1. Manuals
  2. Brands
  3. Thermion Manuals
  4. Paint Sprayer
  5. AVD350
  6. Owner's manual

Thermion AVD350 Owner's Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
04/24/2023
Patent # 5791560; 6683271 B2
Model #77350
Owner's Manual
(Operations and Maintenance)
(CE)
350
AVD
Featuring "VS Technology"
Serial #77094
An innovated product of
Thermion Inc. P.O. Box 780 Silverdale, WA 98383 Toll Free: 877-884-3428 Local 360-692-6469
www.thermioninc.com email: info@thermioninc.com

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the AVD350 and is the answer not in the manual?

Questions and answers

Related Manuals for Thermion AVD350

Summary of Contents for Thermion AVD350

  • Page 1 04/24/2023 Patent # 5791560; 6683271 B2 Model #77350 Owner’s Manual (Operations and Maintenance) (CE) Featuring “VS Technology” Serial #77094 An innovated product of Thermion Inc. P.O. Box 780 Silverdale, WA 98383 Toll Free: 877-884-3428 Local 360-692-6469 www.thermioninc.com email: info@thermioninc.com...

  • Page 2: Declaration Of Conformity For European Community

    Declares that the product: Featuring “VS Technology” 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. Certified by: Alan Rogers President of Thermion Inc.
  • Page 3 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

    Limited Warranty: • Subject to the terms and conditions hereof, Thermion warrants to the user that all new and unused equipment furnished by Thermion is free from defect in workmanship and materials as of the time and place of delivery by Thermion 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 5: Preface

    Section 6: Principals 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 assumes no liability for its use.

  • Page 6: Table Of Contents

    Table of Contents Declaration of Conformity for European Community ......... ii 6.3.2 Feeder Unit ....................15 Important Safeguards and Symbols ............... iii 6.3.3 Control Cables ..................15 Warranty Information ....................iii Constant Operational Checks .............. 16 Preface ..........................iv 6.4.1 Daily Maintenance (8 Hours) ..............

  • Page 7: Introduction

    1.3 General Description The Thermion 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 8: Spray Gun

    1 Introduction (continued) 1.3.2 Spray Gun The spray gun is simple, durable, and lightweight. The patented combination leads carry the atomization air, spray wire, and power to the spray gun from the feeder. 1.3.3 Automatic Speed and Arc Shorting Control This patented AVD system maintains a near perfect arc.

  • Page 9: Safety Measures

    EQUIPMENT MAINTENANCE - Maintain the arc spray equipment in first-class condition. Follow the maintenance recommendations in this Thermion instruction manual. When the electric arc spray system is set up and operated in accordance with the instructions in this manual, the metalizing wires are electrically energized only when the gun is spraying.

  • Page 10: Reduction Of Respiratory Hazards

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

  • Page 11: Eye Protection (Standard Welding Shields And Lens)

    2 Safety Measures (continued) 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 12: System Assembly

    Power Supply Thermion’s AVD350 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 (continued) Component Interconnection This system provides 24 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 gun switch. WARNING - All connections to the feeder from the power supply should be performed with the power supply OFF.

  • Page 14: Front Panel Setting For Start Up

    4 Start Up Settings Use these settings to initially start spraying then adjust to the desired voltage and amperage. A. POWER SUPPLY: The power supply must be set for gas metal arc welding, usually with all optional settings in the off position, i.e. pulsars, etc. The power supply voltage (for cv) or power (for cc) is controlled at the power unit, not at the feeder.

  • Page 15: Voltage

    4 Start Up Settings (continued) Voltage Voltage is controllable at the power supply unit. Being that the wire feeder is using the arc voltage for operations, the feed rate or amperage will automatically increase or decrease as the voltage is increased or decreased.

  • 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

    6 Principles of Operation With the system correctly connected and the power supply turned on, the operator turns on the main switch that energizes the wire feeder controls. The operator then loads the wire as explained in Section 5, adjusts the pressure regulator as specified in spray tables, sets the voltage on approximate settings given in tables, sets the Amps Knob (for wire feed speed control) at 30%, and is ready to fire up.

  • Page 18: Air Nozzle Alignment

    6 Principles of Operation (continued) 6.2. Air Nozzle Alignment CONTACT TUBE CLAMP 50005 50064 HEAD SHIELD CLAMP 50080 CENTER AIR NOZZLE TUBE CONTACT TUBE 50066-1 50063 CENTER AIR NOZZLE HARD WIRE TIP 50066B 50063 CONTACT TIP 50065 CAUTION: Center Air Nozzle must NOT touch contact tips.

  • Page 19: Angle Spray Nozzle Alignment

    6 Principles of Operation (continued) 6.2.1 Angle Spray Nozzle Alignment CONTACT TUBE CLAMP CONTACT TUBE 50005 CONTACT TUBE ANGLE CONTACT TIPS 50076 SPRAY NOZZLE 51085 CONTACT TTP HEAD: .125” (32mm) FAN SPRAY HEAD ANGLE HEAD ASSEMBLY 50064B 50064 PRAY SHIELD CLAMP CAUTION AIR NOZZLE MUST NOT 50080 TOUCH CONTACT TIPS, UNWANTED...

  • Page 20: Jet Nozzle Assembly And Adjustment

    6 Principles of Operation (continued) 6.2.2 Jet Nozzle Assembly and Adjustment Parts Description: A Jet Nozzle Head Assembly 7 Contact Tube Adjusting Set Screws 12 Jet Flow Adapter 1 Jet Nozzle Plastic Body 8 Jet Housing 13 Jet Housing O-Ring 2 Contact Tube Clamp 9 Jet Nozzle (Bevel Facing Tips) 14 Screw for Jet Housing to Head...

  • Page 21: Spray Head/Parts Maintenance

    6 Principles of Operation (continued) 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 use caution to avoid scraping away head material.

  • Page 22: Constant Operational Checks

    6 Principles of Operation (continued) 6.4 Constant Operational Checks AIR NOZZLES - At each shut down cycle, look at air nozzles and remove any buildup. PRAY 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 23: Monthly Maintenance (160 Hours)

    6 Principles of Operation (continued) 6.4.3 Monthly Maintenance (160 Hours) CAUTION: Perform all electrical work with power secured. TIPS – Replace. CONTACT TUBE – Replace. LINERS - Replace - See Section 7. FEED ROLLS - Inspect the knurled surface for wear, replace if required. FEED ROLL BEARINGS - Inspect feed roll bearings;...

  • Page 24: Liner Replacement

    7 Liner Replacement 7.1 Replacement of Single Red Liner Refer to drawing in (Section 9.3.2). Remove Lead Assembly from Wire Feeder and Head Assembly; lay the Lead Assembly out flat and straight. Then remove liner clamp nut (50109), and insert (59018- A), this will expose the liner and allow it to be removed by pulling the liner out of the Lead Assembly.

  • Page 25: Replacement Of Liner For 3/32" (2.4Mm) And Smaller Wire

    7 Liner Replacement 7.2 Liner Replacement for Wire <= 3/32” (2.3mm) Wire • 3/32” (2.4mm) and Smaller Wire A two-liner system (an outer and inner liner) is used when spraying smaller wire diameters. The following instructions detail the liner change out process. Refer to drawing in (Section 9.3.2).

  • Page 26: Air Switch And Main Switch

    8 Air Switch and Main Switch (54012-06A & 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. • Tighten set screw (AlloySS054) Air switch spring wire installed.

  • Page 27: Cable Components

    9 Components 9.1 Cable Components Part Number Description (Parts 1, 2, 3, 6) Front End Assembly 59062-10L1 ½” Combination Lead Assembly ¾” Combination Lead Assembly 55062-13L2 50064 1.6 Assy 1/16" Angle Spray Head Assembly AA564 Assembly Head Assembly – Jet Nozzle 54012-19A Assy Handle Assembly AA060...

  • Page 28: Feeder Components

    9 Components (continued) 9.2 Feeder Components Part Number Description See Section 9.2.1 Air Supply Components See Section 9.2.2 Wire Spindle Assembly 57036-Assembly Feeder Assembly AVD 4W See Section 9.2.3 Wire Drive Components 57036 Feeder Frame Cabinet 50026 Inch Switch 58036-PC10A Front Panel 57036-18 Door Latch and Strike...

  • Page 29: Air Supply Components

    9 Components (continued) 9.2.1 Air Supply Components Part Number Description AA033-1 Air Line 16 ¼ 50033-2 Air Assembly Acetyl Fitting 57036-10 Assy Air Collar Assembly AVD Only AA033 Air Valve 57036-21B Air Assembly Long Pipe 50043 Regulator Filter Combo w/Gauge 50043-1 Regulator w/out Gauge 57036-20B...

  • Page 30: Wire Spindle Assembly

    9 Components (continued) 9.2.2 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 (Cork) HW-4301 Keyed Washer HW-4302 Compression Spring HW-4303 Thumb Screw...

  • Page 31: Wire Drive Components 4 Roll

    9 Components (continued) 9.2.3 Wire Drive Components 4 Roll 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 Wire Drive Straightener Assembly 57901-4W Wire Drive A Main Plate 57910 Wire Drive: Insulated Gear AVD 57912...

  • Page 32: Wire Drive Upper Plate Assembly

    9 Components (continued) 9.2.3.1 Wire Drive Upper Plate Assembly Part Number Description 57902-4 Upper Plate Assembly (Feed Rolls Sold Separately) 57909 Wire Drive A Feed Gear Assembly 57902-01 Wire Drive A Upper Plate 57903 Wire Drive A Pivot Arm 57081-1.6 Feed Rolls 1/16”...

  • Page 33: Wire Drive Straightener Assembly

    9 Components (continued) 9.2.3.2 Wire Drive Straightener Assembly Photo shows 3/32 (1/16 has three cam bushings) Part Number Description 57913A-1/16 Set 1/16" Wire Straightener Assembly (Both Sides) 57913A-3/32 Set 3/32" Wire Straightener Assembly (Both Sides) 57913A-01 1/16” Straightener Back Plate – Left or Right 57913A-02 3/32"...

  • Page 34: Motor Components

    Components (continued) 9.2.4 Motor Components Part Number Description 57910 Insulated Gear 57901 Motor Adaptor HW-4062 Adapter Mounting Screw 77035 Wire Drive Motor HW-4000 Motor Mount Bolts HW-4001 Motor Mount Washer HW-4118 Motor Mount Nut 58034 Motor Mount 54035-Key Motor Shaft Key AA035-2 Motor Mount 54035-1...

  • Page 35: Industrial Cart Assembly

    9 Components (continued) 9.2.5 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) HW-4118 Industrial Cart Caster Mounting Nut...

  • Page 36: Jet Force Nozzle Front End Assembly

    9 Components (continued) 9.3 Jet Force Nozzle Front End Assembly Part # Description 57564-00 1/16 Front End Assembly Jet Nozzle 58564-00 3/32 Front End Assembly Jet Nozzle See Section 9.4.3 Jet Nozzle Head Assembly See Section 9.3.2 Small Wire Lead Components See Section 9.5 Handle and Trigger Assembly AA564-13...

  • Page 37: Front End Components Option

    9 Components (continued) 9.3.1 Spray Head Front End Components Option Part Number Description 59116-1.6 Front End Assembly 10’ AA116-1/16" Front End Assembly 1/16" AVD See Section 9.4. Head Assembly See Section 9.3 Combination Lead Assembly See Section 9.5 Handle and Trigger Assembly 54045 Trigger Cord Connector 54012-20A...

  • Page 38: Small Wire Lead Components

    9 Components (continued) 9.3.2 Small Wire Lead Components (3/32”, 2.2 mm & Smaller) Option Description Part Number Combination Lead: 59062-10L1 10', w/Red Liner for use w/ 3/32” and Smaller Wire 50019-14 Liner, Red 59018-A Insert, 1/16 50109 Liner Nut 50009-2 Shrink Tube Clamp 50062-3B Shrink Tube...

  • Page 39: Lead Components For 3/32" (2.3Mm) & 1/16" (1.6Mm) Wire Opt

    9 Components (continued) 9.3.3 Lead Components for 3/32” (2.3mm) and 1/16” (1.6mm) Wire Option Part Number Description 55062-13L2 Combination Lead: 13', w/Dual Liner for use w/ 1/16 Wire 50018-14 Liner, Violet AA018A Insert, 1/16 50109 Liner Nut 51109-2 Ferrule, 1/8" Liner 50062-3 Comb Lead: Shrink Tube 51016...

  • Page 40: Spray Head Components

    9 Components (continued) 9.4 Spray Head Components CAUTION: Center Air Nozzle must NOT touch contact tips. Unwanted Shorting will occur. Part Number Description 50064-B Assy Head: Assembly Open Nozzle 50005 Head: Contact Tube Clamp 50064-B Head: Fan Spray Head 50064B-1 Head: Side Air Jet Nozzle 50065-1/16 IT Head: Tip...

  • Page 41: Non-Skid Fan Spray Assembly 1/8

    9 Components (continued) 9.4.1 Non-Skid Fan Spray Assembly 1/8" CAUTION: Center Air Nozzle must NOT touch contact tips. Unwanted Shorting will occur. Part Number Description 50064-NS Assy 1/8" Non-Skid Fan Spray Assembly 1/8" 50005 Head: Contact Tube Clamp 50064-B Head: Fan Spray Head 50064-2 Head: Side Air Jet Plug 50065-1/8 IT...

  • Page 42: Angle Spray Head Components Option

    9 Components (continued) 9.4.2 Angle Spray Head Components Part Number Description 50064 Assy Angle Head Assembly 50005 Head: Contact Tube Clamp 50064B Head: .125” (3.2mm) Fan Spray Head 50085A Assy Head: Angle Spray Nozzle 50065-1/16 IT Head: Tip Contact 50076 ET Head: Contact Tube 50063 ET Head: Contact Tube 1/8”...

  • Page 43: Jet Force Nozzle And Head Assembly

    9 Components (continued) 9.4.3 Jet Force Nozzle and Head Assembly Part Number Description AA564-Assembly Jet Nozzle Head Assembly AA564-2 Jet Nozzle Plastic Body 50005 Contact Tube Clamp HW-4137 Screw (SS) 55564-1 Jet Housing Base 50065-1/16 IT AA564-16 Head: Jet Housing Base Small O-Ring AA564-11 Jet Nozzle, Tube Assembly...

  • Page 44: Handle And Trigger Assembly

    9 Components (continued) 9.5 Handle and Trigger Assembly Part Number Description 54012-19A Assy Handle ONLY 57079 Head: Safety/Heat Shield 54012-02 Handle: Lever HW-4202 Screw for Heat Shield Mounting Screw (SS) 54012-04 Handle: Contact 54012-05 Handle: Contact Plunger 54012-06A Handle: Air Switch 54012-06/07S Replacement Wire for Switches 54012-07A...

  • Page 45: System Wiring

    9 Components (continued) 9.6 System Wiring...

  • Page 46: General Troubleshooting

    10 General Troubleshooting Trouble Possible Cause Remedy No wire feed, no air with 1. No 24 Volt to Feeder 1. Check Fuse/Breaker on Power Supply. See Power Supply Manual indicator light off 2. Broken wire in control lead. 3. Power supply might be off. No wire feed at motor inch 1.
  • Page 47 10 General Troubleshooting (continued) Trouble Possible Cause Remedy Power leads heat up 1. Loose /worn electrical connection 1. Tighten or replace if necessary See Section 9.1 2. Oxidized electrical connections 2. Clean electrical connections 3. Excessive current 3. Lower amperage, confirm proper spray parameters See Section 6.1 Wire feeds, cannot establish 1.
  • Page 48 Thermion Inc. P.O. Box 780 Silverdale, WA 98383 Toll Free: 877-884-3428 Local 360-692-6469 www.thermioninc.com email: info@thermioninc.com Printed in the U.S.A. © 2005 Thermion Inc.

Table of Contents