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Thermion PRECISION ARC GENERATION II Owner's Manual

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07/20/2022
Patent # 4512513; 4624410; 5791560; 6683271 B2
Model #58048
Owner's Manual
(Operations and Maintenance)
P
A
RECISION
RC
G
II
ENERATION
Serial #57233
An innovated product of
Thermion Inc. P.O. Box 780 Silverdale, WA Toll Free: 877-884-3428 Local 360-692-6469 Fax 360-447-8314
www.thermioninc.com email: info@thermioninc.com

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Summary of Contents for Thermion PRECISION ARC GENERATION II

  • Page 1 07/20/2022 Patent # 4512513; 4624410; 5791560; 6683271 B2 Model #58048 Owner’s Manual (Operations and Maintenance) RECISION ENERATION Serial #57233 An innovated product of Thermion Inc. P.O. Box 780 Silverdale, WA Toll Free: 877-884-3428 Local 360-692-6469 Fax 360-447-8314 www.thermioninc.com email: info@thermioninc.com...

  • Page 2: Declaration Of Conformity For European Community

    Service: Dean Hooks – 360-265-3649 Declares that the product: Precision Arc Generation II Conforms to the following Directives and Standards: • Machinery Directive: 89/368/EEC • Low Voltage Directive: 73/23/EEC This machinery must be connected to a CE certified power supply.

  • Page 3: Important Safeguards And Symbols

    The operator should read and understand the operating and installation instructions provided with this 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 4: Warranty Information

    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 manufactured by others, such items are sold subject to the warranties of their respective manufacturers, if any.

  • Page 5: Preface

    Section 6: Principles of Operation Section 7: Liner Replacement Section 8: Air Switch and Main Switch Section 9: Components Section 10: General Troubleshooting The information contained in this manual represents our best judgment; however, Thermion Inc. assumes no liability for its use.

  • Page 6: Table Of Contents

    Table of Contents Declaration of Conformity for European Community ........ii Operating Parameters ..............12-13 Important Safeguards and Symbols ..............iii Air Nozzle Alignment 3/16” (4.8mm) Wire Head ......13 Warranty Information ..................iii 6.3.1 Angle Spray Nozzle 3/16” (4.8mm) Wire Head ......14 Preface ........................

  • Page 7: Introduction

    General Description Thermion Inc.’s Precision Arc 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 8: Front End Assembly

    A patented feature of the Thermion Inc. system controls arc shorting. As the arc attempts to short, a sensor detects a change in arc conditions, and the patented feature compensates, recreating atomization 1.3.4 Remote Control of Power Source...

  • Page 9: 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 10: Threshold Limits For Air Concentration Of Hazardous Material

    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 11: Eye Protection (Standard Welding Shields And Lens)

    2 Safety Measures (continued) 2.4.1 Reduction of Noise Hazards - Ear Protection Noise level at any location depends on factors such as equipment operating parameters, background noise, work area size, and wall, floor, and ceiling materials. To determine the exact noise level, it is necessary to measure the sound level to determine the method needed for adequate protection.

  • Page 12: System Assembly

    Power Supply Thermion’s Precision Arc Generation II is uniquely dependent on the power supply being a Miller brand product (Miller Electric Mfg. Co., An Illinois Tool Works Company, 1635 West Spencer Street, Appleton, WI 54914 USA).

  • Page 13: Component Interconnection

    3 System Assembly Diagrams (continued) Component Interconnection This system provides 110 Volt AC power to the feeder unit when the power supply is in ON position. Spray current is provided when the contactor is actuated via the Trigger. WARNING All connections to the feeder from the power supply should be performed with the power supply OFF.

  • Page 14: Controls - Start Up Procedure

    4 Controls - Start Up Procedures Front Panel Setting for Start Up Use these setting to initially start spraying then adjust to the desired voltage and amperage. See Section 9.2.1 for more information. 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.

  • Page 15: Amperage

    4 Controls - Start Up Procedures (continued) Amperage An amp meter 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. Wire Inch An inching switch allows running the wire feed motor, feeding wire through the liner to the head without energizing air or the power supply.

  • Page 16: Operations (General)

    5 Operation (General) Power Supply Refer to the owner's manual for the welding power supply for operation and maintenance. Wire Loading IMPORTANT Lubrication, threading, and adjusting the feed roll pressures are important for smooth thermal spray operation. Proceed as follows: Hand feed the wire through the Fairlead and push onto the feed rolls, assuring your fingers are free of the rolls, jog the wire through the rolls and out the front of the feeder.

  • Page 17: Principals Of Operations

    Wire Size: The Precision Arc Generation II 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.
  • Page 18 6 Principles of Operation (continued) Operating Parameters (continued) Start-up Parameters: Set both the Amp and Voltage dials (on the faceplate) to 50%. Depress the trigger to fire the gun off. If the gun does not fire off, increase the voltage dial by 10% and try again.

  • Page 19: Air Nozzle Alignment 3/16" (4.8Mm) Wire Head

    6 Principles of Operation (continued) 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 20: Angle Spray Nozzle 3/16" (4.8Mm) Wire Head

    6 Principles of Operation (continued) 6.3.1 Angle Spray Nozzle 3/16” (4.8 mm) Wire Head CAUTION: Tighten evenly to prevent heat build-up ANGLE SPRAY NOZZLE 50085A Assy CAUTION: AIR NOZZLE MUST NOT TOUCH TIPS UNWANTED ARCING OR SHORTING WILL OCCUR. FRONT VIEW 51085A Assy: Angle Spray Nozzle Assembly...

  • Page 21: Air Nozzle Alignment <=1/8" (3.2Mm) Wire Head

    6 Principles of Operation (continued) 6.3.2 Air Nozzle Alignment <= 1/8” (3.2 mm) Wire Head SMALL WIRE HEAD 50064B CAUTION: Center Air Nozzle must NOT touch contact tips. Unwanted Shorting will occur.

  • Page 22: Angle Spray Nozzle <=1/8" (3.2Mm) Wire Head

    6 Principles of Operation (continued) 6.3.3 Angle Spray Nozzle <= 1/8” (3.2 mm) Wire Head SMALL WIRE SPRAY HEAD .160 (STANDARD CONTACT TIP GAP) TOP VIEW ANGLE SPRAY NOZZLE 50085A Assy CAUTION AIR NOZZLE MUST NOT TOUCH CONTACT TIPS, UNWANTED ARCING OR SHORTING WILL OCCUR.

  • Page 23: Maintenance

    6 Principles of Operation (continued) 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 made of a plastic material so do not scrape away head material.

  • Page 24: Control Cables

    6 Principles of Operation (continued) 6.4.4 Control Cables The control cables require routine inspection for separation at the connectors and for cuts or breaks in the wire coverings. If any condition of abnormality is notice it must be remedied immediately. CAUTION: when tightening cables, turn the connectors NOT the entire cable or the wires may disconnect and cause shorts.

  • Page 25: Monthly Maintenance (160 Hours)

    6 Principles of Operation (continued) 6.5.2 Weekly Maintenance (40 Hours) (continued) FEEDER CONNECTIONS - Check the fittings inside the feed unit, tighten all bolts that connect the current to the wire feed assembly. POWER SUPPLY - Disconnect the power supply from the primary current. Remove the side covers then remove the dust from inside the machine with an air hose.

  • Page 26: Liner Replacement

    7 Liner Replacement Installation/Replacement Large Wire Liners • Blue Liner for Spraying 1/8" (3.2 mm) Wire • Green 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.

  • Page 27: Installation/Replacement Small Wire

    7 Liner Replacement (continued) 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).

  • Page 28: Air Switch And Main Switch

    8 Air Switch and Main Switch (54012-06A and 54012-07A) Spring Wires #54012-06/07S Installed in #54012-6A and #54012-7A • Loosen set screw (AlloySS054) in brass piece. • Insert spring wire (54012-06/07S) • Wire spring loop is horizontal to the handle body. •...

  • Page 29: Components

    9 Components Cable Components Part Number Description 50058-M Power Supply Cord (Miller) 50058-L Power Supply Cord (Lincoln) 51060-50 MD Control Cable Stretch-out Assembly (Includes 51057 and 51059) 51057 Connector: 19 Pin Male Control Cable 51059 19 Pin Female Connector 58060-03 Cable: Feeder Control PA 5 54012-22A Assy Cable: Trigger Cord 18' Assembly...

  • Page 30: Feeder Components

    9 Components (continued) Feeder Components Part Number Description 58036 Assembly Feeder Assembly See Section 9.2.6 Spindle Assembly See Section 9.2.4 Straightener Assembly See Section 9.2.3 Wire Drive Assembly See Section 9.2.1 Meter Panel Assembly 57956-1/16 Assembly Wire Inlet Fairlead Assembly w/Bearings 57956-4.8 Assembly Wire Inlet Fairlead Assembly w/Bearings 51078-1...

  • Page 31: Meter Panel Components

    9 Components (continued) 9.2.1 Meter Panel Components Part Number Description 58094 4.8 Assembly Meter Panel Assembly 57094-11 Meter Panel: Emergency Stop Switch Assembly 57094-01-M Meter Panel: Digital Amp Meter 54094-2 Meter Handles 57022-A Meter Panel: AMP Dial Knob 54028 Trigger Cord Socket 50026 Inch/Air Switch 57022-V...

  • Page 32: Meter Panel Components - Back Side

    9 Components (continued) 9.2.1.1 Meter Panel Components - Back Side Part Number Description 58094 4.8 Assembly Meter Panel Assembly 57094-03B PC Board Assembly, 15vdc Power Supply 50022 Meter Panel: Speed Control Pot 50025 Meter Panel: Voltage Pot, 1K HW-4100 PA Meter Panel Handle Mounting Screw (SS) HW-4105 PA Digital Meter Cover Mounting Screw 57094-01-M V1...

  • Page 33: Feeder/Air Components

    9 Components (continued) 9.2.2 Feeder/Air Components Part Number Description 50033 Air Valve 50033-2 Acetyl Fitting 57036-02B Air Assembly: Nipple 57036-21B Air Assembly: Long Pipe 57036-22B Air Assembly: Elbow 57036-20B Air Assembly: Long Pipe 50043 Air Filter 57036-22B Air Assembly: Elbow 57036-24B Air Assembly: Pipe HW-4119...

  • Page 34: Wire Drive Components 4.8

    9 Components (continued) 9.2.3 Wire Drive Components 4.8 Part Number Description 57900-6L Assembly 6 Feed Roll Wire Drive - Assembly Left 57900-6R Assembly 6 Feed Roll Wire Drive - Assembly Right See Section 9.2.3.1 Upper Drive Assembly See Section 9.2.4 Straightener Assembly 57913-20 Assy 1.6 Center Guide Assembly...

  • Page 35: Wire Drive Components For 3.2 And Smaller

    9 Components (continued) 9.2.3.1 Wire Drive Components for 3.2 and Smaller Part Number Description 57900-4W Assembly Wire Drive, 4 Roll, With Straighteners See Section 9.2.3.1 Wire Drive A Upper Plate Assembly See Section 9.2.3.2 Straightener Assembly 57901-4L Wire Drive A Main Plate Left 57901-4R Wire Drive A Main Plate Right 57910...

  • Page 36: Wire Drive Upper Plate Assembly

    9 Components (continued) 9.2.3.2 Wire Drive Upper Plate Assembly Part Number Description 57902-4 4 Roll Upper Plate Assembly- Feed Rolls Sold Separately 57902-6 6 Roll Upper Plate Assembly-Feed Rolls Sold Separately 57909 Feed Gear Assembly 57902-01-6 6 Roll Upper Plate 57902-01 4 Roll Upper Plate 57903...

  • Page 37: Wire Straightener

    9 Components (continued) 9.2.4 Wire Straightener Part Number Description 57913A7-Set 1/8-3/16 Straightener 57913A7-R Right side Straightener 57913A7-L Left Side Straightener 57913A7-3.16 1/8-3/16 Straightener Plate 54202 V-Groove Roller 54203-C Cam Adjust Bushing HW-4224 Screw Spacer HW-4008 V-Roller Screw 54202-S V-Roller Spacer Photo Shows 3/32 (1/16 has 3 Cam Bushings) Part Number...

  • Page 38: Motor Components

    9 Components (continued) 9.2.5 Motor Components Part Number Description 57901 Motor Adaptor HW-4062 Screw for Mounting Drive Adapter 58035 Assembly Motor HW-4000 Motor Mount Carriage Bolts HW-4001 Motor Mount Washer HW-4118 Motor Mount Nut AA035-2 Motor Mount 54035-Key Motor: Shaft Key 58034 Motor Mount 54035-1...

  • Page 39: Wire Spindle Assembly

    9 Components (continued) 9.2.6 Wire Spindle Assembly Part Number Description AA038 Wire Spindle Assembly HW-4295 Adapter Plate HW-4296 Brake Plate HW-4297 Friction Washer HW-4298 Brake Plate Lock AA038-01 Spindle Shaft HW-4299 Spindle HW-4300 Friction Washer HW-4301 Keyed Washer HW-4302 Compression Spring HW-4303 Thumb Screw HW-4304...

  • Page 40: Industrial Cart Assembly

    9 Components (continued) 9.2.7 Industrial Cart Assembly Part Number Description 54300 Industrial Cart Assembly 54301 Cart: Frame 54305 Cart: Dual Welding Lead Clamp 54303 Cart: Caster Swivel, Front 54306 Cart: Single Welding Lead Clamp 54304 Cart: Caster Rigid, Rear 54308 Cart: Industrial Cover (Optional) 91845A030 Industrial Cart Caster Mounting Nut...

  • Page 41: Front End Assembly

    9 Components (continued) Front End Assembly Part Number Description 54000-1 3/16 Front End Assembly 54000-1-18 3/16 Front End Assembly 18’ 54116-1/8 1/8 Front End Assembly 13’ 58116-1/16 1/16 Front End Assembly 13’ 54000-3.2 1/8 Front End Assembly 15’ See Section 9.3.1 Combination Lead Components See Section 9.3.2 Head Assembly...

  • Page 42: Lead Components For 3/16" (Mm) Wire

    9 Components (continued) 9.3.1 Lead Components 3/16” (4.8 mm) Wire Part Number Description 51062-15L2 Combination Lead: 15', w/Green Liner 51062-18L2 Combination Lead: 18', w/Green Liner 51077-16 Liner, Green (16') 51077-19 Liner, Green (19’) 51109-1 Liner Insert-3/16" 50109 Liner Nut 51109-3 Ferrule, 3/16"...

  • Page 43: Lead Components For (1/8" 3.2Mm) Wire

    9 Components (continued) 9.3.1.1 Lead Components (1/8” 3.2 mm) Wire Part Number Description 50062-13L1 Combination Lead: 13', w/Blue Liner 51062-15L1 Combination Lead: 15', w/Blue Liner 50078-14 Liner, Blue (14') 50078-16 Liner Blue (16’) 50109-1 Liner Insert-1/8" 50109 Liner Nut 51109-2 Ferrule, 1/8"...

  • Page 44: Small Lead Components (3/32", 2.3Mm And Smaller)

    9 Components (continued) 9.3.1.2 Small Wire Lead Components (3/32”, 2.3 mm and Smaller) Part Number Description Combination Lead: 13', w/Dual Liner for Use With 55062-13L2 3/32” and Smaller Wire 50018-14 Liner, Violet AA018-A Insert, 1/16 -3/32 50109 Liner Nut 51109-2 Ferrule, 1/8"...

  • Page 45: Head Components 3/16" (4.8Mm) Wire

    9 Components (continued) 9.3.2 Head Components 3/16” (4.8 mm) Wire CAUTION: AIR NOZZLE MUST NOT TOUCH TIPS UNWANTED ARCING OR SHORTING WILL OCCUR. Part Number Description 54064 Assembly Head Assembly Head: Center Air Hose (PA) Includes: 54064-1 Assembly 54064-2 and 54064-3 54064-19 Assy Head: Center Air Hose 19’...

  • Page 46: Angle Spray Head Components 3/16" (4.8Mm)

    9 Components (continued) 9.3.2.1 Angle Spray Head Components 3/16” (4.8 mm) CAUTION: AIR NOZZLE MUST NOT TOUCH TIPS UNWANTED ARCING OR SHORTING WILL OCCUR. Part Number Description 54064-1 Assembly Center Air Hose (Includes 54064-2 and 54064-3) 54064-2 Hose to Head Fitting 54064-3 Male Quick Disconnect 50005...

  • Page 47: Spray Head Components (<=1/8" Wire)

    9 Components (continued) 9.3.2.2 Spray Head Components (<= 1/8” Wire) CAUTION: Center Air Nozzle must NOT touch contact tips. Unwanted Shorting will occur. Part Number Description 50064-B Assembly Head: Assembly Open Nozzle 50005 Head: Contact Tube Clamp 50064-B Head: Fan Spray Head 50064B-1 Head: Side Air Jet Nozzle 50065-1/8 IT...

  • Page 48: Angle Spray Head Components <=1/8" (3.2Mm)

    9 Components (continued) 9.3.2.3 Angle Spray Head Components <= 1/8” (3.2 mm) Part Number Description 50064 Assembly Head Assembly 50005 Head: Contact Tube Clamp 50064-B Head: Small Wire .125” (3.2 mm) 50085A Assy Head: Angle Spray Nozzle 50065-1/8 IT Head: Tip Contact 1/8 50065-1/16 IT Head: Tip Contact 1/16 50076 ET...

  • Page 49: Handle And Trigger Assembly

    9 Components (continued) 9.3.3 Handle and Trigger Assembly Part Number Description 54012-19A Assembly Handle ONLY 57079 Head: Safety/Heat Shield 54012-02 Handle: Lever Screw: BHCS 10-32 x 1/2 (SS) HW-4202 Heat Shield Mounting Screw 54012-04 Handle: Contact 54012-05 Handle: Contact Plunger 54012-06A Handle: Air Switch 54012-06/07S...

  • Page 50: Control Box

    9 Components (continued) Control Box Part Number Description 51097 Control Box Assembly 51072G-1 PCB: Complete (with) Relays 50072-2 24 Pin Wire Connector 51082 PCB: Backup Timer Board 51072G PCB: PCB, Blank 51072G 51059-1 Assembly Connector:19 Pin Female (BM) 50058-M Power Supply Cord (Miller) 50058-L Power Supply Cord (Lincoln) 50051...

  • Page 51: System Wiring

    9 Components (continued) 9.4.1 System Wiring...

  • Page 52: Precision Wire Dispenser (Optional)

    Washer: (Zn Plated) HW-4066 Nut: (Zn Plated) Screw: 4 Each - Attach Straightener Arm to Mast HW-4078 2 Each – Attach Wheel to Arm (Installed by Thermion) HW-4079 Screw: Attaches Feeder Mount to Mast HW-4056 Washer: Separates Mast From Arm...

  • Page 53: Precision Wire Dispenser W/Jack (Optional)

    See Figure C Part Number Description Qty. 541200, Assembly Precision: Wire Dispenser Precision Arc Wire Straightener Assembly 54200 Assembly Installed by Thermion HW-4054 Washer HW-4066 Nut (Zn Plated) Screw: 4 Each - Attach Straightener Arm to Mast HW-4078 2 Each - Attach Wheel to Arm...

  • Page 54: General Troubleshooting

    10 General Troubleshooting TROUBLE POSSIBLE CAUSE REMEDY No feed, no air, with indicator light off 1. No 110 VAC to Feeder 1. Check Fuse/Breaker on Power Supply No wire feed at motor jog switch with 1. Blown Fuse on Motor Controller 1.
  • Page 55 Thermion Inc. P.O. Box 780 Silverdale, WA Toll Free: 877-884-3428 Local 360-692-6469 Fax 360-447-8314 www.thermioninc.com email: info@thermioninc.com Printed in the U.S.A. © 2005 Thermion Inc.

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