel,
Steel,Titanium, and Nickel alloys.
Requires V-Drive Rolls,Steel Liners, and 0.4''
(10mm) Extension, which is the default.
To select the proper components, use the size
that corresponds with the hard wire’s diameter.
See the chart on the right for reference.
Part Number Corresponding Wire
Diameter
V-Drive Roll
CMMIXXX0002838PX 0.030”-0.035”
(0.8-0.9mm)
CMMIXXX0002839PX 0.045”-0.063”
(1.1-1.6mm)
Steel Liner
CMUS0010363X01XU 0.030”-0.045”
(0.8-1.1mm)
CMUS0010363X02XU 0.045”-0.063”
(1.1-1.6mm)
Contact Tip
CMUS0011444XXXX0 0.030” (0.8mm)
CMUS0011445XXXX0 0.035” (0.9mm)
CMUS0011446XXXX0 0.047” (1.2mm)
CMUS0010319XXXXU 0.063” (1.6mm)
Extension
CMUS0008377XXXXU
The default 0.4"
(10mm) extension is
used for all hard wire.
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.
1 Getting Started
LightWELD WireFeeder Set-Up Guide 1

Soft Wire Configuration
Use the soft wire configuration for welding with
Aluminum wire or other very soft materials.
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.
See the chart on the right for reference.
Part Number Corresponding
Wire Diameter
U-Drive Roll
CMMIXXX0002723PX 0.030”-0.035”
(0.8-0.9mm)
CMMIXXX0002722PX 0.047”-0.063”
(1.2-1.6mm)
Teflon Liner
CMUS0010362X01XU 0.030”-0.047”
(0.8-1.2mm)
CMUS0010362X02XU 0.047”-0.063”
(1.2-1.6mm)
Contact Tip
CMUS0011444XXXXU 0.030” (0.8mm)
CMUS0011445XXXXU 0.035” (0.9mm)
CMUS0011446XXXXU 0.047” (1.2mm)
CMUS0010319XXXXU 0.063” (1.6mm)
Extension
CMUS0010359XXXXU
The 0.28
(7mm)extension is
used for all soft wire.
Example: To do an Aluminum 5XXX filler weld with 0.047” (1.2mm) Soft wire, use the 0.047”-0.063”
(1.2-1.6mm) U-Drive Roll, the orange 0.030”-0.047” (0.8-1.2mm) Liner, the 0.047" (1.2mm) Contact
Tip, and the 0.28'' (7mm) Extension.
1 Getting Started
2

Drive Rolls
Drive Roll Corresponding
Wire Diameter
Hard Wire
V-Drive Rolls
CMMIXXX0002838PX 0.030”-0.035” (0.8-0.9mm)
CMMIXXX0002839PX 0.045”-0.063” (1.1-1.6mm)
Soft Wire
U-Drive Rolls
CMMIXXX0002723PX 0.030”-0.035” (0.8-0.9mm)
CMMIXXX0002722PX 0.047”-0.063” (1.2-1.6mm)
Each drive roll has 2 different sized grooves to accommodate a range of wire diameters. Notice 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 the desired groove markings are facing out.
Once installed, the visible markings indicate the groove size that is currently in use.
1 Getting Started
LightWELD WireFeeder Set-Up Guide 3

Assembling the Wire Feeder Attachment
Once the components (Drive Rolls, Liner, Contact Tip, and Extension) have been selected according to the
application, the wire feeder unit and equipment can be assembled.
VIDEO: Part 2 - Assembly
Step 1:Prepare the Liner and Housing Tube
1Insert the Liner into the HousingTubeand feed it through, until about an inch (25.4mm) of liner extends
out from the tube. (Tube may also be black or opaque)
2Insert the Nut on to the Liner as shown. Note that the nut has not been inserted into the housing tube.
1 Getting Started
4

Step 2:Connect the Weld Head Adapter and Components
The weld head adapter and components can be assembled from left to right, as shown below.
1Screw the Contact Tip into the Weld Head Adapter.
2Insert the Liner into the Weld Head Adapter until it stops.
3Manually screw the Nut on to the Weld Head Adapter.
4Tighten the Nut on the Weld Head Adapter using a 12mm wrench.
5Push the Housing Tube over the barbed end of the Nut. Move the housing tube back and forth while
simultaneously pushing, until it is flush with the nut.
1 Getting Started
LightWELD WireFeeder Set-Up Guide 5

Step 3:Connecting the Wire Feeder Adapter and Components
The wire feeder adapter and components can be assembled from left to right, as shown below.
1Insert the Liner into the Wire Feeder Adapter until the liner is flush with the end of wire feeder adapter.
2Manually screw the Nut on to the Wire FeederAdapter.
3Tighten the Nut on the Wire Feeder Adapter using a 10mm and 12mm wrenches.
4Push the Housing Tube over the barbed end of the Nut. Move the housing tube back and forth while
simultaneously pushing, until it is flush with the nut.
The photo below is what will be referred to as the Wire Feeder Attachment. This connects the Wire Feeder Unit to the
LightWELD Weld Head. The Wire Feeder Attachment can be disassembled and reassembled according to the hard or
soft wire configurations.
1 Getting Started
6

Setting up the Wire Feeder Unit
Select the appropriate drive rolls based on your application. (Refer to the Drive Roll and Wire Configuration Table.) Open
the wire feeder unit by pushing the tabbed opening toward the back of the wire feeder while swinging the door outward.
Step 1:Insert the Drive Rolls
1Unscrew the Drive Roll Caps.
2Pull down both the handles. This releases the drive roll covers.
3The groove size corresponds with the wire diameter. The groove sizes are marked on the faces of the drive
rolls. Insert the Drive Rolls into the drive roll mechanism, with the desired groove label facing outward.
1 Getting Started
LightWELD WireFeeder Set-Up Guide 7

4Screw the Drive Roll Caps on to secure the drive rolls.
1 Getting Started
8

Step 2: Connect the Wire Feeder Attachment to the Unit
1Using a Phillips Head Screwdriver, loosen the set screw on the wire feeder unit.
2Locate the Wire Feeder Attachment. Insert the Wire Feeder Adapter into the wire feeder unit as far as
possible without it touching the drive roll.
Warning: There should be a slight space between the adapter and drive roll to ensure it does not get
scratched and worn out.
1 Getting Started
LightWELD WireFeeder Set-Up Guide 9

3Using a Phillips Head Screwdriver, tighten the set screw to secure the connection between the wire feeder
attachment and wire feeder unit.
1 Getting Started
10

Step 3:Install the Spool
The wire feeder unit accepts standard 8” (203mm) or 12” (305mm) spools.
1Unscrew the plastic Spool Cap.
2Insert the corresponding Wire Spool for your application. Ensure the spool is installed so the wire will feed
from the bottom.
3Screw the Spool Cap back on to secure the wire spool.
1 Getting Started
LightWELD WireFeeder Set-Up Guide 11

Step 4: Adjust the Wire and Secure the Drive Rolls
1Locate the start of the wire. The start of the wire is usually tied off on the outer panels of the spool.
Note: Maintain tension on the wire to prevent the spool from unraveling.
2Remove 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.
1 Getting Started
12

3Manually 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.
4Ensure 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.
1 Getting Started
LightWELD WireFeeder Set-Up Guide 13

5Secure the wire by pushing the drive roll covers down (1) and pushing the knobs back up into place (2).
Note: The tension on the wire can be adjusted by twisting the knobs on the drive roll mechanism. For
example, if the wire is slipping then you will need to tighten. If the wire kinks, then you will need to
reinstall the wire and loosen the tension.
1 Getting Started
14

Step 5: Feed the Wire
1Plug the wire feeder unit into a standard 110V outlet and turn on the power.
2Ensure the Wire Feeder Attachment is as straight as
possible to prevent the wire from kinking and getting stuck
on this initial feed.
Warning: Ensure that the 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
Wire Feeder Attachment is straightened
across floor
3Unscrew the Contact Tip from the Weld Head Adapter. This is to prevent any potential jamming on the
initial feed.
1 Getting Started
LightWELD WireFeeder Set-Up Guide 15

4Press the ‘Manual Feed’ Button to feed the wire through the Wire Feeder Attachment until it comes out of
the Weld Head Adapter.
5Continue to manual feed until about 2” (50.8 mm) of the wire is exposed. Then, screw the Contact Tip back
into the Weld Head Adapter.
1 Getting Started
16

Step 6:Syncing the Wire Feeder Unit and the LightWELD
1Attach the Synch Cable to the 'TORCH' port located on the front of the Wire Feeder.
2Connect the synch cable wires to the 12-pin I/O connector on the back of the LightWELD unit as shown
below. Ensure the wires are attached to pins 9 & 10.
3Turn the LightWELDunit on using the switch key.
For more information about understanding and using the
LightWELDpanel, review the video titled LightWELD1500
Initial Set Up and System Overview.
1 Getting Started
LightWELD WireFeeder Set-Up Guide 17