Thermal Arc SP 2001 Spool Gun Assembly Owner`s Manual_
Contents
1. m Cable Fitting Two Finger E d i Drive Roll Lever Release Trigger For Purging And Wire CR n Threading Wire Feed Speed Potentiometer Figure 3 3 Special Features of SP 2001 Spool Gun April 6 1998 Revised 3 1 430429 287 DESCRIPTION EQUIPMENT Power Source Compatibility The SP 2001 Spool Gun must be used with a DC type power source The DC type power source can have a CC or CV output however best results are obtained with a CV output WARNING When using the SP 2001 Spool Gun with a CC output power source the filler metal will be at welding voltage any time the power source is turned ON Filler metal contact to the work piece will cause a welding arc The SP 2001 Spool Gun must be used in conjunc tion with a control box not included with the SP 2001 Spool Gun package This control box which connects to the power source may require an adapt er cable Consult the control box owner s manual for details 3 2 April 6 1998 Revised 430429 287 INSTALLATION INSTALLATION Overview The SP 2001 Spool Gun operates in conjunction with a SPC 2001 control box a power source and a cable assembly The SP 2001 Spool Gun will also operate with older control boxes by using a 171312 adapter cable see Figure 4 1 Connections2. OPERATION Prewelding Procedure Follow all installation instructions for the control box and welding power source before attempting to operate the SP 2001 Spool Gun Assembly 1 Make sure all necessary connections have been made Refer to Connections in the Installa tion chapter of this manual 2 Turn ON the power source 3 Depress the gun switch trigger and adjust the flow of shielding gas 4 Remove the gun cover spool cover nozzle assembly and contact tip Disengage the drive roll lever release 5 Install the spool of wire into the Spool Gun Assembly Thread the wire through the input guide between the drive rolls and into the output guide 6 Engage the drive roll lever release and depress the gun switch trigger Adjust the wire feed speed to the desired value by means of the wire feed control in the Spool Gun Assembly handle 7 Allow approximately 6 inches wire to run out Reinstall contact tip nozzle assembly gun cover and spool cover 8 Cut off wire even with the end of the nozzle assembly Welding Procedure WARNING In semiautomatic or automatic wire welding the welding wire wire reel if used input guide feed rolls output guide feedhead and welding gun metal parts are all ELECTRI CALLY HOT Refer to Figure 5 1 Position the Spool Gun Assembly above the work piece and depress the gun switch trigger Depress ing the gun switch trigger enables the ga
3. Prot gez les bouteilles de gaz comprim contre les sources de chaleur intense les chocs et les arcs de soudage Enchainez verticalement les bouteilles un support ou un cadre fixe pour les emp cher de tomber ou d tre renvers es Eloignez les bouteilles de tout circuit lectrique ou de tout soudage MISE EN GARDE LES GAZ D ECHAPPEMENT DES d MOTEURS PEUVENT ETRE MORTELS Les moteurs produisent des gaz d chappement nocifs LE CARBURANT PEUR CAUSER UN IN CENDIE OU UNE EXPLOSION Le carburant est hautement inflammable 1 Arr tez le moteur avant de v rifier le niveau de carburant ou de faire le plein Portez un cran facial ou des lunettes protectrices approuv es Des crans lat raux sont recommand s Portez des v tements appropri s pour prot ger la peau Emp chez tout contact entre une bouteille et une lectrode de soudage N utilisez que des bouteilles de gaz protecteur des d tendeurs des boyauxs et des raccords concus pour chaque application sp cifique ces quipements et les pi ces connexes doivent tre maintenus en bon tat Ne placez pas le visage face l ouverture du robinet de la bouteille lors de son ouverture Laissez en place le chapeau de bouteille sauf si en utilisation ou lorsque raccord pour utilisation Lisez et respectez les consignes relatives aux bouteilles de gaz comprim et aux quipements connexes ainsi que la publica tio
4. Cable Weld 50 1 66 407932 1 Hose 3 8 x 50 1 67 407926 Fitting Cable 1 68 407927 Nut Gas 1 171406 2 Trigger Cord Assembly W Fittings 50 1 A 171406 1 Trigger Cord Assembly W Fittings 25 1 B 69 171409 Plug 6 Socket 1 70 171413 2 Cord Trigger 50 1 A 171413 1 Cord Trigger 25 1 B 71 171411 Plug Amphenol 6 Pin 1 All 72 407865 Ring 1 All 73 171414 Potentiometer 5K Ohm 1 All 74 171412 Dial Feed 1 75 171410 Knob Control 1 April 6 1998 Revised 6 5 430429 287 PARTS LIST CONSUMABLE PARTS HEAVY DUTY FRONT END CONTACT GAS DIFFUSER STANDARD EQUIPMENT C oi CONTACT TIP NOTCHED T 40727 050 407728 230 GAS DIFFUSER 407729 3 64 407733 OF ne ae D CONTACT 407750 050 407751 230 c 407732 3 64 CONTACT D s 407754 3 6 DIFFUSER 407734 3 64 3 64 EXTRA HEAVY DUTY 407735 NOZZLE ASSEMBLIES STANDARD EQUIPMENT NOZZLE ASSEMBLY 407736 CONSISTING OF UN a INSULATING BUSHING 407844 1 NOZZLE BODY 407842 1 407 42 3 4 ORIFICE OPTIONAL FRONT END FIXED NOZZLE CONTACT TIP GAS DIFFUSER NOZZLE ASSEMBLIES NOZZLE ASSEMBLY 407840 CONSISTING OF mo CoE GAS DIFFUSER 407839 1 2050 CUP INSULATING 407839 4 035 40784631 40784134 NOZZLE BUSHING 407839 7 3
5. pais Coupage l arc Plasma PAC mince moyen pais selon AWS 8 2 73 Dimension d lectrode ou Epaisseur de m tal ou Intensit de courant toutes conditions toutes conditions moins de 1 po 25 mm de 1 6 po 25 150 mm plus de 6 po 150 mm moins de 1 8 po 3 mm de 1 8 1 2 po 3 12 mm plus de 1 2 po 12 mm moins de 5 32 po 4 mm de 5 32 1 4 po 4 6 4 mm plus de 1 4 po 6 4 mm toutes conditions toutes conditions toutes conditions toutes conditions toutes conditions toutes dimensions moins de 300 amp res de 300 400 amp res plus de 400 amp res Nuance de de filtre oculaire LES VAPEURS ET LES FUMEES SONT 5 Ne travaillez dans un espace confin que s il est bien ventil DANGEREUSES POUR LA SANTE Le soudage d gage des vapeurs et des fum es dangereuses respirer 1 Eloignez la t te des fum es pour viter de les respirer A l int rieur assurez vous que l aire de soudage est bien ven til e ou que les fum es et les vapeurs sont aspir es l arc Sila ventilation est inadequate portez un respirateur adduc tion d air approuv Lisez les fiches signal tiques et les consignes du fabricant relatives aux m taux aux produits consummables aux rev te ments et aux produits nettoyants sinon portez un respirateur adduction d air Les gaz protec teurs de soudage peuvent d placer l oxyg ne de l air et ainsi causer des ma
6. PRECAUTIONS DE SECURITE EN SOUDAGE A L ARC Instruction 830002 PRECAUTIONS DE SECURITE EN SOUDAGE A LARC MISE EN GARDE LE SOUDAGE A L ARC EST DANGEREUX PROTEGEZ VOUS AINSI QUE LES AUTRES CONTRE LES BLESSURES GRAVES POSSIBLES OU LA MORT NE LAISSEZ PAS LES ENFANTS S APPROCHER NI LES PORTEURS DE STIMULATEUR CARDIAQUE A MOINS QU ILS N AIENT CONSULTE UN MEDECIN CONSERVEZ CES INSTRUCTIONS LISEZ LE MANUEL D OPERATION OU LES INSTRUCTIONS AVANT D INSTALLER UTILISER OU ENTRETENIR CET EQUIPEMENT Les produits et proc d s de soudage peuvent sauser des blessures graves ou la mort de que des dommages au reste du mat riel et la propri t si l utilisateur n adh re pas strictement toutes les r gles de s curit et ne prend pas les pr cautions n cessaires En soudage et coupage des pratiques s curitaires se sont d velopp es suite l exp rience pass e Ces pratiques doivent tre apprises par tude ou entrainement avant d utiliser l equipement Toute personne n ayant pas suivi un entrainement intensif en soudage et coupage ne devrait pas tenter de souder Certaines pratiques concernent les quipements raccord s aux lignes d alimentation alors que d autres s adressent aux groupes lectrog nes La norme Z49 1 de l American National Standard intitul e SAFETY IN WELDING AND CUTTING pr sente les pratiques s curitaires suivre Ce document ainsi que d autres guides que vous devriez conna tre avant d utiliser cet
7. norme ANSI Z49 1 American Welding Society 550 N W LeJeune Rd Miami FL 33128 Safety and Health Standards OSHA 29 CFR 1910 Superintendent of Documents U S Government Printing Office Washington D C 20402 Recommended Safe Practices for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances norme AWS F4 1 American Welding Society 550 NW LeJeune Rd Miami FL 33128 National Electrical Code norme 70 NFPA National Fire Protection Association Batterymarch Park Quincy MA 02269 Safe Handling of Compressed Gases in Cylinders document P 1 Compressed Gas Association 1235 Jefferson Davis Highway Suite 501 Arlington VA 22202 Code for Safety in Welding and Cutting norme CSA W117 2 Asso ciation canadienne de normalisation Standards Sales 276 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 Safe Practices for Occupation and Educational Eye and Face Pro tection norme ANSI Z87 1 American National Standards Institute 1430 Broadway New York NY 10018 Cutting and Welding Processes norme 51B NFPA National Fire Protection Association Batterymarch Park Quincy MA 02269 2 4 8 V 96 430429 287 DESCRIPTION EQUIPMENT DESCRIPTION OF EQUIPMENT General The SP 2001 Spool Gun is a state of the art weld ing gun for use in aluminum welding The lightweight and portable SP 2001 Spool Gun comes complete with a wire feed speed control built into th
8. quipement sont pr sent s la fin de ces instructions de s curit SEULES DES PERSONNES QUALIFIEES DOIVENT FAIRE DES TRAVAUX D INSTALLATION DE REPARATION D ENTRETIEN ET D ESSAI L ELECTROCUTION PEUT ETRE 6 Arr tez tout quipement apr s usage Coupez l alimentation de MORTELLE l quipement s il est hors d usage ou inutilis 7 N utilisez que des porte lectrodes bien isol s Ne jamais plonger les porte lectrodes dans l eau pour les refroidir Ne jamais les laisser trainer par terre ou sur les pi ces souder Ne touchez pas aux porte lectrodes raccord s deux sources de courant en m me temps Ne jamais toucher quelqu un d autre avec l lectrode ou le porte lectrode Une d charge lectrique peut tuer ou br ler grave ment L lectrode et le circuit de soudage sont sous tension d s la mise en circuit Le circuit d alimenta tion et les circuits internes de l quipement sont aussi sous tension d s la mise en marche En soudage automatique ou semi automatique avec EN S fil ce dernier le rouleau ou la bobine de fil le N utilisez pas de c bles lectriques us s endommag s mal logement des galets d entrainement et toutes les piss s ou de section trop petite pi ces m talliques en contact avec le fil de soudage N enroulez pas de c bles lectriques autour de votre corps sont sous tension Un quipement inad quatement N utilisez qu une bonne prise de masse pour la mise la terre in
9. 64 1 2 ORIFICE BODY 407844 3 TP SHORT 407842 5 407839 2 030 CUP 407859 5 035 407839 B 3 64 AE ORIFICE EXTRA LENGTH CONTACT 1 5 CUPS CONTACT TP LONG USE W 407841 2 2 407750 050 mel RE CUP LONG 407731 035 2220 407841 2 407732 3 64 1 2 ORIFICE CONTACT TP EXTRA LONG USE W 407841 3 407839 3 030 407839 6 035 407839 9 3 64 OPTIONAL FRONT END CONTACT TIP GAS DIFFUSER CONTACT TIP 407859 1 030 407859 4 930 GAS DIFFUSER 407859 7 5 64 407846 2 CONTACT SHORT 407859 2 030 407859 5 055 407839 B 3 64 CUP EXTRA LONG 407841 5 1 2 ORIFICE ADJUSTABLE NOZZLE NOZZLE INSULATOR AS INSULATING Gy BUSHING NOZZLE INCLUDES 407843 1 0 2 ORIFICE RINGS O RING 3 REQD NOZZLE 407845 2 4 407847 5 4 ORIFICE Figure 6 2 6 6 April 6 1998 Revised 430429 287 PARTS LIST 407727 407728 407729 407750 407751 407752 notched tip contact IP EN notched tip contact 3 64 notched tip contact ip am 030 standard contact tip 035 standard contact tip 045 3 64 standard contact tip Figure 6 3 April 6 1998 Revised 6 7 430429 287 PARTS LIST This page intentionally left blank 6 8 April 6 1998 Revised 430429 287 DIAGRAMS DIAGRAMS e Note the model and specification number shown on the equipment nameplate e Locate these numbers in
10. Arc by an authorized Thermal repair facility within thirty 30 days of the repair No transportation costs of any kind will be paid under this warranty Transportation charges to send products to an authorized warranty repair facility shall be the responsibility of the customer All returned goods shall be at the customer s risk and expense This warranty supersedes all previous Thermal Arc warranties Thermal Arc is a Registered Trademark of Thermadyne Industries Inc Thermal Arc Inc Effective January 4 1999 Troy Ohio 45373 830538
11. contact of electrode or welding wire to metal objects can cause sparks overheating or fire Protect yourself and others from flying sparks and hot metal Do not weld where flying sparks can strike flammable material Remove all flammables within 35 ft 10 7 m of the welding arc If this is not possible tightly cover them with approved covers Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas FLYING SPARKS AND HOT METAL can cause injury Chipping and grinding cause flying metal As welds cool they can throw off slag CYLINDERS can explode if damaged Shielding gas cylinders contain gas under high pres sure If damaged a cylinder can explode Since gas cylinders are normally part of the welding process be sure to treat them carefully Protect compressed gas cylinders from excessive heat mechani cal shocks and arcs Install and secure cylinders in an upright position by chaining them to a stationary support or equipment cylinder rack to prevent falling or tipping WARNING ENGINE EXHAUST GASES can kill Engines produce harmful exhaust gases Read the Material Safety Data Sheets MSDSs and the manu facturer s instruction for metals consumables coatings and cleaners Work in a confined space only if it is well ventilated or while wearing an air supplied respirator Shielding gases used for welding can displ
12. Base Molded Gun 1 39 No Number Screw 8 32 x 1 1 4 Rd Hd 3 April 6 1998 Revised 6 3 430429 287 PARTS LIST This page intentionally left blank 6 4 April 6 1998 Revised 430429 287 PARTS LIST Parts List For Figure 6 1 Item Part Description Qty Application No Number per Code Assy 40 407885 Motor 1 2 Shaft 1 41 No Number Screw 4 40 x 1 2 Rd Hd 2 All 42 No Number Screw 4 40 x 3 8 FL Hd 1 All 43 407890 Roll Feed 1 44 No Number Screw Set 8 32 x 1 8 1 All 45 171405 Handle Gun 1 All 46 409315 Cup Retaining Switch 1 All 47 No Number Screw 8 32 x 3 4 Rd Hd 2 All 48 409301 Switch Wired 1 49 409308 Trigger 1 All 50 409319 Spring Trigger 1 All 51 409317 Barrel Space Seal 3 Inch 2 All 52 409316 Barrel Outer Sleeve 3 Inch 1 All 53 409318 Insulator Barrel Sheath 3 Inch 1 All 54 409313 Barrel 3 Inch 1 All 55 409305 Liner Barrel 3 Inch 1 56 409310 Cover 1 All 57 409304 Hand Nut Top Cover 1 All 58 409314 Ring Snap 2 59 407887 Spacer Pressure Roll 1 All 60 407889 Roll Pressure 1 All 61 407899 Bushing Pressure Roll 1 All 62 170493 Block Body 1 All 171310 1 Hose amp Cable Assembly W Fittings 50 1 A 171310 2 Hose amp Cable Assembly W Fittings 25 1 B 63 407930 Fitting Power Cable 1 All 64 407928 Ferrule Hose 2 65 407925 1
13. IN LIEU OF ALL OTHERS INCLUDING BUT NOT LIMITED TO ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE LIMITATION OF LIABILITY Thermal Arc shall not under any circumstances be liable for special or consequential damages such as but not limited to damage or loss of purchased or replacement goods or claims of customers of distributor hereinafter Purchaser for service interruption The remedies of the Purchaser set forth herein are exclusive and the liability of Thermal Arc with respect to any contract or anything done in connection therewith such as the performance or breach thereof or from the manufacture sale delivery resale or use of any goods covered by or furnished by Thermal Arc whether arising out of contract negligence strike tort or under any warranty or otherwise shall not except as expressly provided herein exceed the price of the goods upon which such liability is based No employee agent or representative of Thermal Arc is authorized to change this warranty in any way or grant any other warranty PURCHASER S RIGHTS UNDER THIS WARRANTY ARE VOID IF REPLACEMENT PARTS OR ACCESSORIES ARE USED WHICH IN THERMAL ARC S SOLE JUDGMENT MAY IMPAIR THE SAFETY OR PERFORMANCE OF ANY THERMAL ARC PRODUCT PURCHASER S RIGHTS UNDER THIS WARRANTY ARE VOID IF THE PRODUCT IS SOLD TO PURCHASER BY NON AUTHORIZED PERSONS Except with regards to the products listed below this warranty shall remain effective three 3 years
14. SP 2001 SPOOL GUN ASSEMBLY For the Following Specs e 407838B 1 SP 2001 Spool Gun a with 50 Ft Cable Assembly 700 0005 2 SP 2001 Spool Gun with 25 Ft Cable Assembly IHERMAL G A THERMADYNE Company OWNER S MANUAL Number 430429 287 Revised April 6 1998 THERMAL ARC INC TROY OHIO 45373 1085 U S A 430429 287 TABLE CONTENTS INTRODUCTION 1 How Use This Manual 1 1 Equipment Identification 1 1 Receipt Of Equipment 2 0 00 06 ers 1 1 ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS 2 DESCRIPTION OF EQUIPMENT 3 General A wt date Aes amp 3 1 Product Specifications 3 1 Spool Gun Components 3 1 Power Source Compatibility 3 2 INSTALLATION 4 OVOIVIOW ert hes Ae de dp sd Use El lie I A HA 4 1 Gonnectlons eS ed qu 4 1 OPERATION 5 Prewelding Procedure 5 1 Welding Procedure ws 5 2 a sou Say e AIR REOR 5 1 PARTS LIST 6 Equipment Identification 2 e aa a a aa 2 6 1 How To Use This Parts List 2 428 448 Ale ae BE eke 6 1 DIAGRAMS April 6 1998 Revised 430429 287 INTRODUCTION INTRODUCTION How To Use This Manual This Owners Manual usually applies to just the underlined speci
15. See the System Outline drawing 870106 in the Diagrams chapter of this manual for details 1 Connect a weld cable from the power source to the work connection 2 Connect the weld cable from the SPC 2001 to the power source e e Oe mx i gre mme lo Control Box 376908 1 Spool Gun CT 2 Cable Assembly Assembly Optional OR Cable Adapter 3 Connect the control cable from the SPC 2001 to the power source NOTE Adapter cables may be required see the Available Options section of the SPC 2001 manual for part numbers 4 Make the proper gas line connection from the gas supply to the SPC 2001 gas valve inlet 5 Attach the 25 or 50 cable assembly to both the SP 2001 Spool Gun and the SPC 2001 front panel connections NOTE When using an older style control box 376908 1 or 170406 1 a 171312 adapter cable will be required to adapt the cable assembly to the control box front panel connections Control Boxes Control Box 170406 1 100013 1 A 100013 2 171313 1 P a Spool Gun Cable Assembly Figure 4 1 Control Box Spool Gun Connections April 6 1998 Revised 4 1 430429 287 INSTALLATION This page intentionally left blank 4 2 April 6 1998 Revised 430429 287 OPERATION
16. UT ENDOMMAGER L OUIE s bap Entourez l aire de soudage de rideaux ou de cloisons pour L arc de soudage produit une chaleur et des prot ger les autres des coups d arc ou de l blouissement rayons ultraviolets intenses susceptibles de avertissez les observateurs de ne pas regarder l arc br ler les yeux et la peau Le bruit caus par Portez des v tements en mat riaux ignifuges et durables laine certains proc d s peut endommager et cuir et des chaussures de s curit 1 Portez une casque de soudeur avec filtre oculaire de nuance Portez un casque antibruit ou des bouchons d oreille approuv s appropri e consultez la norme ANSI Z49 indiqu e lorsque le niveau de bruit est lev 8 V 96 2 1 PRECAUTIONS DE SECURITE EN SOUDAGE A L ARC Instruction 830002 SELECTION DES NUANCES DE FILTRES OCULAIRES POUR LA PROTECTION DES YEUX EN COUPAGE ET SOUDAGE Op ration de Coupage ou soudage Brasage tendre au chalumeau Brasage fort au chalumeau Oxycoupage mince moyen pais Soudage aux gaz mince moyen pais Soudage l arc avec electrode enrob es SMAW Soudage l arc sous gaz avec fil plein GMAW m taux non ferreux m taux ferreux Soudage l arc sous gaz avec lectrode de tungst ne GTAW Soudage l hydrog ne atomique AHW Soudage l arc avec lectrode de carbone CAW Soudage l arc Plasma PAW Gougeage Air Arc avec lectrode de carbone mince
17. Welding And The Effects Of Low Frequency Electric And Magnetic Fields The following is a quotation from the General Conclusions Section of the U S Congress Office of Technology Assessment Biological Effects of Power Frequency Electric amp Magnetic Fields Background Paper OTA BP E 63 Washington DC U S Government Printing Office May 1989 there is now a very large volume of scientific findings based on experiments at the cellular level and from studies with animals and people which clearly establish that low frequency magnetic fields can interact with and produce changes in biological systems While most of this work is of very high quality the results are complex Current scientific understanding does not yet allow us to interpret the evidence in a single coherent framework Even more frustrating it does not yet allow us to draw definite conclusions about questions of possible risk or to offer clear science based advice on strategies to minimize or avoid potential risks To reduce magnetic fields in the workplace use the following procedures 1 Keep cables close together by twisting or taping them 3 Do not coil or drape cables around the body 2 Arrange cables to one side and away from the operator 4 Keep welding power source and cables as far away from body as practical About Pacemakers The above procedures are among those also normally recommended for pacemaker wearers Consult your doctor for complete informat
18. Z49 1 entitled SAFETY IN WELDING AND CUTTING This publication and other guides to what you should learn before operating this equipment are listed at the end of these safety precautions HAVE ALL INSTALLATION OPERATION MAINTENANCE AND REPAIR WORK PERFORMED ONLY BY QUALIFIED PEOPLE ELECTRIC SHOCK can kill Turn off all equipment when not in use Disconnect power to equipment if it will be left unattended or out of service Use fully insulated electrode holders Never dip holder in water to cool it or lay it down on the ground or the work surface Do not power circuit and machine internal circuits are also d dd Es ao MIR o Poder Be live when power is on In semiautomatic or automatic 4 peop it wire welding the wire wire reel drive roll housing Do not use worn damaged undersized or poorly spliced cables and all metal parts touching the welding wire are Do not wrap cables around your body electrically live Incorrectly installed or improperly Ground the workpiece to a good electrical earth ground grounded equipment is a hazard Do not touch electrode while in contact with the work ground Do not touch live electrical parts circuit Wear dry hole free insulating gloves and body protection Use only well maintained equipment Repair or replace damaged Insulate yourself from work and ground using dry insulating mats parts at once or covers In confined spaces or damp locations do not use a welder with Disc
19. ace air causing injury or death Be sure the breathing air is safe Do not weld in locations near degreasing cleaning or spraying operations The heat and rays of the arc can react with vapors to form highly toxic and irritating gases Do not weld on coated metals such as galvanized lead or cadmium plated steel unless the coating is removed from the weld area the area is well ventilated and if necessary while wearing an air supplied respirator The coatings and any metals containing these elements can give off toxic fumes if welded 5 Watch for fire and keep a fire extinguisher nearby Be aware that welding on a ceiling floor bulkhead or partition can cause fire on the hidden side Do not weld on closed containers such as tanks or drums Connect work cable to the work as close to the welding area as practical to prevent welding current from traveling long possibly unknown paths and causing electric shock and fire hazards Do not use welder to thaw frozen pipes Remove stick electrode from holder or cut off welding wire at contact tip when not in use Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap Wear approved face shield or safety goggles Side shields rec ommended Wear proper body protection to protect skin Keep cylinders away from any welding or other electrical circuits Never allow a welding electrode
20. clean up before starting engine Have only qualified people remove guards or covers for mainte nance and troubleshooting as necessary To prevent accidental starting during servicing disconnect nega tive battery cable from battery Keep hands hair loose clothing and tools away from moving parts Reinstall panels or guards and close doors when servicing is finished and before starting engine SPARKS can cause BATTERY GASES TO EXPLODE BATTERY ACID can burn eyes and skin Always wear a face shield when working on a battery Stop engine before disconnecting or connecting battery cables Do not allow tools to cause sparks when working on a battery Do not use welder to charge batteries or jump start vehicles Observe correct polarity and on batteries Batteries contain acid and generate explosive gases STEAM AND PRESSURIZED HOT Do not remove radiator cap when engine is hot Allow engine to COOLANT can burn face eyes and cool skin Wear gloves and put a rag over cap area when removing cap The coolant in the radiator can be very hot and under Allow pressure to escape before completely removing cap pressure WARNING This product when used for welding or cutting produces fumes or gases which contain chemicals known to the State of California to cause birth defects and in some cases cancer California Health amp Safety Code Sec 25249 5 et seq NOTE Considerations About
21. des b ches approuv es M fiez vous des projections brulantes de soudage susceptibles de p n trer dans des aires adjacentes par de petites ouvertures ou fissures M fiez vous des incendies et gardez un extincteur port e de la main N oubliez pas qu une soudure r alis e sur un plafond un plancher une cloison ou une paroi peut enflammer l autre c t Ne soudez pas un r cipient ferm tel un r servoir ou un baril Connectez le c ble de soudage le plus pr s possible de la zone de soudage pour emp cher le courant de suivre un long par cours inconnu et pr venir ainsi les risques d lectrocution et d incendie Ne d gelez pas les tuyaux avec un source de courant Otez l lectrode du porte lectrode ou coupez le fil au tube con tact lorsqu inutilis apr s le soudage Portez des v tements protecteurs non huileux tels des gants en cuir une chemise paisse un pantalon revers des bottines de s curit et un casque Le piquage et le meulage produisent des particules m talliques volantes En refroidissant la soudure peut projeter du clats de LES ETINCELLES ET LES PROJEC ter TIONS BRULANTES PEUVENT CAUSER DES BLESSURES LES BOUTEILLES ENDOMMAGEES PEUVENT EXPLOSER Les bouteilles contiennent des gaz protecteurs sous haute pression Des bouteilles endommag es peuvent exploser Comme les bouteilles font nor malement partie du proc d de soudage traitez les avec soin
22. e handle and either a 25 ft or 50 ft long cable assembly The SP 2001 Spool Gun must be used in conjunc tion with a control box not included with the SP 2001 Spool Gun package and a DC type power source The DC type power source can have a CC or CV output however best results are obtained with a CV output Product Specifications Wire Aluminum Wire Size 2424111 0 030 0 035 3 64 Wire Package 1 Lb Wire Feed Speed Range 50 650 IPM Welding Current 250 A X 26096 EE 200 A X 210096 Motor Voltage Rating 24 VDC Weight of Spool Gun 3 Lbs Weight of Spool Gun with 25 Cable Assembly 14 Lbs Weight of Spool Gun with 50 Cable Assemblv 22 Lbs 6 12 4 gt Figure 3 1 SP 2001 Spool Gun Dimensions Spool Gun Components The following figures describe and show the vari ous components of the SP 2001 Spool Gun Clear Clear Spool Gun Cover Nozzle Assembly Drive Roll Lever Release Rotate Counterclockwise To Open Drive Rolls Figure 3 2 SP 2001 Spool Gun Assembly One Drive Roll For All Sizes Of Wire 030 035 3 64 TOSS mud Gun Cover Mm 1 asily Attached Gun Constant Non Adjustable Drive Roll Pressure M
23. fication or part numbers listed on the cover H none are underlined they are all covered by this manual To ensure safe operation read the entire manual including the chapter on safety instructions and warnings Throughout this manual the words WARNING CAUTION and NOTE may appear Pay particular attention to the information provided under these headings These special annotations are easily rec ognized as follows WARNING gives information re garding possible personal in jury Warnings will be enclosed in a box such as this CAUTION refers to possible equipment damage Cautions will be shown in bold type NOTE offers helpful information concerning certain operating procedures Notes will be shown in italics Equipment Identification The unit s identification number specification or part number model and serial number usually appear on a nameplate attached to the machine Equipment which does not have a nameplate at tached to the machine is identified only by the specification or part number printed on the shipping container Record these numbers for future refer ence Receipt Of Equipment When you receive the equipment check it against the invoice to make sure it is complete and inspect the equipment for possible damage due to shipping If there is any damage notify the carrier immedi ately to file a claim Furnish complete information concerning damage claims or shipping errors to T
24. from the date Thermal Arc s authorized distributor delivers the product to Purchaser but in no event more than 4 years from the date Thermal Arc delivers the product to the authorized distributor Shorter warranty periods apply to the products listed below On these products the warranty is effective for the time stated below beginning on the date that the authorized distributor delivers the products to the Purchaser Notwithstanding the foregoing in no event shall the warranty period extend more than the time stated plus one year from the date Thermal Arc delivered the product to the authorized distributor ALL OTHER P WEE PRO LITE POWER SUPPLIES POWER SUPPLIES PRO PLUS PRO WAVE LABOR MAIN POWER MAGNETICS STATIC amp ROTATING 3 YEARS 2 YEARS 1 YEAR ORIGINAL MAIN POWER RECTIFIER 3 YEARS 2 YEARS 1 YEAR CONTROL PC BOARD 3 YEARS 2 YEARS 1 YEAR ALL OTHER CIRCUITS AND COMPONENTS INCLUDING 1 YEAR 1 YEAR 1 YEAR BUT NOT LIMITED TO CONTACTORS RELAYS SOLENOID PUMPS POWER SWITCHING SEMI CONDUCTORS ENGINES ENGINES ARE NOT WARRANTED BY THERMAL ARC ALTHOUGH MOST ARE WARRANTED BY THE ENGINE MANUFACTURER SEE THE ENGINE MANUFACTURES WARRANTY FOR DETAILS CONSOLES CONTROL EQUIPMENT HEAT 1 YEAR 1 YEAR 1 YEAR EXCHANGES AND ACCESSORY EQUIPMENT TORCH AND LEADS 180 DAYS 180 DAYS 180 DAYS REPAIR REPLACEMENT PARTS 90 DAYS 90 DAYS 90 DAYS Warranty repairs or replacement claims under this limited warranty must be submitted to Thermal
25. hermal Arc Order Department 2200 Corporate Drive Troy Ohio 45373 1085 Include all equip ment identification numbers as described above along with a full description of the parts in error Additional copies of this manual may be pur chased by contacting Thermal Arc at the address given above Include the Owner s Manual number and equipment identification numbers October 27 1997 Revised 1 1 ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS Instruction 830001 ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS WARNING PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH KEEP CHILDREN AWAY PACEMAKER WEARERS KEEP AWAY UNTIL CONSULTING YOUR DOCTOR DO NOT LOSE THESE INSTRUCTIONS READ OPERATING INSTRUC TION MANUAL BEFORE INSTALLING OPERATING OR SERVICING THIS EQUIPMENT Welding products and welding processes can cause serious injury or death or damage to other equipment or property if the operator does not strictly observe all safety rules and take precautionary actions Safe practices have developed from past experience in the use of welding and cutting These practices must be learned through study and training before using this equipment Anyone not having extensive training in welding and cutting practices should not attempt to weld Certain of the practices apply to equipment connected to power lines other practices apply to engine driven equipment Safe practices are outlined in the American National Standard
26. ion PRINCIPAL SAFETY STANDARDS Safety in Welding and Cutting ANSI Standard Z49 1 from American Welding Society 550 N W LeJeune Rd Miami FL 33126 Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 from Compressed Gas Association 1235 Jefferson Davis High way Suite 501 Arlington VA 22202 Safety and Health Standards OSHA 29 CFR 1910 from Superinten dent of Documents U S Government Printing Office Washington D C 20402 Code for Safety in Welding and Cutting CSA Standard W117 2 from Canadian Standards Association Standards Sales 178 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 Recommended Safe Practices for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances Ameri can Welding Society Standard AWS F4 1 from American Welding Society 550 N W LeJeune Rd Miami FL 33126 Safe Practices for Occupation and Educational Eye and Face Pro tection ANSI Standard Z87 1 from American National Standards Institute 1430 Broadway New York NY 10018 National Electrical Code NFPA Standard 70 from National Fire Protection Association Batterymarch Park Quincy MA 02269 Cutting and Welding Processes NFPA Standard 51B from National Fire Protection Association Batterymarch Park Quincy MA 02269 May 8 1996 2 3 ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS Instruction 830001 This page intentionally left blank 2 4 May 8 1996
27. iveted or welded SPECIFICATION NUMBER 407838B 1 407838B 2 to another part The part descriptions may be indented to show part relationships Todetermine the part number description quan tity or application of an item simply locate the item in question from the illustration and refer to that item number in the corresponding Parts List An Application Code is used to distinguish parts that are applicable only to certain Specifications and or Assemblies This code is found in the right most column of the Parts List If an item inthe Parts List applies to all Specifications or Assemblies the word ALL will be in the Application Code column Refer to the following list to determine the appro priate Application Codes for the Specifications or Assemblies covered by this manual If only the assembly or specification number is listed the use of an Application Code does not apply to this manual APPLICATION CODE April 6 1998 Revised 430429 287 PARTS LIST FOR 3 64 WIRE 52 5 51 SS ui x ES Figure 6 1 Gun and Cable Assembly 6 2 April 6 1998 Revised 430429 287 PARTS LIST Parts List For Figure 6 1 Item Part Description Qty Application No Number per Code Assy 407838B 1 SP 2001 Spool Gun with 50 Ft Cable Assy A 407838B 2 SP 2001 Spool Gun with 25 Ft Cable Assy B 171309 Gun SP 2001 1 1 407873 Hand Nut Spo
28. laises ou la mort Assurez vous que l air est propre la respiration Ne soudez pas proximit d op rations de d graissage de nettoyage ou de pulv risation La chaleur et les rayons de l arc peuvent r agir avec des vapeurs et former des gaz hautement toxiques et irritants Ne soudez des t les galvanis es ou plaqu es au plomb ou au cadmium que si les zones souder ont t gratt es fond que si l espace est bien ventil si n cessaire portez un respirateur adduction d air Car ces rev tements et tout m tal qui contient ces l ments peuvent d gager des fum es toxiques au moment du soudage 2 2 8 V 96 PRECAUTIONS DE SECURITE SOUDAGE A L ARC Instruction 830002 LE SOUDAGE PEUT CAUSER UN IN CENDIE OU UNE EXPLOSION L arc produit des tincellies et des projections Les particules volantes le m tal chaud les projections de soudure et l quipement surchauff peuvent causer un incendie et des br lures Le contact accidentel de l lectrode ou du fil lectrode avec un objet m tallique peut provoquer des tincelles un chauffement ou un incendie Prot gez vous ainsi que les autres contre les tincelles et du m tal chaud Ne soudez pas dans un endroit des particules volantes ou des projections peuvent atteindre des mat riaux inflammables Enlevez toutes mati res inflammables dans un rayon de 10 7 m tres autour de l arc ou couvrez les soigneusement avec
29. n P 1 de la CGA identifi e dans la liste de documents ci dessous Utilisez l quipement l ext rieur dans des aires ouvertes et bien ventil es Si vous utilisez ces quipements dans un endroit confin les fum es d chappement doivent tre envoy es l ext rieur loin des prises d air du b timent Ne faites pas le plein en fumant ou proche d une source d tincelles ou d une flamme nue Si c est possible laissez le moteur refroidir avant de faire le plein de carburant ou d en v rifier le niveau au d but du soudage Ne faites pas le plein de carburant ras bord pr voyez de l espace pour son expansion Faites attention de ne pas renverser de carburant Nettoyez tout carburant renvers avant de faire d marrer le moteur 8 V 96 2 3 PRECAUTIONS DE SECURITE EN SOUDAGE A L ARC Instruction 830002 DES PIECES EN MOUVEMENT PEU VENT CAUSER DES BLESSURES Des pi ces en mouvement tels des ventilateurs des rotors et des courroies peuvent couper doigts et mains ou accrocher des v tements amples 1 Assurez vous que les portes les panneaux les capots et les protecteurs soient bien ferm s 2 Avant d installer ou de connecter un syst me arr tez le moteur DES ETINCELLES PEUVENT FAIRE EX PLOSER UN ACCUMULATEUR L ELECTROLYTE D UN ACCUMU LATEUR PEUT BRULER LA PEAU ET LES YEUX Les accumulateurs contiennent de l lectrolyte acide et d gagent des vapeurs explo
30. ol Cover 1 All 2 407875 Cover Spool 1 All 3 No Number Ring Snap 5 8 1 4 407902 Hand Nut Spool 1 5 407872 Spring Brake Spool 1 6 No Number Washer 3 8 1 All 7 No Number Ring Snap 3 8 1 All 8 No Number Nut Lock 1 4 20 1 All 9 No Number Washer Flat 2 All 10 407871 Spindle Spool 1 All 11 No Number Washer 7 16 Steel 1 All 12 407874 Disc Spool 1 13 No Number Washer Star 1 All 14 No Number Bolt 1 4 20 x 2 7 8 Hex Hd 1 All 15 407896 Rotation Stop Spool Cover 1 16 No Number Lock Nut 1 4 20 1 All 17 170490 Guide Spool 1 All 18 407876 Washer Spool 1 19 No Number Screw 10 32 x 1 2 Rd Hd 1 20 No Number Washer 10 Star 1 All 21 No Number Nut 10 32 1 22 170491 Support Reel 1 All 23 No Number Set Screw 5 16 18 x 3 8 1 24 407898 Bushing Insulator Spool 1 All 25 Delete 26 407945 Clip Cable 1 27 No Number Screw 8 32 x 1 4 Rd Hd 1 All 28 No Number Screw 4 40 x 1 4 Rd Hd 2 All 29 407888 Spring Roll Pressure 1 All 30 407869 Bushing Roll Block 1 All 31 409325 Block Roll 1 All 32 No Number Screw 8 32 x 1 2 FL Hd 1 All 33 No Number Screw 8 32 x 3 8 FL Hd 1 34 407904 Lever Roll Release 1 All 35 No Number Screw 8 32 x 3 8 FL Hd 1 36 407870 Bushing Roll Lever 1 All 37 171408 Receptacle 6 Pin 1 38 171407
31. onnect input power or stop engine before installing or serv AC output unless it is equipped with a voltage reducer Use icing this equipment Lock input power disconnect switch open equipment with DC output or remove line fuses so power cannot be turned on accidentally Wear a safety harness to prevent falling if working above floor Properly install and ground this equipment according to its level Owner s Manual and national state and local codes Keep all panels and covers securely in place Touching live electrical parts can cause fatal shocks or severe burns The electrode and work circuit is electrically live whenever the output is on The input ARC RAYS can burn eyes and skin Wear a welding helmet fitted with a proper shade of filter see NOISE can damage hearing ANSI 249 1 listed in Safety Standards to protect your face and eyes when welding or watching Wear approved safety glasses Side shields recommended Arc rays from the welding process produce intense Use protective screens or barriers to protect others from flash heat and strong ultraviolet rays that can burn eyes and glare warn others not to watch the arc S NEE from some processes can damage Wear protective clothing made from durable flame resistant 9 material wool and leather and foot protection Use approved ear plugs or ear muffs if noise level is high Eye protection filter shade selector for welding Electrode Size i Electrode Size Welding
32. or Cutting Metal Thickness Welding or Cutting Metal Thickness Operation or Welding Current Operation or Welding Current Torch soldering Gas metal arc welding MIG Torch brazing Non ferrous base metal All Oxygen cutting Ferrous base metal All Light Under 1 in 25 mm Gas tungsten arc welding TIG Medium 1 to 6 in 25 150 mm Atomic hydrogen welding All Heavy Over 6 in 150 mm Carbon arc welding Gas welding Plasma arc welding All Light Under 1 8 in 3 mm Carbon arc air gouging Medium 1 8 to 1 2 in 3 12 mm Light Heavy Over 1 2 in 12 mm Heavy Shielded metal arc welding Under 5 32 in 4 mm Plasma arc cutting stick electrodes 5 32 to 1 4 in 4 to 6 4 mm Light Under 300 Amp Over 1 4 in 6 4 mm Medium 300 to 400 Amp Heavy Over 400 Amp May 8 1996 2 1 ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS Instruction 830001 FUMES AND GASES can be hazardous to your health Welding produces fumes and gases Breathing these fumes and gases can be hazardous to your health Keep your head out of the fumes Do not breath the fumes If inside ventilate the area and or use exhaust at the arc to remove welding fumes and gases If ventilation is poor use an approved air supplied respirator WELDING can cause fire or explosion Sparks and spatter fly off from the welding arc The flying sparks and hot metal weld spatter hot work piece and hot equipment can cause fires and burns Accidental
33. s valve wire feed motor and power source the welding process begins To end the weld release the gun switch trigger which disables the gas valve wire feed motor and power source NOTE Atthe end of the work day or when welding has been completed it is recom mended that the gas be SHUTOFF at the cylinder and the power source be turned OFF ON Gun Switch OF ON Gas Valve L OFF ON Wire Feed L OFF ON Power Source L OFF Figure 5 1 Functional Timing Diagram April 6 1998 Revised 5 1 430429 287 OPERATION This page intentionally left blank 5 2 April 6 1998 Revised 430429 287 PARTS LIST PARTS LIST Equipment Identification All identification numbers as described in the In troduction chapter must be furnished when ordering parts or making inquiries This information is usually found on the nameplate attached to the equipment Be sure to include any dash numbers following the Specification or Assembly numbers How To Use This Parts List The Parts List is a combination of an illustration Figure Number and a corresponding list of parts which contains a breakdown of the equipment into assemblies subassemblies and detail parts All parts of the equipment are listed exceptfor commer cially available hardware bulk items such as wire cable sleeving tubing etc and permanently at tached items which are soldered r
34. sives LA VAPEUR ET LE LIQUIDE DE RE FROIDISSEMENT BRULANT SOUS PRESSION PEUVENT BRULER LA PEAU ET LES YEUX Le liquide de refroidissement d un radiateur peut tre br lant et sous pression Seules des personnes qualifi es doivent d monter des protec teurs ou des capots pour faire l entretien ou le d pannage n cessaire Pour emp cher un d marrage accidentel pendant l entretien d branchez le c ble d accumulateur la borne n gative N approchez pas les mains ou les cheveux de pi ces en mou vement elles peuvent aussi accrocher des v tements amples et des outils R installez les capots ou les protecteurs et fermez les portes apr s des travaux d entretien et avant de faire d marrer le moteur Portez toujours un cran facial en travaillant sur un accumu lateur Arr tez le moteur avant de connecter ou de d connecter des c bles d accumulateur N utilisez que des outils anti tincelles pour travailler sur un accumulateur N utilisez pas une source de courant de soudage pour charger un accumulateur ou survolter momentan ment un v hicule Utilisez la polarit correcte et de l accumulateur N tez pas le bouchon de radiateur tant que le moteur n est pas refroidi Mettez des gants et posez un torchon sur le bouchon pour l ter Laissez la pression s chapper avant d ter compl tement le bouchon PRINCIPALES NORMES DE SECURITE Safety in Welding and Cutting
35. stall ou inad quatement mis la terre est dangereux de la pi ce souder Ne touchez pas des pi ces sous tension Ne touchez pas l lectrode lorsqu en contact avec le circuit de Portez des gants et des v tements isolants secs et non trou s soudage terre Isolez vous de la pi ce souder et de la mise la terre au moyen N utilisez que des quipements en bon tat R parez ou rem de tapis isolants ou autres placez aussit t les pi ces endommag es D connectez la prise d alimentation de l quipement ou arr tez Dans des espaces confin s ou mouill s n utilisez pas de source le moteur avant de l installer ou d en faire l entretien Bloquez le de courant alternatif moins qu il soit muni d un r ducteur de commutateur en circuit ouvert ou enlevez les fusibles de l alimen tension Utilisez plut t une source de courant continu tation afin d viter une mise en marche accidentelle Portez un harnais de s curit si vous travaillez en hauteur Veuillez installer cet quipement et le mettre la terre selon Fermez solidement tous les panneaux et les capots le manuel d utilisation et les codes nationaux provinciaux et locaux applicables pour vous prot ger le visage et les yeux lorsque vous soudez ou que vous observez l ex cution d une soudure Portez des lunettes de s curit approuv es Des crans lat raux LE RAYONNEMENT DE L ARC PEUT BRULER LES YEUX ET LA PEAU LE BRUIT PE
36. the model and specification number columns below e Use only those diagrams and instructions that are applicable CONNECTION amp SPECIFICATION SCHEMATIC SYSTEM MODEL NUMBER DIAGRAM OUTLINE SP 2001 407838B 1 FIGURE 7 1 870106 SP 2001 407838B 2 FIGURE 7 1 870106 April 6 1998 Revised 7 1 430429 287 DIAGRAMS SP 2001 Spool Gun Schematic and Connection Diagram e GREEN t GREEN 6 CW ORANGE Ny ORANGE 9 lt gt BLUE BLUE BROWN OR WHITE i BROWN WHITE Figure 7 1 7 2 April 6 1998 Revised STATEMENT WARRANTY LIMITED WARRANTY Thermal Arc Inc Thermadyne Company warrants that its products will be free of defects in workmanship or material Should any failure to conform to this warranty appear within the time period applicable to the Thermal Arc products as stated below Thermal Arc shall upon notification thereof and substantiation that the product has been stored installed operated and maintained in accordance with Thermal Arc s specifications instructions recommendations and recognized standard industry practice and not subject to misuse repair neglect alteration or accident correct such defects by suitable repair or replacement at Thermal Arc s sole option of any components or parts of the product determined by Thermal Arc to be defective THERMAL ARC MAKES NO OTHER WARRANTY EXPRESS OR IMPLIED THIS WARRANTY IS EXCLUSIVE AND
37. to touch any cylinder Use only correct shielding gas cylinders regulators hoses and fittings designed for the specific application maintain them and associated parts in good condition Turn face away from valve outlet when opening cylinder valve Keep protective cap in place over valve except when cylinder is in use or connected for use Read and follow instructions on compressed gas cylinders asso ciated equipment and CGA publication P 1 listed in Safety Standards ENGINES can be hazardous 1 2 Use equipment outside in open well ventilated areas If used in a closed area vent engine exhaust outside and away from any building air intakes 2 2 May 8 1996 ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS Instruction 830001 ENGINE FUEL can cause fire or explosion Engine fuel is highly flammable 1 Stop engine before checking or adding fuel MOVING PARTS can cause injury Moving parts such as fans rotors and belts can cut fingers and hands and catch loose clothing 1 Keep all doors panels covers and guards closed and securely in place 2 Stop engine before installing or connecting unit Do not add fuel while smoking or if unit is near any sparks or open flames Allow engine to cool before fueling If possible check and add fuel to cold engine before beginning job Do not overfill tank allow room for fuel to expand Do not spill fuel If fuel is spilled
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