User:Jstapko/EngLab/ThermalStripper

Powering the Hot Wire Cutter Element
Development of a dedicated scroll saw hot wire cutter is in progress, but until it is completed, the Western Electronics model G thermal wire stripper is well matched to the current and voltage requirements of the scroll saw foam cutter's heating element. To use the thermal stripper in this service, you will need to remove one heating element and use heavy gauge clip leads to connect the thermal stripper and scroll saw foam cutter's leads. The process for doing so is described in detail below.

Materials Needed

 * 1) a Western Electronics Model G Thermal Wire Stripper
 * 2) a small straight blade screwdriver
 * 3) a pair of heavy duty (3-5 amperes capacity) clip leads

1) Access the Thermal Wire Stripper
The thermal wire stripper is generally stored in the storage room, CL-160. Ask a professor or lab assistant to retrieve it for you if you need to use it. For reference, the pictures below show what it looks like from 2 different angles.



2) Loosen Heater Screws
Using the small, straight blade screwdriver, loosen, but do not remove, the screws in the ends of the top two rods.



3) Remove the Upper Element
With the top two screws loosened, grasp the top element between your fingers and pull gently downward to remove it from its mounting holes. If it does not want to come out, try wiggling it gently back and forth, side to side, or up and down. Do not put so much force on it that you bend it our of shape. With a little coaxing, the element should slide downward and be free of the machine.



4) Connect Clip Leads
With the upper element removed, connect one high current clip lead to the top left rod on the thermal stripper and the other to the bottom right rod. This is important because if you connect one to the bottom left, current will flow through the lower element and could melt the covering on the clip lead, while if you connect one to the upper right, only one power supply terminal will be connected so no current will flow through the foam cutter element. connect the other ends of the clip leads to the white wires coming from the scroll saw foam cutter.



5) Cut Foam
Turn the thermal stripper's power switch on, turn the knob up to about 60 or 70 initially, then adjust to a bit higher or lower as needed. While waiting for the element to warm up, turn the scroll saw motor on, and set the speed as desired. If you need to, you can run the cutter with the motor off, but use the motor if possible because otherwise heat can build up in certain spots of the wire, weakening the wire and potentially breaking it.

6) Safety
Cutting foam gives off noxious fumes; Try to open the door of CL-159 to vent fumes. To minimize the fumes generated, use only enough heat as needed to cut the foam, not to melt a wide swath through it. Finally, wear safety glasses when cutting foam, as when operating any power tool in the HCC Lab.

7) Clean Up
When finished using the thermal wire stripper, put the heating element back in, re tighten the screws, and leave it ready for the next person. Assembly is reverse of dis-assembly.

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