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Thermion AVD250 Owner's Manual

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11/09/2023
Patent # 5791560; 6683271 B2
Model #77250
Owner's Manual
(Operations and Maintenance)
(CE)
AVD250
Featuring "VS Technology"
Serial #77103
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

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Summary of Contents for Thermion AVD250

  • Page 1 11/09/2023 Patent # 5791560; 6683271 B2 Model #77250 Owner’s Manual (Operations and Maintenance) (CE) AVD250 Featuring “VS Technology” Serial #77103 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 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.
  • Page 4 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 Section 6: Principals of Operation Section 7: Liner Replacement Section 8: Air Switch and Main Switch Section 9: Component Diagrams 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 Declaration of Conformity for European Community ......... ii Spray Head/Parts Maintenance ............. 14 Important Safeguards and Symbols ............... iii 6.3.1 Combination Leads ..................14 Warranty Information ....................iv 6.3.2 Feeder Unit....................14 Preface ..........................v 6.3.3 Control Cables ..................... 14 Constant Operational Checks ..............
  • Page 7 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...
  • Page 8 1 Introduction (continued) 1.3.1 Wire Feeder The feeder is compact with a carrying handle. The meters, dials, and switches are located on the front of the feed unit for ease of viewing and operation. The drive assembly is a four-roll heavy-duty drive unit.
  • Page 9 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 2.5 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 sometimes double ear protection.
  • Page 11 2 Safety Measures (continued) 2.5 Reduction of Noise Hazards (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 This Arc Spray System is close-coupled designed for shop work. Power Supply Thermion’s AVD250 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 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 4 Controls - Start Up Settings Use these settings to initially start spraying then adjust to the desired voltage and amperage. • POWER SUPPLY: The power supply must be set for gas metal arc welding (MIG), usually with all optional setting 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 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. Amperage: The amperage is controlled through the Amps Knob (for wire feed speed control), which is located on the wire feeder’s front panel.
  • Page 16 5 Operations (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: •...
  • Page 17 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 rheostat (wire feed dial) at 70%, and is ready to fire up.
  • Page 18 6 Principles of Operation (continued) Air Nozzle Alignment (<= 1/8” Wire) Caution: Air Nozzle MUST NOT touch contact tip, unwanted arcing or shorting will occur. Caution: Tighten evenly to prevent heat build-up. Adjusting Contact Tips: Adjust contact tubes to allow wire to converge as shown in this picture. When adjusted correctly, the arc is smooth with a fine even spray .160”...
  • Page 19 6 Principles of Operation (continued) .2.1 Angle Spray Nozzle Alignment (<= 1/8” Wire) CAUTION: Center Air Nozzle must not touch Contact Tip (unwanted arcing or shorting will occur). Front View CAUTION: Tighten evenly to prevent heat build-up. 50085A Assy...
  • Page 20 6 Principles of Operation (continued) 6.3 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.
  • Page 21 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. 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 22 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 23 7 Liner Replacement 7.1 Replacement of Single Red Liner When spraying the AVD 250, a single-liner system is used. The following instructions detail the liner change out process. Refer to drawing in (Section 8.3.2) Remove 59062-10L1 combination leads from wire feeder and head assembly. Lay the lead assembly out flat and straight.
  • Page 24 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. • Tighten set screw(AlloySS054).
  • Page 25 9 Components 9.1 Cable Components Part Number Description 77060 Control Lead Assembly 59116-1.6 Front End Assembly (Parts 1, 2, 4) See Section 9.3 Lead Assembly See Section 9.4 Spray Head Assembly See Section 9.4.3 Trigger Cord Assembly 59004-8 Weld Cable #1 54004-10 Female Dinse to 1/2"...
  • Page 26 9 Components (continued) 9.2 Feeder Components 7072R4 Assy 7072R4 Assy Part Number Description See Section 9.2.1 Air Supply Components See Section 9.2.2 Wire Spindle Assembly 57036-Assy Feeder Assembly See Section 9.2.3 Wire Drive Components 57036 Feeder Frame Cabinet 50026 Inch Switch 58036-PC10A Front Panel 57036-18...
  • Page 27 9 Components (continued) 9.2.1 Air Supply Components Part Number # Description AA033 Air Valve Assembly AA033-1 Air Line 50033-2 Acetyl Fitting 57036-10 Assy Air Collar Assembly AVD Only AA033 Air Solenoid Valve 57036-21B Air Assembly Long Pipe 50043 Air Regulator Filter Combo w/Gauge 50043-1 Air Regulator w/out Gauge 57036-20B...
  • Page 28 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 HW-4301 Keyed Washer HW-4302 Compression Spring HW-4303 Thumb Screw HW-4304...
  • Page 29 9 Components (continued) 9.2.3 Wire Drive Components 4 Roll Part Number Description 59900 Assembly 4 Roll Wire Drive Assembly 57902-4 See Section 9.2.3 57913-20 Assy 1.6 Center Guide Assembly 59901-4 Main Plate 59910 Insulated Gear 57912 Lead Adapter Plate 57207 Lead Clamp 57207 Feed Roll Clamping Knob 150...
  • Page 30 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 31 9 Components (continued) 9.2.4 Motor Components Part Number Description 57910 Insulated Gear 57901 Motor Adaptor HW-4062 Adapter Mounting Screw AA035 Assy Motor HW-4000 Motor Mount Bolts HW-4001 Motor Mount Washer HW-4002 Motor Mount Nut 58034 Motor Mount 54035-3 Motor Brush AA035-2 Motor Support 54035-1...
  • Page 32 9 Components (continued) Front End Components Description Part Number Front End Assembly – 1/16” 59116-1.6 See Section 9.4 Fan Spray Assembly Combination Lead: 10' See Section 9.3.1 See Section 9.4.3 Handle and Trigger Assembly Comb. Lead: Protective Sleeve 51117-13, -15, -18, -20* 54012-20A Assy Cable: Trigger Cord 13’...
  • Page 33 Shrink Tube 51014-1 Feeder Adapter O-Ring 51016 Head Adapter O-Ring 51007 Head Adapter 51014 Feeder Adapter CAUTION: Care must be taken when disassembling Combination Leads. Please return to Thermion for repairs. It is not recommended for user to perform this repair.
  • Page 34 9 Components (continued) Spray Head Components Option 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. CAUTION: Air Nozzle MUST not touch tips.
  • Page 35 9 Components (continued) 9.4.1 Angle Spray Head Components Option CAUTION: Center Air Nozzle must not touch Contact Tip (unwanted arcing or shorting will occur). Front View CAUTION: Tighten evenly to prevent heat build-up. 50085A Assy Part Number Description 50064 1.6 Assy Angle Spray Assembly 1.6"...
  • Page 36 9 Components (continued) 9.4.2 Handle and Trigger Assembly Part Number Description 54012-19A Assy Handle Assembly (No Cord) 57079 Safety/Heat Shield 54012-02 Handle Lever HW-4092 Heat Shield Mounting Screw 54012-04 Handle Contact 54012-05 Handle Contact Plunger 54012-06A Handle Air Switch 54012-06/07S Replacement Wire for Switches 54012-07A Handle Main Switch...
  • Page 37 9 Components (continued) System Wiring...
  • Page 38 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 39 10 General Troubleshooting (continued) Trouble Possible Cause Remedy Wire feed motor runs ho 1. Excessive friction in liners 1. Clean and lubricate liners more frequently, check wire alignment in leads, See Section 6.4.1 Defective motor check friction knob on spool spindle holder, check feed rolls turn freely. See Section 5.2 Replace motor See Section 9.2.5...
  • Page 40 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.

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77250