Sorry this was not answered earlier but you posted this in the WAI Webinars Division which we do not follow. I accidentally noticed it and moved it this morning.
Your information is interesting but not contradictory.
Just so you know, the steam in the annealer is there to prevent oxygen combining with the surface of the copper wire in the annealing section and turning the hot wire black. Protecting the copper from oxygen is the only function of the steam.
Having one wire exit the annealer hot and the other exit OK suggests that the water cooling leg of the annealer is not working properly. Check the pump and rotor plus the wipes. Check the supply piping, water channels and outlets for blockage. It seems as if the water is not properly getting to one channel of the cooling leg.
The lack of proper cooling in one cooling channel of the cooling leg of the annealer will allow the hot wire on the reel to turn black. (Oxidize)
As far as the hard wire is concerned, I think someone turned the annealing voltage down because the wire was turning black. First solve the cooling problem, then restore the annealing voltage.
Peter J. Stewart-Hay
Stewart-Hay Associates www.Stewart-Hay.com
519 641- 3212