Jetline CWF-50 User manual

Jetline Engineering, 15 Goodyear Street, Irvine, CA 92618
Telephone: [phone] • Fax: [phone]
Web Site: www.jetline.com • E-mail: [email protected]
Revised January 2014
Effective with Serial Number 070159
IMPORTANT
Read this manual carefully before installing,
commissioning or operating this product.
OPERATION MANUAL
for
Model CWF-50
Cold Wire Feeder
OM-CWF-50-01-2014

Model CWF-50 Cold Wire Feeder
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Model CWF-50 Cold Wire Feeder
- iii -
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 conrms 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 guaran-
tees or warranties expressed or implied.

Model CWF-50 Cold Wire Feeder
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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 efciency with your welding opera-
tion. Please read 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.

Model CWF-50 Cold Wire Feeder
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Table of Contents
Section I .................................................................................................................................. 1
Safety Precautions ............................................................................................................... 1
A. Arc Welding .............................................................................................................. 1
B. Electric Shock ........................................................................................................... 1
C. Arc Rays.................................................................................................................... 2
D. Fumes and Gases....................................................................................................... 2
E. Cylinders................................................................................................................... 2
F. Welding ..................................................................................................................... 3
G. Moving Parts............................................................................................................. 3
H. EMF Information ...................................................................................................... 3
I. Principal Safety Standards ........................................................................................ 4
Section II .................................................................................................................................. 5
General Description............................................................................................................. 5
Section III .................................................................................................................................. 7
Installation ........................................................................................................................... 7
Section IV ................................................................................................................................ 11
Operating Instructions ....................................................................................................... 11
A. Preparation for Welding .......................................................................................... 11
B. Operation................................................................................................................. 11
C. Wire Guide Positioner............................................................................................. 12
Section V ................................................................................................................................ 15
Wire Feed Accessory Kits ................................................................................................. 15
Section VI ................................................................................................................................ 17
Maintenance....................................................................................................................... 17
Section VII ................................................................................................................................ 19
Optional Accessories ......................................................................................................... 19
A. 607B Spool Cover................................................................................................... 19
B. WGP-2ES Motorized Wire Guide Positioner ......................................................... 19
C. WGP-3 Compact Wire Guide Positioner ................................................................ 19
D. CHWS-100 Wire Straightener ................................................................................ 19

Model CWF-50 Cold Wire Feeder
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Section VIII ................................................................................................................................ 21
Parts Lists .......................................................................................................................... 21

CWF-50 Cold Wire Feeder
- 1 -
Section I
Safety Precautions
CALIFORNIA PROPOSITION 65 WARNING
This product contains chemicals, including lead,
known to the state of California to cause cancer,
and birth defects or other reproductive harm.
Wash hands after use. §248224
A. Arc Welding
Arc Welding can be hazardous. Protect your-
self and others from possible serious injury or
death. Keep children away. Pacemaker wear-
ers keep away until consulting your doctor.
In welding, as in most jobs, exposure to certain
hazards occurs. Welding is safe when precau-
tions 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 qualied
people.
B. Electric Shock
Touching live electrical parts can cause fatal
shocks or severe burns. The electrode and work
circuit is electrically live whenever the output is
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 con-
nected to a properly grounded receptacle
outlet.
6. When making input connections, attach
proper grounding conductor rst - double-
check connections.
7.
Frequently inspect input power cord for
damage or bare wiring. Replace cord imme-
diately if damaged - bare wiring 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
oor level.
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.
WARNING

CWF-50 Cold Wire Feeder
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C. Arc Rays
Arc rays can burn eyes and skin; noise can
damage hearing; ying slag or sparks can injure
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. Chip-
ping, 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 tted with a proper
shade of lter to protect your face and
eyes when welding or watching.
3. Wear approved safety glasses with side
shields.
4. Use protective screens or barriers protect
others from ash and glare; warn others
not to watch the arc.
5. Wear protective clothing made from
durable, ame-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. If ventilation is poor, use an approved
air-supplied respirator.
4. Read the Material Safety Data Sheets
(MSDS) and the manufacturer’s instruc-
tion for metals, consumables, coatings,
cleaners, and degreasers.
5. Work in a conned space only if it is well
ventilated, or while wearing an air-sup-
plied respirator. Always have a trained
watch person nearby.
6. Do not weld in locations near degreasing,
cleaning, or spraying operations. The
heat 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
metals containing these elements can give
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 care-
fully.
1. Protect compressed gas cylinders from
excessive heat, mechanical shocks, slag,
open ames, sparks, and arcs.
2. Install cylinders in an upright position by
securing to a stationary support or cylin-
der rack to prevent falling or tipping.
3. Keep cylinders away from any welding
or other electrical circuits.
4. Never weld on a pressurized cylinder
- explosion will result.

CWF-50 Cold Wire Feeder
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5. Use only correct shielding gas cylinders,
regulators, hoses and ttings designed for
the specic 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 con-
nected for use.
8. Read and follow instructions on com-
pressed gas cylinders, associated equip-
ment, and CGA publication P-1 listed in
Safety Standards.
F. Welding
Welding can cause re or explosion.
Welding on closed containers, such as tanks,
drums, or pipes, can cause them to blow up.
Sparks can y off from the welding arc. The
ying sparks, hot workpiece, and hot equipment
can cause res and burns. Accidental contact of
electrode to metal objects can cause sparks, ex-
plosion, overheating, or re. Check and be sure
the area is safe before doing any welding.
1. Protect yourself and others from ying
sparks and hot metal.
2. Do not weld where ying sparks can
strike ammable material.
3. Remove all ammables within 35 ft. (10.7
m) of the welding arc. If this is not pos-
sible, tightly cover them with approved
covers.
4. Be alert that welding sparks and hot mate-
rials from welding can easily go through
small cracks and openings to adjacent
areas.
5. Watch for re, and keep a re extin-
guisher nearby.
6. Do not weld on closed containers such
as tanks, drums, or pipes, unless they are
properly prepared according 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
unknown paths and causing electric
shock and re hazards.
8. Wear oil-free protective garments such
as leather gloves, heavy shirt, cufess
trousers, high shoes, and a cap.
G. Moving Parts
Moving parts, such as fans, rotors, and belts can
cut ngers and hands and catch loose clothing.
1. Keep all doors, panels, covers, and guards
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 Ef-
fects of Low Frequency Electric and Magnetic
Fields
The following is a quotation from the General
Conclusions Section of the U.S. Congress, Of-
fice of Technology Assessment, Biological
Effects of Power Frequency Electric & Mag-
netic Fields - Background Paper, OTA-BP-E-53
(Washington, DC: U.S. Government Printing
Ofce, May 1989):

CWF-50 Cold Wire Feeder
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“.... there is now a very large volume of scientic
ndings based on experiments at the cellular
level and from studies with animals and people
which clearly establish that low frequency
magnetic elds can interact with, and produce
changes in, biological systems. While most of
this work is of very high quality, the results are
complex. Current scientic understanding does
not yet allow us to interpret the evidence in a
single coherent framework. Even more frustrat-
ing, it does not yet allow us to draw denite
conclusions abut questions of possible risk or to
offer clear science-based advice on strategies to
minimize or avoid potential risks.”
To reduce magnetic elds in the work place, use
the following procedures:
1. Keep cables close together by twisting or
taping them.
2. Arrange cables to one side and away 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
normally recommended for pacemaker wearers.
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 Ofce, Washington, D.C.
20402
National Electric Code, NFPA Standard 70 from
National Fire Protection Association, Battery-
march Park, Quincy, MA 02269
Recommended Safe Practices for the Prepara-
tion 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 Cylin-
ders, 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 Bou-
levard, Rexdale, Ontario, Canada M9W 1R3
Sales Practices for Occupation and Educational
Eye and Face Protection, ANSI Standard Z87.1,
from American National Standards Institute,
1430 Broadway, New York, NY 10018
Cutting and Welding Processes, NFPA Standard
51B, from National Fire Protection Association,
Batterymarch Park, Quincy, MA 02269

CWF-50 Cold Wire Feeder
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Section II
Introduction
The cold wire feeder is designed to supply ller
metal to the weld puddle in a mechanized tung-
sten arc welding application. The system will
accurately feed 0.020”, 0.030”, 0.035”, 0.045”,
0.062” and 0.093” (0.5 to 2.4 mm) hard and soft
wires for mechanized TIG or plasma welding.
The wire feeder can be mounted as an assembly
or the components can be removed from the
mounting plate and installed in a number of
positions with respect to each other.
The system consists of a 9629 control, D.C.
motor-driven four feed roll assembly, spool
adapter, and a wire guide positioner. The
positioner incorporates X-Y-Z movements of
the wire tip. The positioner includes a universal
torch mounting bracket.
The basic components of the wire feeder are:
(See Figure 1)
1. Wire drive unit: consists of motor, drive
housing, and wire spool assembly to feed
wire. (Part number CWF-50-DA.)
2. 9629 Control: includes a keypad, display,
encoder control knob, start, stop, and
emergency stop switches. The SCR motor
controller is built into the control box and
provides a wire feed speed of 4 to 200 IPM
(10 to 508 CPM) with a speed holding
accuracy of +1% of base speed.
For operating details and function of con-
trols, see 9629 Quick Start Guide.
3. WGP-1 Wire Guide Positioner: guides
wire into puddle.
Note: The wire guide positioner can be
used either as a left hand or right hand
assembly. To change conguration as sup-
plied by factory, reverse thumb knob, set
screw, and spring. (See WGP-1 drawing.
item numbers 13, 18, and 24.)
4. Spool adapter: holds 12” (305 mm) diam-
eter wire spools.
5. Wire Feed Accessory Kit: conduit, feed
rolls, inlet guides, outlet guides, and tips
for 0.020”, 0.030”, 0.035”, 0.045”, 0.062”
and 0.093” (0.5 to 2.4 mm) hard and soft
wire. Order kits separately for desired
wire size.

CWF-50 Cold Wire Feeder
- 6 -
Figure 1
CWF-50 Cold Wire Feeder
607B
CLEAR SPOOL COVER (OPTIONAL)
9629
WIRE FEED CONTROL
CWF-50-DA
COLD WIRE FEEDER
6' CABLE
(1.8M)
CONDUIT
STANDARD LENGTH 6 FT
(1.8M)
WGP-1
WIRE GUIDE POSITIONER
6' POWER CORD
(1.8M)
Series 9600 CONTR OL
DOWN
UP
ADJUST
REV FOR
e®
gnireenigne nilte
E-STOP
POWER S TART STOP
MADE IN U.S .A.
e®
gnireenigne nilte
MADE IN U.S .A.
e®
gnireenigne nilte

CWF-50 Cold Wire Feeder
- 7 -
Section III
Installation
As standard, the unit is provided with 6 ft. (1830
mm) of cable between the control and the wire
drive assembly. The control is typically mounted
near the feeder due to the length of the control
cable.
1. To mount the wire drive assembly, trans-
fer mounting holes from the wire feeder’s
aluminum mounting plate to the mount-
ing surface. (See Figure 2 for mounting
hole dimensions.)
2. The 9629 control must be mounted in
a suitable manner providing adequate
ventilation. The control should not be
mounted in a high temperature environ-
ment.
3. Slip the wire guide positioner onto the
torch barrel and tighten the wing nuts.
You may choose from one of three sets
of mounting holes depending upon the
brand of the torch to be used.
The wire guide tip angle should be set
roughly by positioning the guide and
tightening the screw. The tip should be
approximately on the same level as the
tungsten.
4. Select the wire feed accessory kit for the
size wire your application requires. The
kit will include inlet and outlet guides,
conduit, wire guide tip, and feed rolls. Be
sure all components match the wire size
to be used. (Refer to Figure 3)
Proper installation of the wire feed kit is
very critical to the successful operation
of the cold wire feed unit. Proper instal-
lation helps avoid “bird-nesting” at the
feed rolls and smooth wire feed delivery
into the weld puddle.
a. The inlet guide should be inserted
until the “set screw” properly aligns
with the notched section on the
guide. The closer the tapered tip is
to the feed rolls the better.
b. The intermediate guide needs to be
inserted prior to the mounting of the
feed rollers. The intermediate guide
also has a “notched” section which
should align with the screw holding
it in position.
c. The feed rolls need to be mounted
securely. If not tightened, they will
loosen and will eventually fall off.
d. The conduit assembly is then tted
into the outlet guide assembly. This
step may need to be repeated in or-
der to t it correctly. First, the end
and inside of the conduit must be
deburred. The wire must slide freely
into the conduit.
Next the conduit should be cham-
fered. The conduit needs to be as
close as possible to the feed rolls
in order to avoid “bird-nesting”,
especially on soft wires. Putting a
chamfer on the conduit allows you
to get the conduit very close to the
feed rolls.
At this point, slide the conduit
through the outlet guide. You
should extend the conduit beyond
the tapered end of the outlet guide
approximately 1/4” (6 mm). Tighten
the set screw securely, holding the
conduit properly in position.

CWF-50 Cold Wire Feeder
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e. Insert the outlet guide/conduit as-
sembly into the drive roll assembly.
Position it so the chamfered conduit
is very close to the drive rolls. (Make
sure the end of the outlet guide is
clear of the drive rolls.) Tighten the
outlet guide securely by turning the
hand knob.
f. Run the conduit to the torch as re-
quired. Remember sharp twists and
turns affect the ow of the wire. Test
the path of the conduit with the torch
in its fully retracted and extended
positions.
If the conduit is too long, cut the
end, making sure it is completely
deburred.
g. Strip 4” (100 mm) of the outer cover
on the conduit. Slide the bare con-
duit into the wire guide tip. Tighten
the set screw holding the conduit
securely into position.
Note: On a rare occasion, you may
have to pull this end of the conduit
from the tip when initially feeding
wire. Let the wire extend about 6”
to 8” (150 to 200 mm) beyond the
conduit and then feed the wire into
the tip until the conduit is back into
normal position.
The wire guide tip is held in position by
a set screw. The tip can slide into the
clamping mechanism on the WGP-1 Wire
Guide Positioner.
5. Electrical Connections:
As standard, the feeder is shipped with
an electrical connector and 6 ft. (1380
mm) cord suitable for 115 volts 50/60 Hz
power supply. Operation for 220 volts is
congurable.
If you need to start the wire feeder from
a remote signal, you must supply a nor-
mally open, maintained contact closure
to Connector S2, Pins A and B.

CWF-50 Cold Wire Feeder
- 9 -
Figure 2
Mounting Plate Dimensions

CWF-50 Cold Wire Feeder
- 10 -

CWF-50 Cold Wire Feeder
- 11 -
Section IV
Operating Instructions
A. Preparation for Welding
Mount the spool of welding wire on the spool
adapter so the wire will be pulled from the low
side of the coil. Adjust the friction brake on the
wire spool by adjusting the screw in the center
of the spool. If adjusted properly, the spool will
feed smoothly and will not coast or continue to
spin when feeding stops.
Debur the end of the wire, then insert it into the
inlet guide through the feed rolls and the outlet
guide. (Refer to Figure 3).
Press the power switch to the “On” position
and feed the wire into the conduit by press-
ing “Forward” key. Continue to feed the wire
through the conduit and the wire guide tip until
a desired amount extends beyond the tip.
See the Quick Start Guide for various jog
modes.
B. Operation
9629 Control:
The operation of a CWF-50 is not difcult. The
following sequence is suggested:
1. Turn on power to unit.
2. Using the Forward key, inch the wire
forward a little. Trim the wire if there is
a ball on the end of the wire. This step is
especially necessary if feeding wire and
using an arc length control. A ball on the
end of the wire could touch the tungsten
when feeding initially. If the wire con-
tacts the tungsten, you will get a “ball”
on the end of the tungsten. The operator
should stop the weld and resharpen the
tungsten. This action could also cause
adverse effects with the arc length con-
trol.
When the wire is inched forward, this is
a good time to verify the wire’s position.
Adjust if necessary.
3. Retract wire to desired starting position
using the Reverse key.
4. Check wire and wire spool briey. Veri-
fy there is enough wire for the next weld
and that the wire is not wrapped around
the spool holder.
5. Check wire feed speed setting, the start
delay setting, and the stop retract setting.
These settings are critical to achieve the
desired weld.
6. At this point, the unit is ready to feed
wire. If the starting and stopping of the
wire is controlled remotely, the control
will go through the start delay. Once
this delay has timed out, the unit will
proceed to feed wire at the rate set on
the dial.
When the remote start signal quits, the
unit will go through the stop delay, then
stop. The unit then proceeds to enter the
wire retract time, pulling the wire out of
the weld zone. This action prevents the
wire from sticking in the weld puddle at
the end of the weld.
Note: If the retract time is set too long,
the wire could retract up into the wire
tip. If this happens, the wire could, on
occasion, get stuck on the tip on the next
weld.

CWF-50 Cold Wire Feeder
- 12 -
7. If the unit is used manually, the operator
will press the Start button when ready to
feed wire. The start delay will NOT be
activated when using this method. Wire
will feed immediately once in the Run
position.
When wire is no longer required the op-
erator presses the Stop button. The unit
will stop feeding wire immediately and
go into the wire retract procedure.
C. Wire Guide Positioner
Several adjustments are provided on the wire
guide positioner in order to permit the exact
position of the wire as it enters the puddle.
1. Lateral adjustment of 1/4” (1/8” adjust-
ment of tip on each side of weld seam).
(6.4 mm total adjustment, 3.2 mm on
each side.)
2. Vertical adjustment of 1/4” (6.4 mm) tip
to work.
3. Coarse adjustment of guide tip angle, by
loosening screw and setting in approxi-
mate position.
The wire position should be checked at the be-
ginning of the weld.
Jog the wire forward through the control and
make required adjustments on the positioner.
Wire typically enters the weld puddle at the
leading edge of the puddle. The wire should
contact the work piece about .04” (1 mm) in
front of the weld puddle and slide under the
center of the welding arc.
Check tension of drive roll spring. Too much
pressure will deform the wire and too little
pressure will cause wire slippage.

CWF-50 Cold Wire Feeder
- 13 -
Figure 3
Wire Feed Accessory Kit Components

CWF-50 Cold Wire Feeder
- 14 -