OM-9900-CWF-50-01-2014

OPERATION MANUAL
for
Model 9900-CWF-50
Cold Wire Feeder

Revised January 2014

Effective with Serial Number 080454

IMPORTANT

Read this manual carefully before installing,

commissioning or operating this product.

Jetline Engineering, 15 Goodyear Street, Irvine, CA 92618

Telephone: (949) 951-1515 • Fax: (949) 951-9237
Web Site: www.jetline.com • E-mail: sales@jetline.com
9900-CWF-50 Cold Wire Feeder

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 9900-CWF-50 Cold Wire Feeder

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 guaran-
tees or warranties expressed or implied.

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9900-CWF-50 Cold Wire Feeder

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 efficiency 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.

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 9900-CWF-50 Cold Wire Feeder

Table of Contents

Section I �����������������������������������������������������������������������������������������������������������������������������������������1
Safety Precautions................................................................................................................ 1
A. Arc Welding............................................................................................................... 1
B. Electric Shock............................................................................................................ 1
C. Arc Rays..................................................................................................................... 2
E. Cylinders.................................................................................................................... 2
F. Welding...................................................................................................................... 3
G. Moving Parts.............................................................................................................. 3
H. EMF Information....................................................................................................... 3
I. Principal Safety Standards......................................................................................... 4
J. California Proposition 65 Warning............................................................................ 4
Section II �����������������������������������������������������������������������������������������������������������������������������������������5
Introduction.......................................................................................................................... 5
Section III �����������������������������������������������������������������������������������������������������������������������������������������7
Installation............................................................................................................................ 7
Section IV ���������������������������������������������������������������������������������������������������������������������������������������11
Operating Instructions........................................................................................................ 11
A. Preparation for Welding........................................................................................... 11
B. Wire Guide Positioner.............................................................................................. 11
C. 9900 Control............................................................................................................ 11
Section V ���������������������������������������������������������������������������������������������������������������������������������������19
Wire Feed Accessory Kits.................................................................................................. 19
Section VI ���������������������������������������������������������������������������������������������������������������������������������������21
Maintenance........................................................................................................................ 21
Section VII ���������������������������������������������������������������������������������������������������������������������������������������23
Optional Accessories.......................................................................................................... 23
A. 607B Spool Cover.................................................................................................... 23
B. WGP-2ES Motorized Wire Guide Positioner.......................................................... 23
C. WGP-3 Compact Wire Guide Positioner................................................................. 23
D. CHWS-100 Wire Straightener................................................................................. 23

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9900-CWF-50 Cold Wire Feeder

Section VIII ���������������������������������������������������������������������������������������������������������������������������������������25

Parts Lists........................................................................................................................... 25
Section IX ���������������������������������������������������������������������������������������������������������������������������������������35
Electrical Drawings............................................................................................................ 35

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Section I
Safety Precautions
WARNING
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 qualified 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).
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9900-CWF-50 Cold Wire Feeder
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 first - double-
check connections.
Frequently inspect input power cord for
7. 
damage or bare wiring. Replace cord im-
mediately 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
floor 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.
9900-CWF-50 Cold Wire Feeder
C. Arc Rays
Arc rays can burn eyes and skin; noise can dam-
age hearing; flying 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 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 protect
others from flash and glare; warn others
not to watch the arc.
5. Wear protective clothing made from du-
rable, flame-resistant material (wool and
leather) and foot protection where neces-
sary.
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 ex-
haust 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
-2-
(MSDS) and the manufacturer’s instruc-
tion for metals, consumables, coatings,
cleaners, and degreasers.
5. Work in a confined space only if it is
well ventilated, or while wearing an air-
supplied 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 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 cylinder
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.
5. Use only correct shielding gas cylinders,
regulators, hoses and 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 ex-
cept when cylinder is in use or connected
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 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
flying sparks, hot workpiece, and hot equipment
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 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 fire, and keep a fire extinguisher
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).
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9900-CWF-50 Cold Wire Feeder
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 fire hazards.
8. Wear oil-free protective garments such as
leather gloves, heavy shirt, cuffless trou-
sers, 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. Keep all doors, panels, covers, and guards
closed and securely in place.
2. Have only qualified people remove guards
or covers for maintenance and trouble-
shooting 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
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 frequency
magnetic fields can interact with, and produce
changes in, biological systems. While most of
this work is of very high quality, the results are
complex. Current scientific understanding does
9900-CWF-50 Cold Wire Feeder
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 definite
conclusions abut questions of possible risk or to
offer clear science-based advice on strategies to
minimize or avoid potential risks.”
To reduce magnetic fields 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 Office, Washington, D.C.
20402
National Electric Code, NFPA Standard 70 from
National Fire Protection Association, Battery-
march Park, Quincy, MA 02269
-4-
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
Boulevard, 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
J. 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

Section II
Introduction
The cold wire feeder is designed to supply filler
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 CWF-50-9900 comes with motor/tach
generator cable, but no motor control. It is
specifically designed for connection to a 9900-
MCMA1-1 motor control module as part of the
9900 Controller. However, it can be used with
any DC motor controller capable of delivering
0 to 90 volts DC at 1/8 hp. The tach generator
output is approximately 0 to 18 volts DC.
The system consists of a DC motor-driven four
feed roll assembly, spool adapter, and a wire
guide positioner. The positioner incorporates
X-Y-Z movements of the wire tip and includes
a universal torch mounting bracket.
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9900-CWF-50 Cold Wire Feeder
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. 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 configuration as sup-
plied by factory, reverse thumb knob, set
screw, and spring. (See WGP-1 drawing.
item numbers 13, 18, and 24.)
3. Spool adapter: holds 12” (305 mm) diam-
eter wire spools.
4. 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.
5. MCMA1-1 motor control module as part
of a 9900 Control package.
9900-CWF-50 Cold Wire Feeder

6' CABLE
(1.8M)

JETLINE MCM-1
OR
OTHER
WIRE FEED CONTROL

CWF-50-DA
COLD WIRE FEEDER

etline
e ngineering
®

etline ®

MADE IN U.S.A.
e ngineering
MADE IN U.S.A.

607B
CLEAR SPOOL COVER (OPTIONAL)

WGP-1
WIRE GUIDE POSITIONER

CONDUIT
STANDARD LENGTH 6 FT
(1.8M)

Figure 1
CWF-50 Cold Wire Feeder

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Section III
Installation
As standard, the unit is provided with 6 feet
(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. 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.
3. 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.
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9900-CWF-50 Cold Wire Feeder
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 fitted
into the outlet guide assembly. This
step may need to be repeated in or-
der to fit 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.
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
9900-CWF-50 Cold Wire Feeder

outlet guide securely by turning the 4. Electrical Connections:

hand knob. The motor leads require 0 to 90 volts DC
f. Run the conduit to the torch as re- at 1 amp. The tach generator leads output
quired. Remember sharp twists and 0 to 25 volts DC, linear with motor speed,
turns affect the flow of the wire. Test polarity reverses with direction change.
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.

-8-
 9900-CWF-50 Cold Wire Feeder

Figure 2
Mounting Plate Dimensions

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9900-CWF-50 Cold Wire Feeder

- 10 -

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. Then replace the spool retain-
ing ring. 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).
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 us-
ing an arc length control. A ball on the end of
the wire could touch the tungsten when feeding
initially. If the wire contacts the tungsten, you
will get a “ball” on the end of the tungsten. The
operator should stop the weld and re-sharpen
the tungsten. This action could also cause ad-
verse effects with the arc length control.
When the wire is inched forward, this is a good
time to verify the wire’s position. Adjust if
necessary.
Retract wire to desired starting position.
Check wire and wire spool briefly. Verify there
is enough wire for the next weld and that the
wire is not wrapped around the spool holder.
At this point, the unit is ready to feed wire.
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9900-CWF-50 Cold Wire Feeder
B. 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.
C. 9900 Control
Control of the wire feed parameters is through
the 9900, a computer based control. Welding set-
tings are made in the setup windows (screens).
The following pages show instructions.
9900-CWF-50 Cold Wire Feeder
a. Standard Mode: Weld Channel
Program Editor Screen
Channels Window - Wire
Start Delay - Amount of time the start of wire
feed is delayed from when the arc strikes
Weld - Wire feed speed setting during the weld
Stop Delay - Amount of time the wire feed will
continue after the Downslope segment is initi-
ated
Wire Retract - Amount of time the wire will
retract at the end of Stop Delay
No Pulsing - Check this box to run wire continu-
ously without pulsing, even if the weld current
is pulsing
Simple - Check this box to pulse the wire speed
synchronized with the weld current pulsing pa-
- 12 -
rameters and enter the background percentage
for the wire
Dabber - Check this box to turn on the Dabber
function. The value entered in the box is the
distance that the wire is pulled back when the
Current goes into background.
Pulsalation - Check this box to pulse the wire
speed synchronized with the oscillation param-
eters in the Pulsalation mode and to enter the
background percentage for the wire during the
traverse
Synchronized - Check this box to pulse the wire
speed synchronized with the oscillation param-
eters in the Synchronized mode and to enter the
background percentage for the wire during the
traverse
Dabber – How far the wire retracts when in low
current state
 9900-CWF-50 Cold Wire Feeder

b. Enhanced Mode: Weld Channel End – The wire feed speed at the end of the
Program Editor Screen Weld segment
Downslope
Channels Window - Wire
Time – The time the wire feed speed will take
Initial
to slope from the Weld level to the Final level
Wire – The wire feed speed setting during Ini- Final
tial time
Wire – The wire feed speed setting during Final
Time – The time the wire feed speed will re-
time
main at the Initial level, before upslope
Time – The amount of time the wire feed speed
UpSlope
will remain at the Final level
Time – The time the wire feed speed will take
Wire Retract: Time: – The amount of time
to slope from Initial to Weld level
No Pulsing - Check this box to run wire con-
Weld
tinuously without pulsing, even if the weld cur-
Wire – The wire feed speed at the start of the rent is pulsing
weld segment Simple - Check this box to pulse the wire speed

- 13 -
9900-CWF-50 Cold Wire Feeder
synchronized with the weld current pulsing pa-
rameters and enter the background percentage
for the wire
Dabber - Check this box to turn on the Dabber
function. The value entered in the box is the
distance that the wire is pulled back when the
Current goes into background
Pulsalation - Check this box to pulse the wire
speed synchronized with the oscillation pa-
rameters in the Pulsalation mode and enter the
background percentage for the wire during the
traverse
Synchronized - Check this box to pulse the
wire speed synchronized with the oscillation
parameters in the Synchronized mode and enter
the background percentage for the wire during
the traverse
Dabber – How far the wire retracts when in low
current state
- 14 -
c. Welding Run Screen
Channel Configuration Editor - AWire Win-
dow
Profile Information – General information about
the make and model of this channel
Range
Units – Units of measure for this channel (IPM
- inches per minute or CPM - centimeters per
minute)
Minimum Value – Minimum program value for
this channel
Maximum Value – Maximum program value
for this channel
Auxiliary Devices
Indicates if there are auxiliary devices connected
to this channel and the name(s) of the devices.
Gain
This is the input gain for feedback. 1 if jumper
on J1, 5 if jumper on J2, or 10 if jumper on J3
on the 9900-10 board
Equivalent DC Reference Volts
Out – The analog voltage needed out of the
9900-10 control board to get the range setting
In – The feedback voltage that is applied at the
input of the module for this range setting
Misc Info
Max Analog Pulses/Second – Maximum pulses
for this power supply
ARC Type – Arc type for this channel (TIG,
MIG, or Plasma)
Encoder Type – Pulse Generator, Encoder, or
NA for none

Encoder Counts/Revolution – The number of
ticks on the encoder
Gear Ratio – The ratio of the gears on the en-
coder
Closed Looping Parameters
Closed Loop Sensitivity – The percentage of
the error between set and actual that is removed
on each loop. Large numbers may result in
overshoot
I-Term - Reserved
Closed Loop Delay – Amount of time after the
channel is started before the closed loop routine
becomes active
- 15 -
9900-CWF-50 Cold Wire Feeder
Operator Speeds
Trim Limit – The percentage of change that the
operator is allowed to make for this channel
during the welding of the part
Step Size – The percentage of change that the
user makes each time the +/- keys are pressed
Jog Speed – Percentage of maximum speed for
the channel to move during jog
Retract – Percentage of maximum speed that the
wire moves during a retract
9900-CWF-50 Cold Wire Feeder
Channel Configuration Editor – DWire
Profile Information – General information about
the make and model of this channel.
Range
Units – Units of measure for this channel (Inch
or Centimeter)
Minimum Value – Minimum program value for
this channel
Maximum Value – Maximum program value
for this channel
Auxiliary Devices
Indicates if there are auxiliary devices connected
to the channel and the name(s) of the devices
- 16 -
Equivalent DC Reference Volts
In – The feedback voltage that is applied at the
input of the module for this range setting
Misc Info
Stepper Counts/Revolution – Stepper counts per
revelation on the motor.
Drive Ratio – The gear ratio of the stepper drive
Movement Type – Radial (for circumferential
welding positioned) or Linear (track & carriage,
turning rolls)
Acceleration/Deceleration – The acceleration/
deceleration speed of the stepper motor.
Pull Back Speed – How fast the wire moves
backwards when in dabbing

Encoder Type – Pulse Generator, Encoder, or
NA for none for actual travel speed
Encoder Counts/ Revolution – The number ticks
on the encoder
Gear Ratio – Gear Ratio between encoder shaft
and the unit measure (eg. 25 encoder shaft turns
per inch of travel)
Closed Looping Parameters
Closed Loop Sensitivity – The percentage of
the error between set and actual that is removed
on each loop. Larger numbers may result in
overshoot.
Closed Loop Delay – Amount of time after the
channel is started and before the closed loop
routine becomes active.
Operator Speed
Trim Limit – The percentage of change that the
operator is allowed to make for this channel
during the welding of the parts.
Retract – Percentage of maximum speed that the
wire moves during retract.
Step Size – The percentage of change that the
user makes each time the +/- keys are pressed.
Jog Speed – Percentage of maximum speed for
the channel to move during jog.
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9900-CWF-50 Cold Wire Feeder
d. Advanced Mode: Weld Channel
Program Editor Screen
Segment Variable Info - AWire
Clr – Reset all the variables for this segment
First – Go to the first segment (Initial)
Prev – Go to the previous segment
Next – Go to the next segment
Last – Go to the last segment
Segment Name – Which segment is currently
displayed
Timing Type and Timing Value
Time – The time the system will remain in this
segment
Start Value – The wire speed at the start of this
segment
End Value – The wire speed at the end of this
segment
None – Check this box to run wire continuously
without pulsing in this segment, even if the weld
current is pulsing
Simple – Check this box to pulse the wire speed
synchronized with the weld current pulsing pa-
rameters and enter the background percentage
for the wire
Dabber - This box to turn on the Dabber func-
tion. The value entered in the box is the distance
that the wire is pulled back when the Current
goes into background
Pulsalation – Check this box to pulse the wire
speed synchronized with the oscillation pa-
rameters in the Pulsalation mode and enter the
background percentage for the wire during the
traverse
9900-CWF-50 Cold Wire Feeder

Synchronized – Check this box to pulse the

wire speed synchronized with the oscillation
parameters in the Synchronized mode and enter
the background percentage for the wire during
the traverse

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 9900-CWF-50 Cold Wire Feeder

Section V

Wire Feed Accessory Kits

Wire Size *Complete Conduit - 6 Outlet Inlet Guide Wire Guide Feed Rolls **Curved
Accessory ft (2 m) Guide Tip & Inlet Wire Guide
Kit Guide Tip
0.020” 20B6020K 42-23 OG-020 056192 WGT-020 053693
(0.5 mm) PT-40-NAT
0.030” 20B6030K 44N3545 OG-035-45 056192 WFT-030 046780 CWGT-030
(0.8 mm)
0.035” 20B6035K 44N3545 OG-035-45 056192 WGT-035 046781 CWGT-035
(0.9/1 mm)
0.045” 20B6045K 44N3545 OG-035-45 056193 WGT-045 046782 CWGT-045
(1.2 mm)
0.062” 20B6062K 45N116 OG-062 056195 WGT-062 046784
(1.6 mm)
0.093” 20B6093K 18630F OG-17 056196 WGT-093 046789
(2.4 mm)

*Includes inlet and outlet guides, feed rolls, wire guide tip, and 6 ft (2 m) conduit.
**Requires WGP-3 wire guide positioner for curved tips.
Wire Feed Roll Kits, parts and optional items are sold separately.

- 19 -
9900-CWF-50 Cold Wire Feeder

Figure 3
Wire Feed Accessory Kit Components

- 20 -
 9900-CWF-50 Cold Wire Feeder

Section VI

Maintenance

Periodically clean the drive rolls of dirt and

chips. Occasionally check the wear of liners,
tips, and guides.
Always replace fuse with one of equal value —
3 amp fast blow.
Periodically check, and replace if necessary,
the carbon brushes on the motor. Failure to re-
place worn brushes could cause severe damage
to motor control.

WARNING
Maintenance and electrical work must be
performed by experienced and trained per-
sonnel.

CAUTION
Whenever repairs are required, always turn
all power controls off and disconnect all elec-
trical cables from power supply.

- 21 -
9900-CWF-50 Cold Wire Feeder

- 22 -

Section VII
Optional Accessories
When you purchased your cold wire feeder,
you may not have been aware of optional en-
hancements for your unit. Jetline is pleased to
offer these enhancements which can be added
to your system in the field.
If you are interested in these features, please
do not hesitate to contact Jetline directly or the
nearest distributor for more information.
A. 607B Spool Cover
The 607B is a clear plastic cover designed and
manufactured for Jetline’s wire feeders. The
cover mounts around the spool holder and en-
cases the standard “30 lb/12 inch” wire spool
which fits onto the spool mounting adaptor.
The main purpose of the cover is to protect
the wire from dust and weld particle build-up.
The clear plastic allows the operator to see the
spool effectively. Installing the spool cover is a
simple, perhaps 5 minute, job.
B. WGP-2ES Motorized Wire
Guide Positioner
The standard wire feed unit is provided with
a manually adjusted WGP-1 wire guide
positioner. In some applications, the operator
cannot easily get to the positioner to make the
desired alterations to the wire’s location as it
enters the weld puddle. Due to the cast and he-
lix in some wires, the need to adjust the wire’s
position can be required.
- 23 -
9900-CWF-50 Cold Wire Feeder
Jetline offers the WGP-2ES motorized positioner
so the operator can adjust the position of the
wire from a remote location. The positioner in-
cludes the motorized wire positioner, the mo-
tor control, and a joystick pendant which the
operator uses to move the wire guide tip to the
desired position. Speed of motion is adjustable
to provide accurate positioning as desired by
the operator.
C. WGP-3 Compact Wire Guide
Positioner
In some applications, the space envelope re-
quired by the standard WGP-1 is too large.
Jetline manufactures a wire guide positioner
which requires less space, yet still gives the
operator the ability to adjust the wire position.
The WGP-3 is designed to attach directly to
the torch, but includes a curved wire guide tip.
Wire is fed vertically until the moment where it
is angled into the weld puddle.
D. CHWS-100 Wire Straight-
ener
In some applications, minor deviations in wire
position are a result of the cast in the wire. The
wire straightener can help limit the twist by us-
ing a 3 roll action. Tension on the center roll
is adjustable. The unit mounts on the inlet side
of the drive roll assembly. The straightener is
designed to work on 0.035” and 0.045” (0.9/1.0
and 1.2 mm) wire.
9900-CWF-50 Cold Wire Feeder

- 24 -
 9900-CWF-50 Cold Wire Feeder

Section VIII

Parts Lists

The following pages provide a detailed parts The following parts lists are included in this
list of all the elements of the cold wire feed manual. Their appropriate page numbers are
unit. They are arranged so that the parts list listed.
on the right hand page corresponds with the as- Wire Feed Assembly............................... 26/27
sembly illustrated on the left hand page. Item
numbers shown in the parts list refer to those WGP-1 Wire Guide Positioner................ 28/29
numbers contained in the balloons in the draw-
ing. On each parts list, the quantities shown WGP-2ES Wire Guide Positioner........... 30/31
are the number of items used in that particular
assembly. WGP-3 Wire Guide Positioner................ 32/33
Two columns are included in the list to show
the spare parts which are recommended to be
stocked by the user. The two levels can be de-
fined as follows:
Level 1 These are the spares recommended
for US domestic users whose use of
the product does not exceed 2000
hours per year.
Level 2 These are the spares recommended
for international use of the product or
for US domestic users who will use
the products in excess of 2000 hours
per year.

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9900-CWF-50 Cold Wire Feeder

- 26 -
 9900-CWF-50 Cold Wire Feeder

CWF-50-DA
Cold Wire Feeder Assembly

Recommended
Item Part Level Level
No. No. Description Qty I II

2 CWF-20B-100 Mounting Plate..........................................................1

3 CWF-20B-110 Mounting Bracket.....................................................1
4 CWF-20B-120 Cover Assembly........................................................1
5 Drive Housing, includes:..........................................1
046779 Housing.....................................................................1
053842 Gear...........................................................................4 2
10-32x7/8 Flat Head Screw......................................................12
1/2-20x1 1/4 Hex Head Screw.......................................................4
6 0467__ Gear Driven Roll Kit.................................................1
(See chart in Section V for complete part number)
7 OG-030/045 Outlet Guide (See chart in Section V)......................1
8 44N3545 Conduit and Liner (See chart in Section V)..............1
9 WGT-0__ Wire Guide Tip..........................................................1
(See chart in Section V for complete part number)
10 CWF-10-WG-60 Gear Reducer............................................................1
11 95611AO31 Insulating Washer......................................................1
12 8527K134 Insulating Tube, 36” (914 mm) length......................1
13 Natural Hard Fiber Insulation...................................2
14 Natural Hard Fiber Insulation...................................2
15 053841 Drive Gear.................................................................1 1
16 374831-A Spool Adapter............................................................1
17 MT3353-42CZ Motor, DC Servo, with flange...................................1
18 6010 Shielded Cable, 8 ft (2.5 m)......................................1
19 3106A-145-6P Cable Connection......................................................1
20 CWF-10-4R-9 Set Screw Collar.......................................................1
21 CWF-20B-140 Retainer.....................................................................1
22 8-32X5/8 Socket Head Screw...................................................1
23 8-32X5/16 Button Head Screw...................................................4
24 1/4-20X1/2 Socket Head Screw...................................................4
25 1/4-20X5/8 Flat Head Screw........................................................4
26 3/8-16X1 1/4 Hex Head Screw.......................................................2
27 3/8 Flat Washer...............................................................2

- 27 -
9900-CWF-50 Cold Wire Feeder

4/14/08
WIRE GUIDE POSITIONER

L
WGP-1

- 28 -
 9900-CWF-50 Cold Wire Feeder

WGP-1
Wire Guide Positioner

Recommended
Item Part Level Level
No. No. Description Qty I II

2 WGP-1-230 Base...........................................................................1
3 WGP-1-100 (REV E) Cam Plate..................................................................1
4 WGP-1-200 Housing.....................................................................1
5 WGP-1-210 (REV E) Bar.............................................................................1
6 WGP-1-220 Clamp........................................................................1
7 WGP-XXX Shown for Reference (part of Wire Feed Kit)
8 WGP-1-240 Stud...........................................................................2
9 WGP-1-250 V-Block.....................................................................2 1
10 Guide, Dowell...........................................................1
11 Fulcrum Pin, Dowell.................................................1
12 Hinge Pin, Dowell.....................................................1
13 CL-1-KHS Knurled Head Screw.................................................1 1 1
14 CL-1-KN Knurled Nut..............................................................1 1 1
15 CL-1-SB Swing Bolt................................................................1
16 WGP-1-16 Lift Pin......................................................................1
17 6655K13 Thrust Bearing..........................................................1
18 VV-38 Compression Spring..................................................1 1
19 1/4-20x7/8 Socket Head Screw...................................................2
20 1/4-20x5/8 Socket Head Screw...................................................2 2 2
21 1/4 Flat Washer...............................................................1
22 11256 Compression Spring..................................................1 1
23 3025 Knob..........................................................................2 1 1
24 3/8-16-5/16 Nylock Set Screw......................................................1
25 WGP-1-260 V-Mount (Optional Item, Large Clamp Kit).............1
26 WGP-1-261 V-Clamp (Optional Item, Large Clamp Kit).............1
27 WGP-1-262 Stud (Optional Item, Large Clamp Kit)....................2
28 1/4-20-5/8 Socket Head Screw...................................................2
29 WGP-1-263 Base Extension (Optional Item, extended base).......1
30 1/4-20x3/4 Socket Head Screw (Optional Item, extended base).....2
31 6435K12 Collar, 1/4 diameter...................................................1
32 6391K143 Bronze Bearing, 1/4 x 1/2 x 1...................................1

- 29 -
 9900-CWF-50 Cold Wire Feeder

- 30 -
COLD WIRE GUIDE POSITIONER,
SPECIAL MOTORIZED VERSION

WGP-2ES E 4/10/08
 9900-CWF-50 Cold Wire Feeder

WGP-2ES (Rev E)
Motorized Wire Guide Positioner

Recommended
Item Part Level Level
No. No. Description Qty I II

2 WGP-1 Basic Wire Guide Assembly.....................................1

5 WGP-2-5 (REV C) Motor Bracket, detail................................................1
6 WGP-2-6 Screw.........................................................................1
7 WGP-2-7 Motor Bracket, detail................................................1
8 WGP-2-10 Driven Pulley, detail..................................................1
9 1375K34 Driven Pulley, detail..................................................2
10 WGP-2-10 Driven Pulley............................................................1
11 1679K86 Belt............................................................................2 1 1
12 WGP-2-9 Motors and Cable Assembly, set...............................1
13 4-40x1/4 Socket Head Screw...................................................6
14 DWM-202 Cover.........................................................................2
15 #2-216 O-ring seal.................................................................4
16 9045 Control Assembly, for reference
17 Lift Pin, detail...........................................................1

- 31 -
 9900-CWF-50 Cold Wire Feeder

- 32 -
COMPACT WIRE GUIDE POSITIONER,
FOR COLD WIRE FEEDERS

WGP-3 D 4/10/08
 9900-CWF-50 Cold Wire Feeder

WGP-3
Compact Wire Guide Positioner

Recommended
Item Part Level Level
No. No. Description Qty I II

2 WGP-3-2 Base Detail................................................................1

3 WGP-3-3 Yoke Detail...............................................................1
4 WGP-3-4 Slide Detail................................................................1
5 WGP-3-5 Rotor Detail...............................................................1
6 WGP-1-250 V-Block Detail..........................................................2 1
7 WGP-1-240 Stud...........................................................................2
8 WGP-3-8 Pin Detail..................................................................1
9 WGP-3-9 Clamp Detail.............................................................1
10 WGP-3-10 Tube Detail................................................................1
11 WGP-3-11 Spacer Detail.............................................................1
12 Fender Washer...........................................................1
13 XX-68 Compresion Pin.........................................................1 1
14 L-35 Compresion Pin.........................................................1 1
15 2813 Compresion Pin.........................................................1
16 CL-1-KHS Knurled Head Screw.................................................1 1 1
17 CL-6-KHS Knurled Head Screw.................................................1 1 1
18 CL-2-SLB Button, radius loc......................................................1
19 1/4-20x3/4 Socket Head Screw...................................................3 2 2
20 1/4 Flat Washer...............................................................1
21 1/420 Hex Nut.....................................................................1
22 1/4-20x2 1/4 Hex Head Screw.......................................................1
23 1/8x3/4 Roll Pin.....................................................................1
24 CWGT Curved Wire Guide Tip Detail..................................1
25 3025 Knob..........................................................................2 1 1

- 33 -
9900-CWF-50 Cold Wire Feeder

- 34 -
 9900-CWF-50 Cold Wire Feeder

Section IX

Electrical Drawings
Each longitudinal seam welder made by Jetline
has an electrical control schematic. These draw-
ings are identified by job number and are part of
the document package shipped with your system.

MCMA-1 Schematic.....................................36
MCMA-1 Module Layout.............................37

- 35 -
9900-CWF-50 Cold Wire Feeder

- 36 -
 9900-CWF-50 Cold Wire Feeder

- 37 -