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Spinarc MA-400 Operation Manual

Air-cooled welding torch
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Houston, Texas USA  +1-832-585-1244  i nfo@weldrevol ution. com
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SpinArc®, Weld Revolution® and the Weld Revolution Logo are a registered trademarks of Weld Revolution LLC.
Patents Pending in multiple countries.
Weld Revolution LLC
www.weldrevolution .com
Operation Manual
MA-400
Air-Coo led
TM
SpinArc
®
Welding Torch
MA-400 Air-Cooled, SpinArc
Revision 23
Welding Torch
®
01-03-2018

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Summary of Contents for Spinarc MA-400

  • Page 1 Operation Manual Model #: MA-400 Air-Coo led SpinArc ® Welding Torch SpinArc®, Weld Revolution® and the Weld Revolution Logo are a registered trademarks of Weld Revolution LLC. Patents Pending in multiple countries. MA-400 Air-Cooled, SpinArc Welding Torch ® Revision 23 01-03-2018...
  • Page 2 Thank You for Choosing Weld Revolution® Thank you for selecting a Weld Revolution product. The SpinArc® welding torch you have purchased is a breakthrough in new technology that has been carefully assembled, thoroughly tested and is ready to weld. Each product goes through a series of quality tests; and every system is weld tested prior to shipment to ensure the highest performance.

  • Page 3: Table Of Contents

    Contents SAFETY PRECAUTIONS – READ BEFORE USING ........................4 Introduction....................................10 How it Works ....................................10 What’s Included ................................... 10 Available Models ..................................10 Optional Accessories ................................. 10 Consumables & Replacement Parts ............................. 10 Specifications ....................................11 Installation ...................................... 12 Connecting Trigger Cable (TC-15) to wire feeder and/or aux equipment ..............

  • Page 4: Safety Precautions - Read Before Using

    SAFE TY PR ECAU TIONS – READ BEFORE USING Welding is not particularly hazardous when certain safety practices are followed. Everyone using this equipment should be thoroughly trained in safe welding practices. Failure to observe safe practices may cause serious injury. Handling welding torches presents no danger if the ...
  • Page 5 Arc Rays  Do not weld or cut where the atmosphere may contain flammable dust, gas, or liquid vapors (such as gasoline). ARC RAYS can burn eyes and skin.  Connect work cable to the work as close to the Arc rays from welding and cutting welding or cutting area as practical to prevent processes produce intense visible...
  • Page 6 conditions are present: in damp locations or while Cylinders wearing wet clothing; on metal structures such as floors, gratings or scaffolds; when in cramped Compressed gas cylinders contain gas positions such as sitting, kneeling or lying; or when under high pressure. If damaged, a there is a high risk of unavoidable or accidental cylinder explode.
  • Page 7 FLYING METAL OR DIRT can injure or kill  Reinstall doors, panels, covers or guards when maintenance is finished and before reconnecting Welding, cutting, chipping, wire  input power. Keep away from pinch points such as brushing and grinding cause sparks and drive rolls.
  • Page 8 TRAPPED AIR PRESSURE AND WHIPPING HOSES can IMPORTANT: Be sure to follow your facility’s lock out / tag out procedures. injure  Release air pressure from tools and system before servicing, adding or changing attachments opening California Proposition 65 Warnings compressor oil drain or oil fill cap.
  • Page 9 Safety Standards  NFPA Standard 70-1978, NATIONAL ELECTRICAL  ANSI Standard Z49.1, SAFETY IN WELDING AND CODE obtainable from the National Fire Protection CUTTING, American Welding Society, 2501 N.W. 7th Association, 470 Atlantic Avenue, Boston, MA 02210. St., Miami, 33125. Free download http://www.aws.org/technical/AWS_Z49.pdf...

  • Page 10: Introduction

    This manual provides basic instructions for Weld Revolution’s MA-400 Mechanized Air-Cooled Welding Torch. This product delivers the benefits of Weld Revolution’s innovative and patented SpinArc® welding technology in a mechanized torch that can also be used semi-automatically with the optional hand welding kit.

  • Page 11: Specifications

    Specifications Table 2 Max Amperage Air-Cooled: 300 Amps/100% D.C. 80/20 Ar/CO  With Water-Cooled Nozzle: 400 Amps/100% D.C. 80/20 Ar/CO  Rating based on tests that comply with IEC 60974-7 specifications Rotation Diameter 1 – 8 mm (0.039 - 0.315 in.) at the wire tip tool-free adjustability in increments of approximately 1 mm Spin Direction Clockwise &...

  • Page 12: Installation

    Installation Step 1: Install Power Pin The power pin attaches to the feeder end of the weld cable. This required part enables the torch to connect to the specific wire feeder model in use. Power pins are sold separately (see Replacement Parts).
  • Page 13 position, plug it into a grounded electrical outlet. Do not remove the grounding plug from the cable. Isolate the Control Box from all sources of high frequency. Step 6: Control Cable Connect the orange control cable to both the torch and the Control Box. Be careful to fully hand tighten both ends.

  • Page 14: Connecting Trigger Cable (Tc-15) To Wire Feeder And/Or Aux Equipment

    4. Once connected, the arc start button on the bug will initiate the welding arc (close the trigger circuit in the wire feeder) and start the rotation on the SpinArc welding torch. Use the delay knob on the Control Box if you need to start the welding arc first, and then start the spin a few seconds later.
  • Page 15 Wire Feeder Trigger Connection Adaptors In order to pass the arc start/stop trigger signal to the wire feeder, you will need the correct trigger lead jumper adaptor. The following table covers the most common welding machines. Table 4 Part Number Description 175.9121 Lincoln Electric 5-PIN trigger adaptor...

  • Page 16: Operation

    Control Box Settings The Control Box is an integral part of the MA-400 SpinArc® Welding System. This is the user interface for setting the Mode Setting, Spin Speed (RPM), the Spin Direction (CW or CCW) and the Spin Start Delay (0 – 5 seconds).

  • Page 17: Torch Adjustments

    Spin Direction (CC/CCW) The spin direction is determined from the welder’s perspective while it is welding. The clockwise (CW) or counterclockwise (CCW) rotation is orientated looking down at the weld from the torch. In other words, looking into the shielding gas nozzle would be opposite of the spin direction setting. The spin direction may be arbitrary in many situations.
  • Page 18 The spin diameter increases by approximately 0.039 in. (1.0 mm) with each setting (1 to 8). Due to the design of the spinning mechanism, the spin diameter at the end of the electrode will be larger than the spin diameter at the contact tip. As shown in the figure below, the contact tube assembly has a fixed pivot point and the tube is driven in a circular motion by an eccentric rotational drive system.

  • Page 19: Application Notes

    Vertical Welding Progression In general, the SpinArc® welding process is better suited for vertical down welding (vs. vertical up). Gas Nozzles The gas nozzle must be selected in relation to the weld joint details. For example, in a narrow gap joint it may prove favorable to use a contact tip that is extended beyond the end of the nozzle.

  • Page 20: Consumables

    Consumables Contact Tips Table 7 Tregaskiss Style Wire Dia. Part # Description .035” (0.9 mm) CT403-27-35 CrZr Extended Life HD for 0.035 in. (0.9 mm) CT403-21-45 Tapered Tip for .045 in. (1.2 mm) wire .045” (1.2 mm) CT403-20-45 Heavy Duty for .045 in. (1.2 mm) Wire CT403-27-45 CrZr Ext.

  • Page 21: Replacement Parts

    R eplacement Parts Page 21 of 40...
  • Page 22 Table 11 Item Description Part # CA-6 (6 ft.) CA-10 (10 ft.) CA-15 (15 ft.) Cable Assembly CA-XX (desired length in even 1 foot increments between 3 – 20 ft.) Upper Cap 1028 O-Ring, Power Stud 1037 Power Stud 1053 O-Ring, Outer Body 1099 Spin Shaft Assembly...

  • Page 23: Control Cables

    Table 12 PN: MA-400-XX MA-400 SpinArc® Welding System (see note below) ITEM PART # DESCRIPTION QTY. CA-XX Cable Assembly WR-K1 Cable Kit Refer Table below Power Pin WR-K1 Strain Relief 1028 Upper Cap MA-400-TB Replacement MA-400 Torch Body CC-6 Control Cable XX denotes the length of the weld cable in feet.

  • Page 24: Replacement Cable Assembly

    Replacement Cable Assembly In the event the cable is damaged it can be replaced by ordering a replacement from our Customer Service Team by calling +1-832-585-1244. Table 14 Part # Description CA-6 Replacement Cable Assembly, 6 ft. (1.8 m) CA-10 Replacement Cable Assembly, 10 ft.

  • Page 25: Maintenance

    Maintenance Preventative Maintenance Schedule At a minimum, these parts must be inspected and/or replaced according the following schedule. In demanding applications or severe environments, inspect more often. These should be done by the welder/operator and shop maintenance personnel. A more detailed inspection and repair procedure follow for each. Table 17 Part Hourly...

  • Page 26: Shielding Gas Nozzles

    Shielding Gas Nozzles It is important to keep the gas nozzle clear from weld spatter. Spatter build up inside the nozzle can interfere with the rotation. As needed, remove the nozzle and use welding plyers to clear any weld spatter buildup. Anti-spatter or ceramic spray can also be used to coat the inside of the nozzle, spin shaft, contact tip extension and the contact tip.
  • Page 27 Check that Flexure is secure by twisting (not bending) Spin Shaft by hand, it should not NOTICE twist. Do not force the Spin Shaft to twist as this will damage the Flexure. Spin Shaft Replacement Procedure Use Flexure Nut Tool to remove Outer Flexure Nut 2.

  • Page 28: Wire Liners

    Table 18 PN: K1752 Spin Shaft Replacement Kit ITEM PART # DESCRIPTION QTY. A1554 Spin Shaft Assembly 1032 Flexure 1034 Flexure Clamp, Spin Shaft 1033 Flexure Clamp, Body Wire Liners The liner runs through the welding cable. Having a properly functioning liner NOTICE It’s is critical to good wire feeding and acceptable welding performance.

  • Page 29: Flexure Nuts

    Flexure Nuts It is important that both flexure nuts remain tight. These keep the flexure from NOTICE rotating, which is key to efficient power transfer and a stable welding arc. Flexure Nut Inspection & Tightening Procedure Gently grab the Spin Shaft and try to spin it about its centerline axis (it should not twist by hand) 2.

  • Page 30: Flexure

    Flexure The Flexure (PN 1032) should be inspected and included in the preventive NOTICE maintenance program. Part life depends on the crank setting and spin speed (see Table 4 for recommended maximum settings). Operating within these recommendations provides optimum life and performance. Operating above these RPMs will reduce part life.

  • Page 31: Power Stud

    Power Stud Make sure Power Stud is tight in to the Torch Body 2. Inspect O-ring and replace, if cut or worn 3. Ensure cable clamp is tight on the Power Stud Tighten Cable Clamp, 5 mm Hex Wrench Check Tightness, ½” (12 mm) Wrench Table 19 PN: A1552 Power Stud Assembly ITEM...

  • Page 32: Accessories & Parts

    Accessories & Parts Hand Welding Kit The mechanized torch can be used by hand with the optional Hand Welding Kit. Part # HWK-1 Control Box Mounting Kit The Control Box can be easily attached to existing welding equipment, carts, or other parts with our mounting kit. Includes heavy-duty magnetic base.

  • Page 33: Troubleshooting

    Tr ouble shooting Problem Possible Cause Corrective Action 1. Wire feeding Improper or worn drive rolls Replace drive rolls problems (chatter, bird’s 2. Incorrect drive roll tension 2. Adjust tension at feeder nest, burn back, arc flaring) 3. Wrong size liner 3.
  • Page 34 Problem Possible Cause Corrective Action 5. Weld Porosity Incorrect gas flow Adjust gas flow rate (could be too high or too low) 2. No shielding gas 2. Install full tanks, check for hose leaks, check regulator/flowmeter for proper function 3. Poor gas flow 3.
  • Page 35 Problem Possible Cause Corrective Action 8. Erratic Spin (off Electrical interference (a) Move Control Box and weld cable away from center, slow sources of electrical noise, e.g. high frequency TIG start, (b) Use short Control Cable, don’t exceed 15 ft. (3m) intermittent) (c) use shorter welding cable (d) verify grounding pin in place on Control Box...

  • Page 36: Faq

    Problem Possible Cause Corrective Action 13. Arc initiates Wire feeding issue See #1 above and stops abruptly 2. Trigger circuit closed by 2. On Aux. equipment, turn weld start to OFF. Turn auxiliary equipment (e.g., OFF welding power source. Restart welder. bug) or during power up of weld power source 3.

  • Page 37: Limited Warranty

    180 Days  All SpinArc® welding systems, including the MA-400. This includes the originally supplied Control Box and torch body.  Consumables, welding cable, control cables and replacement parts are NOT COVERED under this warranty.
  • Page 38 Customer Assistance Policy Weld Revolution LLC does not warrant or guarantee or assume any liability with respect to any information or advice given. Our employees are not in a position to verify the information provided or to evaluate the engineering requirements for any customer. Additionally, the provision of any information or advice does not create, expand, or alter any warranty on our products.
  • Page 39 Page 39 of 40...
  • Page 40 All return shipments must have an RMA #. Weld Revolution LLC 19511 Wied Road, Suite E Spring, TX 77388 USA www.weldrevolution.com Phone: +1-832-585-1244 Fax: +1-832-585-1109...

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