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Thermion 500 Owner's Manual

Metalizer, spray master
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MANUAL
August 24, 2007
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ARC SPRAY METALIZING SYSTEMS
OWNER'S MANUAL
(OPERATIONS AND MAINTENANCE)
Thermion Metalizer
Thermion
Thermion Spray Master
Thermion 500
MANUFACTURED BY
SILVERDALE, WASHINGTON, USA
Phone: 360-692-6469 or
1-877-884-3428
FAX: 360-447-8314
Email:
info@thermioninc.com
file 50115 US 1.098

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  • Page 1 MANUAL August 24, 2007 ARC SPRAY METALIZING SYSTEMS OWNER’S MANUAL (OPERATIONS AND MAINTENANCE) Thermion Metalizer Thermion Thermion Spray Master Thermion 500 MANUFACTURED BY SILVERDALE, WASHINGTON, USA Phone: 360-692-6469 or 1-877-884-3428 FAX: 360-447-8314 Email: info@thermioninc.com file 50115 US 1.098...
  • 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;...
  • 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 14922-1, Thermal spraying -- Quality requirements of thermally sprayed structures -- Part 1: Guidance for selection and use. Edition: 1 (monolingual) -- ICS: 25.220.20 -- Descriptors: coating processes, coatings, quality, rules (instructions), specifications, spraying, thermal spraying -- Last updated on 1998-01-17.
  • Page 8 Thermion Arc Spray System. The arc spray process and Thermion 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 Warranty Information Limited Warranty 1) Subject to the terms and conditions hereof, Thermion Inc. warrants to the user that all new and unused equipment furnished by Thermion Inc. is free from defect in workmanship and materials as of the time and place of delivery by Thermion Inc.
  • Page 10 Section 5: Operation (General) Section 6: Principals of Operation Section 7: Liner Replacement Section 8: Parts for Various Wire Sizes Section 9: Parts Diagrams The information contained in this manual represents our best judgment; however, Thermion Inc. assumes no liability for its use.
  • Page 11 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 P.O. Box 0780 4955 N.W. Uff Da Lane Silverdale, WA 98383 USA...

  • 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 Safety Measures Reduction of Fire and Explosive Hazards Reduction of Respiratory Hazards Threshold Limits for Air Concentration of Hazardous Material Personal Protection...
  • Page 13 Wire Loading and Drive Adjustment Principles of Operation Operating Parameters Air Nozzle Alignment (Bridge Master Head) 6.2.1 Angle Spray Nozzle (Bridge Master Head) Air Nozzle Alignment (Thermion 500 Head) 6.3.1 Air Nozzle Alignment (Hard Wire) 6.3.2 Angle Spray Nozzle (Thermion 500 Head) Maintenance 6.4.1...

  • Page 14: Introduction

    1 Introduction 1.1 General Information and Safety A. 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, troubleshooting which should be read, understood, and followed for the safe and effective use of the equipment.

  • Page 15: Receiving And Handling

    1.3 General Description The Thermion Inc. arc spray machine is a pusher 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 Inc. instruction manual. 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.

  • Page 18: Threshold Limits For Air Concentration Of

    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...

  • Page 19: Eye Protection

    2.4 Personal Protection (cont’.) 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: System Assembly

    3 System Assembly...

  • Page 21: Location

    3.1 Location This Arc Spray System is designed for remote location operation; the feed unit is located near the work site. The power supply can be remotely located with all operational controls at the feeder. 3.2 Power Supply IMPORTANT Refer to manufacturer's power supply 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: Voltage

    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. 4.2 Amperage An ammeter is provided at the feeder for operator convenience. The amperage is controlled through the wire feed speed control, which is located on the wire feed unit.

  • Page 24: Wire Runback

    4.7 Wire Runback The wire runback feature creates a gap at the wire's end to aid arc starting. When the spraying is stopped, the wires are retracted on the end of the stopping sequence. The amount of run back is determined by a pot (adjustment) located on the electrical panel.

  • Page 25: 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: Completely lubricate the inside of each liner prior to threading each spool of wire by disconnecting the leads from the wire feeder.

  • Page 26: Principles Of Operation

    The Thermion Inc. Bridge Master 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 be up 42 lbs/hr for aluminum, 150 lbs/hr for zinc, and 110 lbs/hr for zinc/aluminum. Deposit efficiencies of up to 70% have been obtained with these materials.

  • Page 27: Operating Parameters

    However, this equipment runs 3/32" material best at 200-250 amps and 1/8" and 3/16" between 250 and 500 amps. Alloyed material of 1/16” and 3/32" size operates and maintains reasonable chemistry at 180-250 AMPS. Adjusting Parameters: Set the wire feeder volt dial on 80% &...

  • Page 28: Air Nozzle Alignment (Bridge Master Head)

    6.2 Air Nozzle Alignment 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 29: Angle Spray Nozzle (Bridge Master Head)

    6.2.1 Angle Spray Nozzle HEAD...
  • Page 30 6.3 Air Nozzle Alignment (Thermion 500)
  • Page 31 6.3.1 Air Nozzle Alignment (Hard Wires) FOR 1/16” HARD/CORED WIRES AND 3/32” CORED WIRES (COPPER, BRASS, BRONZE, STEAL, NICKEL, STAINLESS, ETC.)
  • Page 32 6.3.2 Angle Spray Nozzle (Thermion 500)
  • Page 33 6.4 Maintenance 6.4.1 Spray Head /Parts Maintenance: a. 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 do not scrape away head material.
  • Page 34 6.4.3 Feeder Unit The feeder unit is low maintenance and mostly requires cleaning and inspections. Keeping the feed rolls and gearing clean of dust and grit will extend life and provide better service. A daily cleaning with an air blow gun usually does it.

  • Page 35: Air Nozzle Alignment (Thermion 500 Head)

    6.5 Maintenance Schedule 6.5.1 Constant Operational Checks AIR NOZZLES- At each shut down cycle, look at air nozzles and remove any buildup. SPRAY TEXTURE- If the spray becomes course, or rough, check tip and air nozzle alignment. SPRAY PATTERN- If the spray pattern changes, check tip and air nozzle alignment.
  • Page 36 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 screw driver to spread the male prong for a tight fit.

  • Page 37: Replacing Wire Liner

    7 Replacing Wire Liner 3/8" BLUE LINER (FOR SPRAYING 1/8" [3MM] WIRE) 7/16" ORANGE LINER (FOR SPRAYING 4MM, & 3/16" [4.8MM] WIRE) Refer to drawing in (SECTION 9.3). Remove 51062 liner assembly from wire feeder, Lay the liner assembly out flat and straight. Then remove liner clamp 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 of Small Wire Liners 3/32” (2.4MM) 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 50062-13 combination leads (cable assembly) from wire feeder, Lay the cable assembly out flat and straight.

  • Page 40: Parts Required For Various Wire Sizes

    8 Parts Required for Various Wire Sizes Tube, Liner Head Tip, Feed Roll Wire Size Liner Contact Clamp Ferrule Insert Contact Kit No. Type 50019 1/16" 50065-1/16 50081-1/16 50063 50109 51109-2 50018-A 50018 14 gauge 2 each 8 each 2 each 2 each 2 each 2 each...

  • Page 41: Cable Components

    9.1 Cable Components...

  • Page 42: Feeder Components

    9.2 Feeder Components 51094 PANEL FRONT 50033 VALVE SOLENOID 50023 METER AMP 1 ½ 52039 REGULATOR AIR 50022 POT SPEED 50038 SPINDLE ASSY 51028 TRIG SW RECEPT 51036-22 LEAD CONNECTOR-TWECO 50036-27 LIGHT INDICATOR 50078 INLET LINER 50026-1 SWITCH INCH BOOT 50090-ASSY GUIDE INLET ASSEMBLY 50026...

  • Page 43: Lead Components

    9.3 Lead Components (1/8”, 3MM, & Larger Wire) 12.5 FT FOR USE WITH 1/8” & SMALLER WIRE 51062 51007 ADAPTER HEAD 51016 O-RING 50008 CABLE, BRAIDED POWER 50009 AIR HOSE 50062-3 SHRINK TUBE 51014-1 O-RING 51014 ADAPTER FEEDER 51109 NUT, LINER CLAMP INSERT OUTER 3/16”...
  • Page 44 9.3.1 Lead Components (3/32”, 2.3MM & Smaller) COMBINATION LEAD ASSEMBLY 1/8” & 51062 SMALLER 51007 ADAPTER HEAD 51016 O-RING 50008 CABLE BRAIDED 50009 AIR HOSE 50062-3 SHRINK TUBE 51014-1 O-RING 51014 ADAPTER FEEDER 50018 LINER, OUTER (VIOLET) 50019 LINER INNER (RED) 50109 NUT, LINER 50018-A...

  • Page 45: 5100 Spray Head Components

    9.4 Spray Head Components A 51064 HEAD, BRIDGE MASTER B 50012 HANDLE 1 50011 SWITCH TRIGGER 2 50003 SCREW CAP 1/4-20 X 1/2 3 50015 RELIEF STRAIN 4 50012-1 SWITCH AIR SWEEP ASSEMBLY 5 50012-2 BOOT AIR SWITCH 6 51079 SHIELD BRIDGE MASTER 7 50080 CLAMP SHEILD...
  • Page 46 9.4.1 Spray Head Components (Thermion 500) 51064 HEAD, BRIDGE MASTER 50012 HANDLE 50003 SCREW CAP 1/4-20 X 1/2 50015 RELIEF STRAIN 50012-1 SWITCH AIR ASSEMBLY 50012-2 BOOT AIR SWITCH 50011 SWITCH TRIGGER 50079 SHIELD 500 50080 CLAMP SHEILD 50005 CLAMP CONTACT TUBE...

  • Page 47: Wire Drive Components

    9.5 Wire Drive Components 10, 11 16, 17 13, 14, 15 WIRE DIRVE FEED ROLL 50031 ASSY ROLL PIN 2075523 FLAT WASHER ¼ 64009431 CAPSCREW – 5/16-18X1-3/4 KNOB 50031-5 61340166 SPRING 182W54 NUT 5/16-18 63350121 RETAINER 50031-4 GEAR & INSULATOR ASSY 50031-1 OUTLET GUIDE (4) FEED ROLL...

  • Page 48: Motor Components

    9.6 Motor Components Drive Adapter 50046 Gear Insulated 999179 Gear Stop Collar 50047 Motor Assembly ¼ HP 51035 Motor Assembly 1/8 HP 50035 3/16 Key...

  • Page 49: System Wiring

    9.7 System Wiring...

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