Jet Lline HWP-50E User manual

OPERATION MANUAL
for HWP-50E
Hot Wire Process
OM-HWP-50E-02-2014
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: [phone] !Fax: [phone]
Web site: www.jetline.com !E-mail: [email protected]

HWP-50E Hot Wire Process
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HWP-50E Hot Wire Process
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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.
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.

HWP-50E Hot Wire Process
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NOTICE
The installation, operation and maintenance guidelines set out in this manual will enable you to maintain
theequipmentinpeakconditionandachievemaximumefficiencywithyourweldingoperation. Pleaseread these
instructions carefully to become aware of every advantage.
CAUTION
Only experienced personnel familiar with the operation
and safe practice of welding equipment should install
and/or use this equipment.

HWP-50E Hot Wire Process
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Table of Contents
SectionI ...............................................................................1
Safety Precautions ..................................................................1
A. ArcWelding ............................................................1
B. ElectricShock...........................................................1
C. ArcRays ...............................................................2
D. Fumes and Gases ........................................................2
E. Cylinders...............................................................2
F. Welding................................................................3
G. MovingParts............................................................3
H. EMFInformation ........................................................3
I. PrincipalSafetyStandards .................................................4
J. California Proposition 65 Warning ...........................................4
SectionII ..............................................................................5
Introduction .......................................................................5
SectionIII..............................................................................9
Specifications......................................................................9
A. HWP-200E-1-220-A1000 Hot Wire Power Supply ..............................9
B. HWP-200E-1-A1000 Hot Wire Power Supply .................................10
C. 9302C Hot Wire Voltage Control ...........................................11
D. WF-50WireFeedhead ...................................................12
E. 9629HW Wire Speed Control ..............................................13
F. HotWireTorch.........................................................14
G. Wire Positioner Assembly ................................................14
SectionIV ............................................................................15
InstallationandSetup ..............................................................15

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SectionV .............................................................................19
Operation........................................................................19
SectionVI ............................................................................21
Maintenance......................................................................21
SectionVII............................................................................23
PartsList ........................................................................23
SectionVIII ...........................................................................39
PCB Descriptions .................................................................39
A. HWP-200-6-1 Voltage Reference Board .....................................39
B. PCM4AnalogIsolatorBoard..............................................42
C. TransformerRatings.....................................................44
SectionIX ............................................................................45
ElectricalDiagrams ................................................................45

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Section I
Safety Precautions
WARNING
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
circuitiselectricallylivewhenevertheoutputis
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
immediatelyif damaged - barewiring can
kill.
8. Turn off all equipment when not in use.
9. If earth grounding of the workpiece 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.

HWP-50E Hot Wire Process
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13. Keep all panels and covers securely in
place.
14. Clamp work cable with good metal-to-
metal contact to workpiece or worktable
as near the weld as practical.
C. Arc Rays
Arc rays can burn eyes and skin; noise can
damagehearing; flyingslag or sparks caninjure
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 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. Ifventilation is poor, use anapproved 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-
suppliedrespirator.Alwayshaveatrained
watch person nearby.
6. Do not weld in locations near degreasing,
cleaning,orsprayingoperations.Theheat
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
metalscontainingtheseelementscangive
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
cylinderrack to prevent fallingortipping.

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3. Keepcylinders away fromanyweldingor
other electrical circuits.
4. Never weld on a pressurized cylinder -
explosion will result.
5. Use only correct shielding gas cylinders,
regulators,hosesand 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
flyingsparks,hotworkpiece,andhotequipment
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
properlypreparedaccording 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
unknownpathsandcausingelectricshock
and fire hazards.
8. Wearoil-free protectivegarmentssuch as
leather gloves, heavy shirt, cuffless
trousers, high shoes, and a cap.
G. Moving Parts
Moving parts, such as fans, rotors, and belts can
cut fingers and hands and catch loose clothing.
1. Keepalldoors,panels,covers,andguards
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 &
MagneticFields-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
frequencymagneticfields caninteractwith, and
produce changes in, biological systems. While
most of this work is of very high quality, the

HWP-50E Hot Wire Process
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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 abut questions of
possible risk or to offer clear science-based
advice on strategies to minimize or avoid
potential risks."
Toreducemagneticfieldsintheworkplace,use
the following procedures:
1. Keep cables close together by twisting or
taping them.
2. Arrangecablesto one side andaway 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 workpiece as
close to the weld as possible.
About Pacemakers:
The above procedures are among those also
normallyrecommendedforpacemakerwearers.
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
NationalElectricCode,NFPAStandard70from
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
EyeandFaceProtection,ANSIStandardZ87.1,
from American National Standards Institute,
1430 Broadway, New York, NY 10018
CuttingandWeldingProcesses,NFPAStandard
51B,fromNationalFireProtectionAssociation,
Batterymarch Park, Quincy, MA 02269
J. California Proposition
65 Warning
Thisproductcontainschemicals,includinglead,
knownto the state ofCaliforniatocause cancer,
and birth defects or other reproductive harm.
Wash hands after use. §248224

HWP-50E Hot Wire Process
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Section II
Introduction
The hot wire welding process produces a high
quality weld with a high deposition rate of the
fillermaterial. Itdiffersfromthe morecommon
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 I2R heating of the filler
wire as it approaches the weld puddle drives off
most of the volatile surface contamination.
Since hydrogen or hydrogen containing
compoundsentrappedonthesurfaceofthefiller
metal are a primary cause of porosity in high
performance materials, use of the hot wire
processcanbeexpectedtoremovethispotential
source of difficulty.
Thehot wireweldingprocessisideallysuitedto
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
ACoutputwaveformiselectronicallygenerated
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
adjustablefrom2to15VACthroughthe9302C
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
suppliedwithwirefeedkitsfor0.045”(1.2mm)
and1/16”(1.6mm)diameterwires and can feed
at speeds from 12 to 600 IPM (30 to 1,525
mm/min).
9629HW Speed Control
The control of wire feed speed is effected
throughthe9629HWmicroprocessorcontroller.
The control sets and maintains the desired wire
feedspeedandprovides controlofwire 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
Thetorchguidesthewireintotheweldpool 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.

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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.

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HWP-50E SYSTEM INTERCONNECTION

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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

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B. HWP-200E-1-A1000 Hot
Wire Power Supply
Input
Voltage: 380/415/440-480 V ±5%
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

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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)

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5.25 in
(133 mm)
1.38 in
(35 mm)
2.50 in
(62 mm)
22.0 in
(559 mm)
8.0 in
(204 mm)
0.38 in
(9 mm)
13.38 in
(340 mm)
DIA 13.25 in
(337 mm)
CLEAR PLASTIC
SPOOL COVER
6.0 in
(152 mm)
4X DIA 0.344 in
(9 mm)
MOUNTING HOLES
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: 9629HW Microprocessor
Control

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10 in
(254 mm) 0.5 in
(13 mm)
6 in
(152 mm)
0.875 in
(21 mm)
UP
DOWN
EMERGENCY
STOP
RIGHT
LEFT
STOPSTARTSTOP
ADJUST
WIRE SPEED 245.0 ipm
Series 9600 CONTROL
S1
S2
S3
8 in
(203 mm)
CRS
8.75 in
(222 mm)
CRS
8 in
(203 mm)
4X DIA 0.3125 in
(8 mm)
MOUNTING HOLES
E. 9629HW 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)

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F. Hot Wire Torch
G. Wire Positioner Assembly