Add-On Capstan Wire Feed System

The Thermal Arc WF-100 Cold Wire Capstan Feeder is a compact, lightweight, precisionwire feeder for robotic or automation fixture applications. The Capstan's small size andlightweight (less than 6lbs.) allows the wire feeder to be placed directly on the automatedfixture or robot wrist. The Capstan also provides an increase in wire drive contact area bywrapping the wire around the wire drive wheel.

This wire drive method has three major benefits:

- Plastic deforms the filler wire, virtually eliminating wire cast.

- Increased drive force eliminates wire slip, flattening and damage to wire surface.

- Integral wire straightener on the discharge side of the feeder allows the Wire Driveto precisely locate the filler wire independent of wire cast.

MARKETS

- Aerospace/Aircraft- Automotive- Robotics- Automated Welding Systems Integrators

The WF-100 Capstan Feeder is designed for the WC-1 Weld Process Controller

WF-100Wire Feed SystemWF-100

Wire Feed System

Capstan Wire Feeder and Control Parts List

U.S. Plasma Manual Customer Care: 800-426-1888 / FAX 800-535-0557Thermadyne Canada Customer Care: 905-827-1111 / FAX 905-827-3648page 2

PLASMA WELDING SYSTEM CONFIGURATION......................................................................................1WF-100 CAPSTAN WIRE FEEDER ............................................................................................................3

SYSTEM DESCRIPTION ......................................................................................................................3DRIVE TYPES.......................................................................................................................................4PRODUCT MANUALS...........................................................................................................................4FILLER WIRE SPECIFICATIONS.........................................................................................................40.030” to 0.052” STEEL ALLOY WIRE CONFIGURATIONS................................................................5

CAPSTAN DRIVE TORCH BRACKET ASSEMBLY ...................................................................................7ADJUSTABLE ROBOTIC MOUNT ASSEMBLY .........................................................................................8PIVOT LINK ARM .........................................................................................................................................9LINER/CASING RETAINER .........................................................................................................................9WIRE SPOOL ASSEMBLY.........................................................................................................................10WIRE SPOOL LINER ASSEMBLIES .........................................................................................................11ARTICULATOR LINER AND CASING.......................................................................................................12COLD WIRE PLASMA TORCH ARTICULATOR ASSEMBLY..................................................................13CONTACT TIPS ..........................................................................................................................................15

DDeessccrriippttiioonn Page

Ordering Information

Capstan Wire Feeder and Control Parts List

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Capstan Wire Feeder and Control Parts List

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PLASMA WELDING SYSTEM CONFIGURATION These illustrations indicate the standard equipment required for a Plasma welding configuration.

Contact Tips (See Page 15)

Capstan Wire Feeder Mounting(See Next Page)

Articulator Liner and Casing (See Page 12)

Wire Spool Liner Assembly(See Page 11)

Wire Spool AssemblyP/N: S2A5001 (See Page 10)

1-3/8” Adjustable Articulator Assembly

P/N: E2A5194 (See Page 13)

Plasma Welding Wire Feed System Configuration

Capstan Wire Feeder and Control Parts List

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Capstan Wire Feeder and Control Parts List

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Liner/Casing RetainerP/N: S2A5002 (See Page 9)

Pivot Link Arm P/N: E2M5816 (See Page 9)

Adjustable RoboticMount Assembly (See Page 8)

Capstan Wire Feeder (See Page 3)

Torch Bracket AssemblyP/N: E2A5190 (See Page 7)

Capstan Wire Feeder Mounting

Capstan Wire Feeder and Control Parts List

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Capstan Wire Feeder and Control Parts List

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WF-100 CAPSTAN WIRE FEEDER

SYSTEM DESCRIPTION

The Capstan Wire Feeder is a compact, lightweightprecision wire feeder for robotic or automated fixtureapplications. This product was introduced in 1989.Industry analysts project dramatic growth in the use of robots for arc welding in future years. In a random surveyby an independent consultant 21 out of 55 people interviewedhad robotic or fully auotmated welding operations and 12people out of 21 who did have robotoc or auotmated weldingoperations experienced problems with feeding welding wire.Major problems cited were wire cast, helix, and wire feedspeed control.

The Capstan's small size and light weight (less than 6 lbs.) allows the wire feeder to be placed directly on the automated fixture or robot wrist, The Capstanalso provides an increase in wire drive contact area by wrapping the wire around the wire drive wheel.

This wire drive method has three major benefits:

Plastic deforms the filler wire, virtually eliminating existing wire cast.

Increased drive force eliminates wire slip, flattening and damage to wire surface.

Integral wire straightener on the discharge side of the feeder allows the Wire Drive to precisely locate the filler wire independent of wire cast.

The WF-100 Capstan wire feed drive can be used with the WC-1 Thermal Arc Process Controller

MARKETS

Aerospace/Aircraft Automotive Automotive Satellite Industries OEM's - Arc Welding Robots Automated Welding Systems Integrators

ADVANTAGES OVER COMPETITION

Wire feed speed accuracy Broad dynamic range Better/more versatile control Better control over wire position in the weld joint Ability to mount on robot arm Competitive price Process versatility (GTAW, PAW)

Capstan Wire Feeder and Control Parts List

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Capstan Wire Feeder and Control

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DRIVE TYPES

The WF-100 Capstan Wire Drive can be purchased in various configurations as follows:

PART NO. DESCRIPTION E2A5099 WF-100 PWM Drive with 9 CM Motor

Wire Feed Range: 10 - 625 IPM (4-265 mm/s) Motor Full Load Pull Capacity: 20 LBS (9 kg) Operation / Installation Manual

Note: WF-100 Drives are not equipped with any specific wire component parts. Specific wire kits must be ordered separately for each wire diameter and filler wire material.

Interface Control Circuit for WC-1 Process Controller

PART NO. DESCRIPTION C3A5005 Interface Control Circuit (Includes Wire Feed Printed Circuit Board)

Note: Must be ordered when using WC-1 Process Controller

FILLER WIRE SPECIFICATIONS

The WF-100 requires different component parts for each diameter of filler wire used. Refer to next sections to select the correct drive wheel and inlet wire guide for the wire diameter and filler wire material required. There are four primary configurations for the WF-100.

1. 0.030” to 0.052” Steel Alloy Wire Configuration 2. 0.030” to 0.062” Aluminum Wire Pick-up Block Configuration 3. 0.030” to 0.052” Aluminum Wire Straightener Configuration 4. 0.062” Aluminum Wire Straightener Configuration

Parts List

Capstan Wire Feeder and Control Parts List

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Capstan Wire Feeder and Control

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0.030” to 0.052” STEEL ALLOY WIRE CONFIGURATIONS

When using a 0.030” to 0.052” steel alloy filler wire with the capstan, a Steel Alloy Wire Kit specifically made for each size wire must be installed on the capstan. All parts that are wire size specific in these kits are marked with color codes to prevent mixing incompatible parts. Figure 1 shows all the parts that are included in these kits. The capstan drive is not part of these kits.

CONFIGURATION KITS

WIRE SIZE COLOR CODES PART NO.0.030” (0.8mm) White E2A5164 0.035” (0.9mm) Red E2A5165 0.040” (1.0mm) Gold E2A5166 0.045” (1.1mm) Yellow E2A5167 0.047” (1.2mm) Yellow E2A5167 0.052” (1.3mm) Blue E2A5168

COMPONENT PARTS

The drawing below shows the location of the common and wire specific parts that are included in the Steel Alloy Wire Kits.

Figure 1: Steel Alloy Wire Component Parts

Standard Hand Capstan Drive(not included in kits)

Liner - 1' Long P/N: X7C5033

Hex Fitting P/N: X6F5061

O-Ring P/N: X4S5010

6-32 x 1/4 Lg. Socket Head Cap Screw4 Places

Wire Feed Cover (not included in kits)

#10 Internal Lock Washer

Spring P/N: X2N5003

Wire Out Guide P/N: E2M5594

8-32 x 3/16 Lg. Sckt. Set Screw

Bearing P/N: X2B0373

Stripper P/N: E2M5593

Cam Follower P/N: X2B5028

Stripper Bearing SpacerP/N: E2M5590

6-32 x 3/4 Lg. Button Hd Screw2 Places

Stripper Cover P/N: E2M5592

10-32 x 3/4 Lg. Button Hd Screw

Capstan Wheel (see next page)

Inlet Wire Guide (see next page)

Torch Liner (see next page)

Parts List

Capstan Wire Feeder and Control Parts List

U.S. Plasma Manual Customer Care: 800-426-1888 / FAX 800-535-0557Thermadyne Canada Customer Care: 905-827-1111 / FAX 905-827-3648page 8

Capstan Wire Feeder and Control

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PART NO. DESCRIPTION E2M5583 Capstan Wheel for 0.030" (0.8mm) Wire E2M5157 Capstan Wheel for 0.035" (0.9 mm) Wire E2M5633 Capstan Wheel for 0.040" (1.0 mm) Wire E2M5156 Capstan Wheel for 0.045" (1.1 mm) and 0.047" (1.2 mm) Wire E2M5584 Capstan Wheel for 0.052" (1.3 mm) Wire E2M5616 Inlet Wire Guide for 0.030" (0.8 mm) Wire E2M5617 Inlet Wire Guide for 0.035" (0.9 mm) Wire E2M5634 Inlet Wire Guide for 0.040" (1.0 mm) Wire E2M5619 Inlet Wire Guide for 0.045" (1.1 mm) and 0.047" (1.2 mm) Wire E2M5620 Inlet Wire Guide for 0.052" (1.3 mm) Wire E7C5001 Torch Liner for 0.030" (0.8 mm) Wire to 0.047" (1.2 mm) Wire E7C5002 Torch Liner for 0.052" (1.3 mm) Wire E2M5590 Stripper Bearing Spacer E2M5592 Stripper Cover E2M5593 Stripper E2M5594 Wire Out Guide X2B0373 Bearing X2B5028 Cam Follower X2N5003 Pressure Roller Shoe Spring X4S5010 O-Ring X6F5061 Hex Fitting X7C5033 Liner, 1 foot long

0.030” to 0.052” STEEL ALLOY WIRE CONFIGURATIONS

Capstan Wire Feeder and Control Parts List

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Capstan Wire Feeder and Control

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CAPSTAN DRIVE TORCH BRACKET ASSEMBLY Bracket Assembly is required to install our Articulator Liner and Casing onto the Capstan Drive.It includes a quick disconnect fitting for easy installation of welding wire liner.

ASSEMBLIES

PART NO. DESCRIPTION E2A5190 Capstan Drive Torch Bracket Assembly

E2M5810

X6F5090

E2M5813

COMPONENT PARTS

PART NO. DESCRIPTION E2M5813 Capstan Drive Torch Bracket E2M5810 Insulating Block X6F5090 Quick Disconnect Fitting

Parts List

Capstan Wire Feeder and Control Parts List

U.S. Plasma Manual Customer Care: 800-426-1888 / FAX 800-535-0557Thermadyne Canada Customer Care: 905-827-1111 / FAX 905-827-3648page 10

Capstan Wire Feeder and Control

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ADJUSTABLE ROBOTIC MOUNT ASSEMBLY Robotic Mount can be installed onto Capstan with or without the Torch Bracket installed. Also, it can be installed on either side of Capstan.

ASSEMBLIES

PART NO. DESCRIPTION E2M5646 Adjustable Robotic Mount Assembly for Right Side Mounting E2A5120 Adjustable Robotic Mount Assembly for Left Side Mounting

E2M5711

E2M5710

Right Side Mounting Left Side Mounting

COMPONENT PARTS

PART NO. DESCRIPTION E2M5710 Bracket Base E2M5711 Bracket Arm

Note: Both right and left side mountings use the same component parts.

Parts List

Capstan Wire Feeder and Control Parts List

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Capstan Wire Feeder and Control

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PIVOT LINK ARM Pivot Link Arm operates with the Robotic Mount to make pivot adjusts for the Capstan Wire Feeder. The Arm has five mounting holes for installation onto your fixture.

ASSEMBLIES

PART NO. DESCRIPTION E2M5816 Pivot Link Arm

LINER/CASING RETAINER This retainer is an inexpensive way to capture welding wire liner and casing.

ASSEMBLIES

PART NO. DESCRIPTION S2A5002 Casing/Liner Retainer

Parts List

Capstan Wire Feeder and Control Parts List

U.S. Plasma Manual Customer Care: 800-426-1888 / FAX 800-535-0557Thermadyne Canada Customer Care: 905-827-1111 / FAX 905-827-3648page 12

Capstan Wire Feeder and Control

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WIRE SPOOL ASSEMBLY This assembly will accommodate a 12” diameter welding wire spool. It is supplied with a quick disconnect fitting for easy installation of welding wire liner and casing.

ASSEMBLIES

PART NO. DESCRIPTION S2A5001 Wire Spool Assembly

COMPONENT PARTS

PART NO. DESCRIPTION S2M5027 Wire Spool Stand S2M5028 Wire Spool Arm S2M5029 Wire Spool Cover S2M5177 Wire Spool Shaft Bracket X6Z5053 Spool Holder Assembly X6F5090 Female Quick Disconnect Fitting X6F5105 ¼” NPT Female x ½” NPT Male PVC Schedule 80 Bushing

Parts List

Capstan Wire Feeder and Control Parts List

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Capstan Wire Feeder and Control

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WIRE SPOOL LINER ASSEMBLIES Our Wire Spool Liner Assemblies are supplied in 10’ and 15’ lengths for both steel alloy and aluminum wire. They are supplied with quick disconnect fittings for ease of installation to Wire Spool Assembly and Capstan Wire Feeder.

ASSEMBLIES

PART NO. DESCRIPTION E7A5001 10’ Long Assembly for 0.030” – 0.047” Steel Alloy Wire E7A5002 15’ Long Assembly for 0.030” – 0.047” Steel Alloy Wire E7A5003 10’ Long Assembly for 0.052” – 0.062” Steel Alloy Wire E7A5004 15’ Long Assembly for 0.052” – 0.062” Steel Alloy Wire E7A5005 10’ Long Assembly for 0.030” – 0.035” Aluminum Wire E7A5006 15’ Long Assembly for 0.030” – 0.035” Aluminum Wire E7A5007 10’ Long Assembly for 0.040” – 0.052” Aluminum Wire E7A5008 15’ Long Assembly for 0.040” – 0.052” Aluminum Wire E7A5009 10’ Long Assembly for 0.062” Aluminum Wire E7A5010 15’ Long Assembly for 0.062” Aluminum Wire

Tube Fitting P/N: X6F5104

Modified QD Fitting P/N: E2M5824

LinerLiner Casing

QD Fitting P/N: X6F5102

Tube Fitting P/N: X6F5104

10’ or 15’

COMPONENT PARTS

PART NO. DESCRIPTION E7C5007 10’ Long Liner for 0.030” – 0.047” Steel Alloy Wire E7C5008 15’ Long Liner for 0.030” – 0.047” Steel Alloy Wire E7C5009 10’ Long Liner for 0.052” Steel Alloy Wire E7C5010 15’ Long Liner for 0.052” Steel Alloy Wire E7C5011 10’ Long Liner for 0.030” – 0.035” Aluminum Wire E7C5012 15’ Long Liner for 0.030” – 0.035” Aluminum Wire E7C5013 10’ Long Liner for 0.040” – 0.052” Aluminum Wire E7C5014 15’ Long Liner for 0.040” – 0.052” Aluminum Wire E7C5015 10’ Long Liner for 0.062” Aluminum Wire E7C5016 15’ Long Liner for 0.062” Aluminum Wire E7C5017 10’ Long Liner Casing E7C5018 15’ Long Liner Casing X6F5104 Tube Fitting E2M5824 Modified Quick Disconnect Fitting X6F5102 Male Quick Disconnect Fitting

Parts List

Capstan Wire Feeder and Control Parts List

U.S. Plasma Manual Customer Care: 800-426-1888 / FAX 800-535-0557Thermadyne Canada Customer Care: 905-827-1111 / FAX 905-827-3648page 14

Capstan Wire Feeder and Control

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ARTICULATOR LINER AND CASING These Articulator Liners and Casings are 3 foot long but can be supplied in longer lengths as required for both steel alloy and aluminum wire.

ASSEMBLIES

PART NO. DESCRIPTION E7A5011 3’ Long Assembly for 0.030” – 0.047” Steel Alloy Wire E7A5012 3’ Long Assembly for 0.052” – 0.062” Steel Alloy Wire E7A5013 3’ Long Assembly for 0.030” – 0.035” Aluminum Wire E7A5014 3’ Long Assembly for 0.040” – 0.052” Aluminum Wire E7A5015 3’ Long Assembly for 0.062” Aluminum Wire

3’

Liner Liner Casing

COMPONENT PARTS

PART NO. DESCRIPTION E7C5019 Liner for 0.030” – 0.047” Steel Alloy Wire E7C5020 Liner for 0.052” Steel Alloy Wire E7C5021 Liner for 0.030” – 0.035” Aluminum Wire E7C5022 Liner for 0.040” – 0.052” Aluminum Wire E7C5023 Liner for 0.062” Aluminum Wire E7C5024 Liner Casing

Parts List

Capstan Wire Feeder and Control Parts List

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Capstan Wire Feeder and Control

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COLD WIRE PLASMA TORCH ARTICULATOR ASSEMBLY The Articulator Assembly provides a convenient means for adjusting the position of the cold wire with respect to the PAW welding torch. The articulator provides X –Y– Z-axis motion and a pivot axis for wire impingement angle. The cold wire feed guide assembly is isolated from the torch mount and uses a replaceable contact tip. The articulator may be used as a hot wire torch by connecting a power cable to the wire guide assembly.

COMPLETE ASSEMBLIES

PART NO. DESCRIPTION E2A5194 1-3/8” Adjustable Articulator Assembly

Note: Contact tips are not supplied with assemblies. See Component Parts below for a list of contact tips.

Parts List

Capstan Wire Feeder and Control Parts List

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Capstan Wire Feeder and Control

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Plasma Torch (Reference Only)

Contact Tip (For Reference Only)

2

15

3

10

15

8

9

14 5

6

12

14

4 13

7

11

COMPONENT PARTS

ITEM PART NO. DESCRIPTION 1 E2M5762 Articulator “Y” Adjust Clamp 2 E2M5763 Articulator Tip Retainer 3 E2M5838 1-3/8” Articulator Front Torch Barrel Clamp 4 E2M5839 1-3/8” Articulator Rear Torch Barrel Clamp 5 E2M5840 Articulator “XY” Adjust Clamp 6 E2M5841 Articulator “X” Adjust Shaft 7 E2M5842 Articulator “Y” Adjust Shaft 8 E2M5843 Hex Adaptor 9 X6F5085 5/16” Tube Fitting 10 #8-32 x 1-1/2” Long Socket Cap Head Screw 11 #8-32 x 1/2” Long Socket Cap Head Screw 12 #8-32 x 7/8” Long Socket Cap Head Screw 13 #8-32 Hex Nut 14 #10-32 x 1/4” Long Socket Set Screw 15 #5/16-18 Hex Nut

Parts List

Capstan Wire Feeder and Control Parts List

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Capstan Wire Feeder and Control

CONTACT TIPS Listed below are the contact tips for the Articulator Assembly.

COMPONENT PARTS

PART NO. DESCRIPTION X7T5005 0.030" Solid or Flux Core Wire X7T5003 0.035" Solid or Flux Core Wire X7T5004 0.045"/0.047” Solid or Flux Core Wire X7T5033 0.052” Solid or Flux Core Wire X7T5034 0.030" Aluminum or Stainless Steel Wire X7T5026 0.035" Aluminum or Stainless Steel Wire X7T5002 0.045"/0.047” Aluminum or Stainless Steel Wire X7T5035 0.052” Aluminum or Stainless Steel Wire X7T5027 0.062" Aluminum or Stainless Steel Wire

NOTE: Consult factory for additional required components and pricing.

Parts List

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Capstan Wire Feeder and Control Parts List

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Capstan Wire Feeder and Control Parts List

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