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CK WORLDWIDE WF5 User Manual

CK WORLDWIDE WF5
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1
Cold Wire Feeder Manual
September 2015
CK Worldwide, Inc.
3501 C St. N.E. Auburn, WA 98002
tel: (253) 854-5820
tel: (800) 426-0877
fax: (253) 939-1746
The important safeguards and instructions appearing in
this pamphlet should be read and understood prior to
operating your equipment.
NOTE:
Safety Warning ................................................................
Warranty ..........................................................................
Introduction .....................................................................
Description ......................................................................
TIG Welding Process ........................................................
Specifi cations ..................................................................
Check List ........................................................................
Optional Items .................................................................
Installation .......................................................................
Operation .........................................................................
Welding ............................................................................
Maintenance ....................................................................
Troubleshoot Chart ...........................................................
Cables and Guides ............................................................
Feeding Diffi cult Wires / Bracket Extensions ....................
Electrical Diagram ...........................................................
Functions of Controls ........................................................
Parts Lists: WF5 Feed Unit Left Side ....................
WF5 Feed Unit Right Side .................
CWH1812 Hand Torch .......................
CWH2312 Hand Torch .......................
CWHTL312 Hand Torch .....................
Parts Lists: CWH3512 Hand Torch.........................
CWM2312 Machine Torch .................
CWM3512 Machine Torch .................
CWMT412 Machine Torch .................
CWMT512 Machine Torch .................
CWH Wire Feed Hand Unit .................
CWMES Remote Switch ....................
Drive Rolls .......................................................................
Spare Parts .....................................................................
CWH1812 Head Accessories .............................................
CWH2312 Head Accessories .............................................
CWHTL312 Head Accessories .........................................
CWH3512 ........................................................................
CWM2312 Head Accessories ............................................
CWM3512 Head Accessories ............................................
CWMT412 Head Accessories ..........................................
CWMT512 Head Accessories ..........................................
Tungsten Electrode Information ......................................
Tungsten Preparation ......................................................
Welding Parameters .......................................................
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CK WORLDWIDE WF5 Specifications

General IconGeneral
BrandCK WORLDWIDE
ModelWF5
CategoryWelding System
LanguageEnglish

Summary

Safety Information and Precautions

General Safety Warning

Crucial safety advice for potential injury or death.

Electrical Shock Prevention

Steps to prevent severe burns or fatal electric shock.

Fume and Gas Protection

Guidance on protecting health from welding fumes and gases.

Compressed Gas Cylinder Safety

Instructions for safe handling and securing gas cylinders.

Arc Ray and Noise Protection

Measures to protect eyes, skin, and hearing from welding hazards.

Fire and Burn Prevention

How to prevent fires and burns from welding operations.

Special Situation Precautions

Safety guidelines for specific welding scenarios and pacemakers.

Equipment Maintenance Safety

Essential safety practices for maintaining welding equipment.

Additional Safety Standards

References to industry standards for safe welding practices.

Warranty and Introduction

Product Warranty

Details the warranty period and terms for the cold wire feed unit.

System Overview

Introduces the patented CK Cold Wire TIG System and its purpose.

Product Description

WF5 Wire Feed Unit

Describes the WF5 unit's components and capabilities for wire feeding.

Torch Outfit

Details the TIG torch outfit, including feed cable and wire guide.

TIG Welding Process

Welding Process Fundamentals

Explains the TIG process, shielding, and filler metal addition.

Current Polarity Types

Describes DCSP, DCRP, and ACHF for TIG welding.

Specifications

WF5 Wire Feed Unit Specs

Lists voltage, phase, dimensions, weight, and wire feed ranges.

Torch Specifications

Details ratings, cooling, and cable lengths for hand and machine torches.

Installation

Setup Checklist and Optional Items

Lists required items and optional accessories for installation.

Installation Steps

Provides step-by-step instructions for connecting the wire feeder.

Fitting and Threading Wire

Guides on installing wire into the feed mechanism and cable.

Wire Feed Roll Adjustment

Instructions for adjusting feed rolls for proper wire grip.

Spool Brake Adjustment

How to adjust the spool brake for smooth wire feeding.

Operation and Maintenance

Pre-Welding Preparations

Steps before welding for optimal system performance.

Welding Techniques

Guidance on torch angle and wire feeding for hand and machine welding.

Routine Maintenance

Procedures for cleaning and inspecting components like feed cable and brushes.

Troubleshooting

Problem Identification and Solutions

A chart to diagnose and resolve common issues with the wire feeder.

Cables and Guides

Wire Feed Cable Types

Lists feed cable types for different wire and torch configurations.

Feeding Difficult Wire

Recommendations for using extension brackets for challenging wire feeds.

Electrical Diagram

WF5 Wire Feeder Circuit Diagram

Illustrates the internal electrical connections of the WF5 unit.

Controls and Indicators

Front Panel Controls Overview

Identifies and explains the function of each control on the WF5 unit.

Parts Lists and Diagrams

WF5 Wire Feed Unit Parts

Diagram and list of parts for the left side of the WF5 unit.

WF5 Wire Feed Unit Right Side Parts

Diagram and list of parts for the right side of the WF5 unit.

Hand Torch Parts Lists

Part numbers and diagrams for CWH1812 and CWH2312 torches.

Hand Torch Parts Lists

Part numbers and diagrams for CWHTL312 and CWH3512 torches.

Machine Torch Parts Lists

Part numbers and diagrams for CWM2312 and CWM3512 torches.

Machine Torch Parts Lists

Part numbers and diagrams for CWMT412 and CWMT512 torches.

Wire Feed Hand Unit & Remote Switch Parts

Parts for CWH hand unit and CWMES remote switch.

Drive Rolls and Spare Parts

Selector charts for drive rolls and recommended spare parts.

Head Accessories

8 Series (CWH1812) Accessories

Lists cups, collets, heat shields for the 8 Series torch.

2 Series (CWH2312) Accessories

Lists cups, collets, heat shields for the 2 Series torch.

3 Series (CWHTL312/CWH3512) Accessories

Lists accessory parts for 3 Series torches.

2 Series (CWM2312) Accessories

Lists accessory parts for the CWM2312 torch.

3 Series (CWM3512) Accessories

Lists accessory parts for the CWM3512 torch.

3 Series (CWMT412) Accessories

Lists accessory parts for the CWMT412 torch.

3 Series (CWMT512) Accessories

Lists accessory parts for the CWMT512 torch.

Tungsten Electrode Information

Tungsten Electrode Characteristics

Describes properties of different tungsten electrode types.

Technical Information Chart

Provides data on amperage, gas flow, and travel speed.

Tungsten Preparation and Usage

Tungsten Tip Preparation

Details how to prepare tungsten tips for DC and AC welding.

Tungsten Extension and Grinding

Information on tungsten extensions and grinding techniques.

Torch and Rod Positioning

Guidance on correct torch angle and rod placement during welding.

Welding Parameters by Material

Aluminum Welding Parameters

Recommended settings for welding aluminum.

Titanium Welding Parameters

Recommended settings for welding titanium.

Magnesium Welding Parameters

Recommended settings for welding magnesium.

Deoxidized Copper Welding

Parameters and notes for welding deoxidized copper.

Stainless Steel Welding

Parameters and notes for welding stainless steel.

Low Alloy Steel Welding

Parameters and notes for welding low alloy steel.

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