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Thermion BRIDGEMASTER Owner's Manual

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MANUAL
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(OPERATIONS AND MAINTENANCE)
File: c:\msoffice\winword\thermion\manuals\bridgemaster 2005
Patent # 4512513; 4624410; 5791560; 6683271 B2
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SERIAL #
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OWNER'S MANUAL
MANUFACTURED BY
SILVERDALE, WASHINGTON, USA
Phone: 360-692-6469
Toll Free: 877-884-6428
Fax: 360-447-8314
Web Site:
www.thermioninc.com
July 19, 20075
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  • Page 1 MANUAL July 19, 20075 Patent # 4512513; 4624410; 5791560; 6683271 B2 SERIAL # ________________________________________ OWNER’S MANUAL (OPERATIONS AND MAINTENANCE) MANUFACTURED BY SILVERDALE, WASHINGTON, USA Phone: 360-692-6469 Toll Free: 877-884-6428 Fax: 360-447-8314 Web Site: www.thermioninc.com File: c:\msoffice\winword\thermion\manuals\bridgemaster 2005...
  • Page 2 The US Thermal-Spray Standards Program: Thermal-spray standards in the United States are developed by several professional societies that include American Society for Testing and Measurement (ASTM) for test & measurements methods and composition specifications; American Welding Society (AWS) for feedstock, equipment acceptance, application process, training & certification; American Water Works Association (AWWA) for thermal-spray zinc potable water tank linings;...
  • Page 3 US Published Standards: ASTM D 4541, Test Method for Pull-Off Strength of Coating Using Portable Adhesion Testers. This test method covers a procedure for evaluating the pull-off strength (commonly referred to as adhesion) of a coating by determining either the greatest perpendicular force (in tension) that a surface area can bear before a plug of material is detached, or whether the surface remains intact at a prescribed force (pass/fail).
  • Page 4 US Standards In-Preparation ANSI/AWS A5.33/A5.33M:199X, Specification for Solid and Composite Wires, and Ceramic Rods for Thermal Spraying, 01/19/99 (ballot to publish). This specification defines the as manufactured, chemical composition classification requirements for solid and composite wires and ceramic rods for thermal spraying. Requirements for standard sizes, marking, manufacturing, and packaging are included.
  • Page 5 US Standards In-Preparation ANSI/AWS C2.20-9X, Specification for Thermal Spraying Zinc Anodes on Steel Reinforced Concrete, Committee Draft #2, February 18, 1999. Ballot CD-205, Approval to publish. Due 03/31/99. This AWS standard is a specification for thermal spraying zinc anodes on steel reinforced concrete.
  • Page 6 ISO Standards of TC 107 SC 5, Thermal Spraying (12 standards issued) ISO 2063:1991 Metallic and other inorganic coatings -- Thermal spraying -- Zinc, aluminum and their alloys ISO/DIS 14231 Thermal spraying -- Acceptance inspection of thermal spraying equipment ISO/DIS 14232 Thermal spraying -- Powders -- Composition -- Technical supply conditions ISO/DIS 14916 Thermal spraying -- Determination of tensile adhesive strength...
  • Page 7 ISO Standards of TC 107 SC 5, Thermal Spraying ISO/DIS 14916, Thermal spraying -- Determination of tensile adhesive strength. Edition: 1 (monolingual) ICS: 25.220.20 Descriptors: adhesion tests, adhesive strength, coating processes, coatings, determination, spraying, tension tests, tests, thermal spraying -- Last updated on 1998-01-17 ISO/DIS 14917, Thermal spraying -- Terminology, classification.
  • Page 8 The operator should read and understand the operating and installation instructions provided with this Thermion Inc. arc spray system. The arc spray process and Thermion Inc. arc spray equipment share similarities with welding processes and equipment. Improper use or maintenance may cause serious injury or death. Your end user should have training or experience in safe practices for the arc spray process before operating the arc spray equipment.
  • Page 9 Thermion Inc. is free from defect in workmanship and materials as of the time and place of delivery by Thermion Inc. or its agent. With respect to trade accessories or other items manufacture by others, such items are sold subject to the warranties of their respective manufacturers, if any.
  • Page 10 Section 6: Principles of Operation Section 7: Liner Replacement Section 8: Parts Required for Various Wire Sizes Section 9: Components Section The information contained in this manual represents our best judgment; however, Thermion Inc. assumes no liability for its use.
  • Page 11 Service Notice If, after reading this manual, and consulting with your distributor you have additional questions regarding the operation of this piece of equipment, please call, fax, or write: Thermion PO Box 780 Silverdale, WA. 98383 USA Voice: (360) 692-6469...

  • Page 12: Table Of Contents

    Table of Contents Page Section Contents Introduction General Information and Safety Receiving and Handling General Description 1.3.1 Wire Feeder 1.3.2 Spray Gun 1.3.3 Arc Shorting Control 1.3.4 Remote Control of Power Source Safety Measures Reduction of Fire and Explosive Hazards Reduction of Respiratory Hazards Threshold Limits for Air Concentration of Hazardous Material...
  • Page 13 Table of Contents, continued Page Section Contents Principles of Operation 6.1. Operating Parameters Air Nozzle Alignment 3/16” (4.8 mm) Wire Head 6.2. Angle Spray Nozzle 3/16” (4.8 mm) Wire Head 6.2.1. Air Nozzle Alignment <= 1/8” (3.2 mm) Wire Head 6.3.

  • Page 14: Introduction

    1 Introduction 1.1 General Information and Safety General Information presented in this manual and in the power supply manual, and on labels, tags and plates provided on the unit pertains to equipment design, installation, operation, maintenance, and troubleshooting all of which should be read, understood, and followed for the safe and effective use of the equipment.

  • Page 15: General Description

    1.3 General Description Thermion Inc.’s Bridgemaster Spray Machine is a push type arc spray system that has a patented feature, which controls arc shorting. This equipment is designed to spray most wires, i.e., stainless, low alloy steels, bronzes, aluminum, zinc, zinc-aluminum, babbitt, etc.

  • Page 16: Safety Measures

    EQUIPMENT MAINTENANCE Maintain the arc spray equipment in first-class condition. Follow the maintenance recommendations in this Thermion Instruction Manual located in Sections 6.4-6.5.4. DANGER: All dust, having considerable caloric value, can be explosive. This dust includes: flour, starch, hard rubber dust, wood flour, aluminum dust, and the dust of other metals.

  • Page 17: Reduction Of Respiratory Hazards

    2.2 Reduction of Respiratory Hazards WARNING For shop work being performed by an operator without an air fed hood, a suitable spray booth and an adequate exhaust system are required to avoid the toxic or noxious effects of dust, fumes, and mists which may be generated by arc spraying. The following is for information only;...

  • Page 18: Threshold Limits For Air Concentration Of Hazardous Material

    REDUCTION OF NOISE HAZARDS: Noise from a Thermion Inc. arc spray gun range between 80 and 120 decibels. At this level, most Governmental Health Agencies require ear protection and sometimes double ear protection.

  • Page 19: Eye Protection

    2.4 Personal Protection (continued) WARNING the noise made by the arc spray gun is loud enough to cause the operator discomfort and can cause hearing damage. Adequate protection should always be used. The operator and other personnel close to the arc spray operation must be protected from excessive noise.
  • Page 20 3 System Assembly (drawing shows optional straighteners)

  • Page 21: Location

    3.1 Location This Arc Spray System is designed for remote location operation; the feed unit can be located near the work site while the power supply can be located outside the dust environment. 3.2 Power Supply IMPORTANT Refer to manufacturer's instruction manual for hook up and operation requirements for the power supply and to select correct output cables in relation to power source location and work site distance, and operational amperage.

  • Page 22: Service Air

    3.3.4 Service Air Clean dry air is used as the atomizing gas and coolant for gun leads. 65 cfm of air volume must be available; a 1/2" IPS minimum supply line at 120 PSI maximum should be used to supply this air volume. Optimum regulated air pressure for general purpose spraying should be 95 PSI.
  • Page 23 4 Controls Start Up Settings: Use these setting to initially start spraying then adjust to the desired voltage and amperage. A. POWER SUPPLY: The power supply must be set for remote operations and for gas metal arc welding, usually with all optional setting in the off position, i.e. pulsars, etc. The power supply voltage (for CV) or power (for CC) are controlled at the feeder.

  • Page 24: Controls (Start Up Procedures)

    4 Controls Full control of all functions can be provided at the wire feeder. One multi-conductor lead provides the inter-connection from the power supply to the control box and from the control box to the feeder. 4.1 Voltage Voltage is controllable at the wire feeder. Voltage is an indicator of arc gap; the higher the voltage, the larger the distance between the two wires in the arc.

  • Page 25: Air Sweep/Inch

    4.6 Air Sweep/Inch* The air sweep is for cleaning dust from the surface prior to arc spraying. The air is turned on with the trigger switch located on the spray head. When partially depressing the trigger switch the air will turn on, holding that position, the air will spray without feeding wire.

  • Page 26: Operation (General)

    5 Operation (General) 5.1 Power Supply Refer to the owner's manual for the welding power supply for operation and maintenance. 5.2 Wire Loading and Drive Adjustment IMPORTANT Lubrication, threading, and adjusting the feed roll pressures are important for smooth thermal spray operation. Proceed as follows: 1.

  • Page 27: Principles Of Operation

    This happens very fast and does not effect coating quality. Low Energy High Deposition The Thermion Bridgemaster Model is capable of spraying 3/16" diameter aluminum, zinc, or zinc/aluminum wire. The amperage requirement for spraying this wire is 350- 500 amps. At this energy level the spray rate can 42 lbs/hr for aluminum, 150 lbs/hr for zinc, and 110 lbs/hr for zinc/aluminum.

  • Page 28: Operating Parameters

    Wire Size: The Bridgemaster can spray up to 3/16" diameter wire. 1/8" (3.2 mm) and 3/16" (4.8 mm) diameter aluminum and zinc are the optimum size for the Thermion equipment. 1/16" (1.6 mm) and 3/32" (2.4 mm) diameters are the most common used sizes of the hard wire types.

  • Page 29: Air Nozzle Alignment 3/16" (4.8 Mm) Wire Head

    6.2 Air Nozzle Alignment 3/16” (4.8 mm) Wire Head Align contact tips to maintain wires directly in center of air nozzle. Set contact tips prior to operation, perform spraying for a few minutes, then check wire position and realign if wire position has changed.

  • Page 30: Angle Spray Nozzle 3/16" (4.8 Mm) Wire Head

    6.2.1 Angle Spray Nozzle 3/16” (4.8 mm) Wire Head...

  • Page 31: Air Nozzle Alignment <= 1/8" (3.2 Mm) Wire Head

    6.3 Air Nozzle Alignment <= 1/8” (3.2 mm) Wire Head...

  • Page 32: Angle Spray Nozzle <= 1/8" (3.2 Mm) Wire Head

    6.3.2 Angle Spray Nozzle <= 1/8” (3.2 mm) Wire Head...

  • Page 33: Maintenance

    6.4 Maintenance 6.4.1 Spray Head /Parts Maintenance: Spray Head: The outer body of the spray head requires occasional cleaning to eliminate any possibility of metal dust that could cause arc shorting between the contact tubes. A small stiff brush or knife blade can be used to scrape off the accumulated metal dust, the head is a plastic material so don’t scrape away head material.

  • Page 34: Combination Leads

    6.4.2 Combination Leads Liners: The liners inside the combination leads are considered consumable parts and require periodic replacement due to wear or accumulation of dust or grit. The wear life can be extended by using methods to minimize the amount of dirt that gets into the system.

  • Page 35: Maintenance Schedule

    6.5 Maintenance Schedule 6.5.1 Constant Operational Checks 1. AIR NOZZLES- At each shut down cycle, examine air nozzles and remove any buildup. 2. AIR NOZZLE ADJUSTMENT- The side air jet nozzles may need adjustment periodically. Remove the nozzle from the head and place into a vise. By hand bend the nozzle tube to required fit.

  • Page 36: Weekly Maintenance (40 Hours)

    6.5.3 Weekly Maintenance (40 Hours) CAUTION: Perform all electrical work with power secured. 1. CABLE CONNECTIONS- Check all electrical lead connections from power supply to wire feeder. The connections must fit firmly, a loose fit will cause the leads to heat up. Use a screwdriver to spread the male prong for a tight fit.

  • Page 37: Liner Replacement

    7 Liner Replacement 3/8" (9.5 mm) BLUE LINER FOR SPRAYING 1/8" (3.2 mm) WIRE 7/16" (11.1 mm) ORANGE LINER FOR SPRAYING 3/16" (4.8 mm) WIRE Refer to drawing in (SECTION 9.3) Disconnect leads (51062) liner assembly from wire feeder. Lay the liner assembly out flat and straight. Then remove liner nut (50109), insert (51019-1) and ferrule (51109-3), this will expose the liner and allow it to be removed by pulling the liner out of the liner assembly.
  • Page 38 7.1 Installation / Replacement Small Wire Liners 3/32” (2.4 mm) and Smaller Wire A two-liner system (an outer and inner liner) is used when spraying the smaller wire diameters. The following instructions detail the liner change out process. Refer to drawing in (SECTION 9.3.1) Remove combination leads (50062-13 cable assembly) from wire feeder;...

  • Page 39: Parts Required For Various Wire Sizes

    8 Parts Required for Various Wire Sizes Tube, Liner Wire Tip, Feed Roll Head Type Liner Contact Clamp Ferrule Insert Size Contact Kit No. 1/16" 50019 SMALL WIRE 50065-1/16” 50081-1/16” 50076 50109 51109-2 50018-A 14 gauge 50018 2 each 8 each 2 each 2 each 2 each...

  • Page 40: Components Section

    9. Components Section Cable Components Feeder Components 9.2.1 Wire Drive Components 9.2.2 Wire Straightener Assembly (Optional) 9.2.3 Motor Components 9.2.4 Industrial Cart Assembly (Optional) Front End Assembly Lead Components 3/16” (4.8 mm) 9.3.1 Lead Components 1/8” (3.2 mm) Wire 9.3.1.1 Lead Components 3/32”...

  • Page 41: Cable Components

    9.1 Cable Components 50058 Power Supply Cord 51060-XX Control Lead Assy 51057 Control Cable Connector 51059 19 Pin Female Connector 50045-13 Trigger Cord...

  • Page 42: Feeder Components

    9.2 Feeder Components 51036 Assy Feeder Assembly 51094 Assy Meter Panel Assembly See 9.2.3 Motor Assembly See 9.2.1 Wire Drive Assembly 54094-2 Meter Handles 50036-27 Indicator Light 51028 Trigger Receptacle 50026 Inch/Air Switch 50022 Pot Amp 50025 Pot Volt 50023 Amperage Meter 50024 Volt Meter...

  • Page 43: Wire Drive Components

    9.2.1 Wire Drive Components 9, 10, 11, 12 16, 17 13, 14, 15 WIRE DRIVE 4 ROLL ASSY 54031 FLAT WASHER ¼ 64309431 CAPSCREW – 5/16-18 X 1-3/4 ROLL PIN 2075523 61340166 KNOB 50031-05 NUT 5/16-18 63350121 SPRING 50031-04A GEAR & INSULATOR ASSY 54031-01 RETAINER 50031-04...
  • Page 44 9.2.2 Wire Straightener Assembly (Optional) 54200 Assembly Wire Straightener Assembly 54201 Roller Mount 54202 V-Groove Rollers 54203 Cam Adjuster Bushing 54204 Roller Mount Screw 54205 Bearing Plate Mount 54206 Insulator Support 54207 Support Mounting Nut 54208 Support Mounting Washer 54209 Attachment Bullet...

  • Page 45: Motor Components

    9.2.3 Motor Components 54046 Drive Adapter 54046-1 Retaining Ring 54031-01 Gear Insulated 50047 Gear Stop Washer 54035 Assembly Motor Assembly 54035-KEY Motor Key 92356A58 Carriage Bolts 54035-3 Motor Mount 54035-1 Coupling Sleeve Rt. Angle 54035-2 Coupling Sleeve Gear Housing...
  • Page 46 9.2.4 Industrial Cart Assembly (Optional) 54300 Industrial Cart Assembly 54301 Frame 54302 Tool Box 54303 Front Swivel Caster 54303-1 Caster Swivel Brake 54304 Rear Rigid Caster 54305 Dual Welding Lead Clamp 54306 Single Control Lead Clamp...

  • Page 47: Front End Assembly

    9.3 Front End Assembly 54000-1 Front End Assembly See Sec 9.3.1 Lead Components See Sec 9.3.2 Head Components See Sec 9.3.3 Trigger Assembly 54045 Trigger Cord...

  • Page 48: Lead Components 3/16" Wire

    9.3.1 Lead Components 3/16” (4.8 mm) A 51062-15L2 Combination Lead: 15', w/Orange Liner 1 51007 Head Adapter 2 50008 Braided Cable 3 50009 Hose 3/4" 4 50009-1 Air Hose Clamp 5 50009-2 Shrink Tube Clamp 6 51014 Feeder Adapter 7 51014-1 O-Ring, Feeder Adapter 8 51016 O-Ring, Head Adapter...
  • Page 49 9.3.1.1 Lead Components (1/8” 3.2MM) Part # Description Combination Lead: 13', w/Blue Liner for use with 1/8” & 50062-13L1 smaller wire 51007 Head Adapter 50008 Braided Cable 50009 Hose 3/4" 50009-1 Air Hose Clamp 50009-2 Shrink Tube Clamp 51014 Feeder Adapter 51014-1 O-Ring, Feeder Adapt 51016...

  • Page 50: Lead Components 1/8" (3.2 Mm) Wire

    9.3.1.2 Lead Components 3/32” (2.3 mm) & Smaller Wire PART # Description Combination Lead: 13', w/Dual Liner for use with 3/32” & 50062-13L2 smaller wire 51007 Head Adapter 50008 Comb. Lead: Braided Cable 50009 Hose 3/4" 50009-1 Air Hose Clamp 50009-2 Shrink Tube Clamp 51014...

  • Page 51: Spray Head Components 3/16" (4.8 Mm) Wire

    9.3.2 Spray Head Components 3/16” (4.8 mm) Wire 51064 Assy Head Assembly 51064 Head Fan Spray 50080 Clamp, Shield 50005 Clamp, Contact Tube 51064S-1 Nozzle Fan Side Air Jet 51076 Contact Tube 51065-3/16” Contact Tip 51079 Shield 50066 Center Air Nozzle Tip 50066-1 Center Air Nozzle Air Tube CAUTION: CENTER AIR NOZZLE MUST NOT TOUCH...

  • Page 52: Spray Head Components<= 1/8" (3.2 Mm) Wire

    9.3.2.1 Spray Head Components <= 1/8” (3.2 mm)Wire 50005 Head: Contact Tube Clamp 50064-B Head: Fan Spray 50064B-1 Side Air Jet Nozzle 50065-XX Tip, Contact 50066 Center Air Nozzle, Tip 50066-1 Center Air Nozzle, Tube 50066-2 Center Air Nozzle, O-Ring 50076 Contact Tube - 1/8"...

  • Page 53: Angle Spray Head Components 3/16" (4.8 Mm) Wire

    9.3.2.2 Angle Spray Head Components 3/16” (4.8 mm) 50005 Head: Contact Tube Clamp 51064 Head: Angle Spray 51085 Head: Angle Spray Nozzle 51065-XX Head: Tip Contact 51076 Head: Contact Tube 50080 Head: Shield Clamp...

  • Page 54: Angle Spray Head Components<= 1/8" (3.2 Mm) Wire

    9.3.2.3 Angle Spray Head Components <= 1/8” (3.2 mm) 50064 Assy Head Assembly 50005 Head: Contact Tube Clamp Head: .125” (3.2 mm) Fan Spray 50064B 50085 Head: Angle Spray Nozzle 50065-XX Head: Tip Contact 50076 Head: Contact Tube 50080 Head: Shield Clamp ...

  • Page 55: Handle And Trigger Assembly

    9.3.3 Handle and Trigger Assembly 50045 Assy Handle Assembly (W/Out Cord) 50003 ¼ -20 Cap Screws 50015 Strain Relief 50012-1 Air Switch 50012-2 Air Switch Boot 50011 Trigger Switch 50012 Handle Handle Assembly with 13’ Cord 50045-13...

  • Page 56: Control Box

    9.4 Control Box 51097 Control Box Assembly 51072G-1 PC Board Assembly 50072-2 24 Pin Wire Connector 51082 Back Up Timer 51072G PC Board 51059-1 Connector 19 Pin 50058 Power Supply Cord 50051 Bridge Rectifier 50052 Transformer 50049 Relay 51048 Motor Controller 51097-RM Control Box 50036-17...

  • Page 57: System Wiring

    9.4.1 System Wiring...

  • Page 58: General Troubleshooting

    9.5 GENERAL TROUBLESHOOTING TROUBLE POSSIBLE CAUSE REMEDY No feed, no air, with indicator 1. No 110 VAC to Feeder 1. Check Fuse/Breaker on Power light off Supply No wire feed at motor jog sw with Blown Fuse on Motor Controller 1.
  • Page 59 9.5 GENERAL TROUBLESHOOTING (continued) TROUBLE POSSIBLE CAUSE REMEDY Wire twists or spirals in liner 1. Low Voltage 3. Raise Voltage 2. Clogged Contact Tubes or Tips 4. Clean/Replace Tubes & Tips Excessive dust and smoke 1. High Voltage 2. Lower Voltage Slit spray pattern 1.

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