Tweco Spool Gun Spool Gun User manual

Type
User manual
Issue Date: May 6, 2011
Manual No: 89210004Revision: A
Safety and Operating
Instructions
SPOOL GUN
English
WE APPRECIATE YOUR BUSINESS!
Congratulations on your new Tweco
®
product. We are proud to have you
as our customer and will strive to provide you with the best service and
reliability in the industry. This product is backed by our extensive warranty
and world-wide service network. To locate your nearest distributor or service
agency call 800-426-1888, or visit us on the web at www.tweco.com.
This Manual has been designed to instruct you on the correct installation
and use of your Tweco
®
product. Your satisfaction with this product and its
safe operation is our ultimate concern. Therefore, please take the time to
read the entire manual, especially the Safety Precautions. They will help you
to avoid potential hazards that may exist when working with this product.
YOU ARE IN GOOD COMPANY!
The Brand of Choice for Contractors and Fabricators
Worldwide.
Tweco
®
is a Global Brand of Arc Welding Products for Thermadyne
Industries Inc. We manufacture and supply to major welding industry
sectors worldwide including; Manufacturing, Construction, Mining,
Automotive, Aerospace, Engineering, Rural and DIY/Hobbyist.
We distinguish ourselves from our competition through market-leading,
dependable products that have stood the test of time. We pride ourselves
on technical innovation, competitive prices, excellent delivery, superior
customer service and technical support, together with excellence in sales
and marketing expertise.
Above all, we are committed to develop technologically advanced products
to achieve a safer working environment within the welding industry.
i
WARNINGS
Read and understand this entire Manual and your employer’s safety practices before
installing, operating, or servicing the equipment. While the information contained in
this Manual represents the Manufacturer’s judgment, the Manufacturer assumes no
liability for its use.
Tweco Spool Gun: SG160TA-12-3035
Set-up and Safe Operating Procedures
Instruction Guide Number 89210004
Published by:
Thermadyne
®
Industries, Inc.
2800 Airport Rd.
Denton, TX. 76208
(940) 566-2000
www.thermadyne.com
U.S. Customer Care: (800) 426-1888
International Customer Care: (940) 381-1212
Copyright © 2011 Thermadyne Industries, Inc. All rights reserved.
Reproduction of this work, in whole or in part, without written permission of the publisher is prohibited.
The publisher does not assume and hereby disclaims any liability to any party for any loss or damage caused by any
error or omission in this Manual, whether such error results from negligence, accident, or any other cause.
Publication Date: May 2011
Record the following information for Warranty purposes:
Where Purchased:
Purchase Date:
Equipment Serial #:
ii
Table of Contents
SECTION 1: SAFETY PRECAUTIONS ....................................................................... 1-1
SECTION 2: MODEL SPECIFICATIONS .................................................................... 2-4
SECTION 3: INSTALLATION AND OPERATION ........................................................ 3-5
3.01 Connecting the spool gun ................................................. 3-5
3.03 Installing the wire spool ................................................... 3-6
SECTION 4: CARE AND MAINTENANCE .................................................................. 4-9
4.01 Changing the contact tip ................................................... 4-9
4.02 Changing the wire conduit .............................................. 4-10
4.03 Changing the drive rolls ................................................. 4-11
SECTION 5: TROUBLESHOOTING CHECK LIST ...................................................... 5-13
SECTION 6: REPLACEMENT PARTS LIST .............................................................. 6-14
STATEMENT OF WARRANTY ................................................................................. 6-16
SET-UP AND SAFE OPERATING PROCEDURES
1-1
89210004
Safety Precautions
SECTION 1:
SAFETY PRECAUTIONS
WARNING
SERIOUS INJURY OR DEATH may result if welding and cutting equipment is not properly
installed, used, and maintained. Misuse of this equipment and other unsafe practices
can be hazardous. The operator, supervisor, and helper must read and understand the
following safety warnings and instructions before installing or using any welding or cutting
equipment, and be aware of the dangers of the welding or cutting process. Training
and proper supervision are important for a safe work place. Keep these instructions for
future use. Additional recommended safety and operating information is referenced in
each section.
ELECTRIC SHOCK CAN CAUSE INJURY OR DEATH
Install and maintain equipment in accordance with the National Electrical Code (NFPA
70) and local codes. Do not service or repair equipment with power ON. Do not operate
equipment with protective insulators or covers removed. Service or repair to equipment
must be done by qualifi ed and/or trained personnel only.
Do not contact electrically live parts. Always wear dry welding gloves that are in good
condition. Aluminized, protective clothing can become part of the electrical path. Keep oxygen cylinders,
chains, wires, ropes, cranes, and hoists away from any part of the electrical path. All ground connections
must be checked periodically to determine if they are mechanically strong, and electrically adequate for
the required current. When engaged in AC welding/cutting under wet conditions or where perspiration
is a factor, the use of automatic controls for reducing the no load voltage is recommended to reduce
shock hazards. Accidental contact must be prevented when using open circuit voltage exceeding 80
volts AC, or 100 volts DC by adequate insulation or other means. When welding is to be suspended for
any length of time, such as during lunch or overnight, all electrode holders and electrodes should be
removed from the electrode holder and the power supply should be turned OFF to prevent accidental
contact. Keep MIG-Guns, electrode holders, Tig torches, Plasma torches, and electrodes away from
moisture and water. See safety and operating references 1, 2, and 8.
SMOKE, FUMES, AND GASES CAN BE DANGEROUS TO YOUR HEALTH
Ventilation must be adequate to remove smoke, fumes, and gases during operation to
protect operators and others in the area. Vapors of chlorinated solvents can form the
toxic gas “Phosgene” when exposed to ultraviolet radiation from an electric arc. All
solvents, degreasers, and potential sources of these vapors must be removed from the
operating area. Use air-supplied respirators if ventilation is not adequate to remove all
fumes and gases. Oxygen supports, and vigorously accelerates fi re and should never be used for
ventilation. See safety and operating references 1, 2, 3, and 4.
1-2
SET-UP AND SAFE OPERATING PROCEDURES
89210004Safety Precautions
ARC RAYS, HOT SLAG, AND SPARKS CAN INJURE EYES AND BURN SKIN
Welding and cutting processes produce extreme localized heat and strong ultraviolet
rays. Never attempt to weld/cut without a federally compliant welding helmet with the
proper lens. A number 12 to 14 shade fi lter lens provides the best protection against
arc radiation. When in a confi ned area, prevent the refl ected arc rays from entering
around the helmet. Approved shielding curtains and appropriate goggles should be used
to provide protection to others in the surrounding area. Skin should be protected from arc rays, heat,
and molten metal. Always wear protective gloves and clothing. All pockets should be closed and cuffs
sewn shut. Leather aprons, sleeves, leggings, etc. should be worn for out-of-position welding and cutting,
or for heavy operations using large electrodes. Hightop work shoes provide adequate protection from
foot burns. For added protection, use leather spats. Flammable hair preparations should not be used
when welding/cutting. Wear ear plugs to protect ears from sparks. Where work permits, the operator
should be enclosed in an individual booth painted with a low refl ective material such as zinc oxide. See
safety and operating references 1, 2, and 3.
WELDING SPARKS CAN CAUSE FIRES AND EXPLOSIONS
Combustibles reached by the arc, ame, ying sparks, hot slag, and heated materials
can cause fi re and explosions. Remove combustibles from the work area and/or provide
a fi re watch. Avoid oily or greasy clothing as a spark may ignite them. Have a fi re
extinguisher nearby, and know how to use it. If welding/cutting is to be done on a metal
wall, partition, ceiling, or roof, precautions must be taken to prevent ignition of nearby
combustibles on the other side. Do not weld/cut containers that have held combustibles.
All hollow spaces, cavities, and containers should be vented prior to welding/cutting to permit the escape
of air or gases. Purging with inert gas is recommended. Never use oxygen in a welding torch. Use only
inert gases or inert gas mixes as required by the process. Use of combustible compressed gases can
cause explosions resulting in personal injury or death. Arcing against any compressed gas cylinder can
cause cylinder damage or explosion. See safety and operating references 1, 2, 5, 7, and 8.
NOISE CAN DAMAGE HEARING
Noise from the air carbon-arc process can damage your hearing. Wear protective hearing
devices to ensure protection when noise levels exceed OHSA standards. Adequate hearing
protection devices must be worn by operators and surrounding personnel to ensure
personal protection against noise. See safety and operating references 1, 2, and 6.
WARNING
This product contains chemicals, including lead, or otherwise produces chemicals
known to the State of California to cause cancer, birth defects and other reproductive
harm. Wash hands after handling.
(California Health & Safety Code § 25249.5 et seq.)
SET-UP AND SAFE OPERATING PROCEDURES
1-3
89210004
SAFETY AND OPERATING REFERENCES
1. Code of Federal Regulations (OSHA) Section 29, Part 1910.95, 132, 133, 134, 139, 251, 252,
253, 254 and 1000. U.S. Government Printing Offi ce, Washington, DC 20402.
2. ANSI Z49.1 “Safety in Welding and Cutting”.
3. ANSI Z87.1 “Practice for Occupational and Educational Eye and Face Protection”.
4. ANSI Z88.2. “Standard Practice for Respiratory Protection”. American National Standards
Institute, 1430 Broadway, New York, NY 10018.
5. AWS F4.1. “Recommended Safe Practices for Welding and Cutting Containers”.
6. AWS C5.3. “Recommended Practices for Air Carbon-Arc Gouging and Cutting”. The American
Welding Society, 550 NW Lejeune Rd., P.O. Box 351040, Miami, FL 33135.
7. NFPA 51B. “Fire Prevention in Cutting and Welding Processes”.
8. NFPA-7. “National Electrical Code”. National Fire Protection Association, Battery Park, Quincy,
MA 02269.
9. CSA W117.2. “Safety in Welding, Cutting and Allied Processes”. Canadian Standards Association,
178 Rexdale Blvd., Rexdale, Ontario, Canada M9W 1R3.
Safety Precautions
2-4
SET-UP AND SAFE OPERATING PROCEDURES
89210004
SECTION 2:
MODEL SPECIFICATIONS
Description Rating
Rated Welding Current C0
2
160A
Duty Cycle 20%
Wire Diameter (Normal) 0.023-0.035 (Normal)
Wire Diameter (Stainless Steel) 0.023-0.030 (Stainless Steel)
Maximum Wire Feed Speed 630 in./min. (16 m/min.)
Maximum Wire Spool Size
Diameter: 4” (100 mm)
Width: 1.75” (45 mm)
Motor Voltage 24V DC
Model Specifi cations
SET-UP AND SAFE OPERATING PROCEDURES
3-5
89210004
SECTION 3:
INSTALLATION AND OPERATION
3.01 CONNECTING THE SPOOL GUN
1. Make sure the welding
power source is turned
OFF before connecting
the welding gun.
2. Open side panel and
loosen thumb screw.
3. Insert the back end of the
Spool gun into the gun
receiving bushing.
4. Tighten thumb screw and
replace side panel.
5. Connect gas supply fi tting
and tighten with a wrench.
6. Align Control Plug to
panel fi tting and tighten
securely.
Installation and Operation
3-6
SET-UP AND SAFE OPERATING PROCEDURES
89210004
3.02 ADJUSTING WIRE FEED PRESSURE AND SPEED
1. Use a screwdriver to adjust the wire
feed pressure. Turn the adjusting
screw clockwise to decrease, or
counterclockwise to increase pressure
on the wire feed drive rolls.
2. Adjust the “AMP“ (Wire Feed Speed)
knob on the power supply to adjust
the wire speed feed.
Direction Result
Clockwise Increase Speed
Counterclockwise Decrease Speed
3.03 INSTALLING THE WIRE SPOOL
1. Remove the spool cover by loosening
the cover screw by hand.
2. Slide the wire spool onto the shaft.
Installation and Operation
SET-UP AND SAFE OPERATING PROCEDURES
3-7
89210004
3. Press the red button on top of the gun to
release pressure from the drive rolls.
4. Push the wire through the guide and into
the wire feed drive rolls.
5. Make sure the welding power source is
turned ON before proceeding to step 6.
6. Press the trigger to feed the wire into
the conductor tube and cut the wire to
obtain the correct wire stick-out.
Installation and Operation
3-8
SET-UP AND SAFE OPERATING PROCEDURES
89210004
7. Adjust the friction nut on the spool shaft
to apply the correct wire tension. Spool
should stop when trigger is released.
8. Replace the wire spool cover and hand
tighten the cover screw.
Installation and Operation
SET-UP AND SAFE OPERATING PROCEDURES
4-9
89210004
SECTION 4:
CARE AND MAINTENANCE
4.01 CHANGING THE CONTACT TIP
NOTE
Replace contact tip if hole is enlarged or deformed.
1. Select the correct contact tip according
to the wire used.
2. Remove the nozzle from the gun to
reveal the contact tip.
3. Remove the contact tip using pliers if
needed. Replace contact tip and tighten
securely.
NOTE
Periodically clean spatter from the inside of the nozzle and holes of the gas diffuser. Use
anti-spatter spray for best results.
Care and Maintenance
4-10
SET-UP AND SAFE OPERATING PROCEDURES
89210004
4.02 CHANGING THE WIRE CONDUIT
NOTE
Replace liner if hole is obstructed. Make sure the end of the liner is smooth.
1. Turn the power source OFF and
disconnect the gun.
2. Unscrew the nozzle and remove it
from the conductor tube.
3. Remove the diffuser from the
conductor tube using a wrench.
Care and Maintenance
SET-UP AND SAFE OPERATING PROCEDURES
4-11
89210004
4. Remove the conductor tube by
unscrewing the nut at the base.
5. Pull the liner out and replace.
Repeat steps 1-4 in reverse order to
reassemble the gun.
4.03 CHANGING THE DRIVE ROLLS
NOTE
Turn power supply OFF before replacing drive rolls.
1. Remove the screws which secure the
upper and lower drive rolls. It may be
necessary to remove drive roll side of
gun case to change lower drive roll
(see steps 2 and 3).
2. Loosen four handle screws. Turn
ring on the bottom of the handle
(surrounding the speed control knob)
one-quarter turn counter-clockwise,
and remove.
Care and Maintenance
4-12
SET-UP AND SAFE OPERATING PROCEDURES
89210004
3. Remove one screw holding each
drive roll in place. Press the red
button on top of the gun to relieve
pressure on the rolls if necessary.
Remove the drive rolls, and install the
new drive rolls in reverse order.
4. Perform steps 1-3 in reverse order to
reassemble the gun.
Care and Maintenance
SET-UP AND SAFE OPERATING PROCEDURES
5-13
89210004
SECTION 5:
TROUBLESHOOTING CHECK LIST
Problem Possible Cause Corrective Action
Drive rolls turn but
wire will not feed or
wire is not feeding
through
Incorrect drive rolls
Be sure the wire diameter being used is
stamped on the drive rolls. Replace drive
rolls if necessary.
Incorrect drive roll
pressure
Check and correct drive roll pressure. Turn
pressure adjusting screw clockwise until
the wire feeds properly or doesn’t slip.
(See page 3-6)
Worn or dirty drive rolls Clean or replace drive rolls.
Incorrect wire spool
friction
Adjust the friction nut on the spool shaft to
nd the correct wire tension.
(See page 4-8)
Worn or dirty outlet liner Clean or replace liner.
Rusty or dirty wire Replace wire. (See page 3-6)
Partially arced, melted, or
improper size contact tip
Replace contact tip.
Variable arc
Contact tip worn or
incorrect size
Replace contact tip.
Incorrect wire feed speed
Adjust wire speed by turning speed
control knob clockwise (to max) or
counter-clockwise (to min). (See page 3-6)
Troubleshooting Check List
6-14
SET-UP AND SAFE OPERATING PROCEDURES
89210004
SECTION 6:
REPLACEMENT PARTS LIST
1
2
3
5
6
10
4
8
9
7
11
1
2
3
5
6
1
0
4
8
9
7
Ref
#
Stock
Number Part Number Description
Image
1
1110-1100 11-23 Contact Tip .023 (0.6 mm)
1110-1101 11-30 Contact Tip .030 (10.8 mm)
1110-1102 11-35 Contact Tip .035 (10.9 mm)
2
1210-1300 21T-37 Nozzle 3/8" (9.5 mm)
1210-1100 21-37 Nozzle 3/8" (9.5 mm)
1210-1110 21-50 Nozzle 1/2" (12.7 mm)
1210-1112 21-50F Nozzle 1/2" (12.7 mm)
1210-1120 21-62 Nozzle 5/8" (15.9 mm)
3 1510-1101 51 Gas Diffuser
4 2031-2107 SPG66065 Conduit
5 2031-2227 WSPDRC Drive Roll Cover
Replacement Parts List
SET-UP AND SAFE OPERATING PROCEDURES
6-15
89210004
Ref
#
Stock
Number Part Number Description
Image
6 2031-2225 WSP62180 Conductor Tube
7
2031-2228 WSPDR023 .023 Drive Roll Assembly
2031-2234 WSPGR023 .023 Guide Roll Assembly
2031-2229 WSPDR035045 .035 Drive Roll Assembly
2031-2235 WSPGR035045 .035 Guide Roll Assembly
2031-2250 WSPDRU023
.023 Drive Roll Assembly - U-Shaped
Smooth
2031-2251 WSPGRU023
.023 Guide Roll Assembly - U-Shaped
Smooth
2031-2252 WSPDRU035045
.035 Drive Roll Assembly - U-Shaped
Smooth
2031-2253 WSPGRU035045
.035 Guide Roll Assembly - U-Shaped
Smooth
8 2031-2233 WSPSCC Spool Case Cover
9 2031-2232 WSPSC Complete Spool Case
10 2031-2226 WSP62N Conductor Tube Nut
11 2031-2231 WSP92 Trigger Assembly
NS
2031-2237 WSPMOTOR Replacement Motor
2031-2239 WSPKEY Key Stock for Drive Roll
Replacement Parts List
6-16
STATEMENT OF WARRANTY
LIMITED WARRANTY: THERMADYNE
®
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 THERMADYNE products as stated below, THERMADYNE shall, upon notifi cation
thereof and substantiation that the product has been stored, installed, operated, and maintained
in accordance with THERMADYNE’s specifi cations, 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 THERMADYNE’s sole option, of any components or
parts of the product determined by THERMADYNE to be defective.
THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ALL OTHER WARRANTIES,
EXPRESS OR IMPLIED, INCLUDING ANY WARRANTY OF MERCHANTABILITY OR
FITNESS FOR A PARTICULAR PURPOSE.
LIMITATION OF LIABILITY:
THERMADYNE 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 the “Purchaser”) for service interruption.
The remedies of the Purchaser set forth herein are exclusive and the liability of THERMADYNE 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 THERMADYNE whether arising out of contract, negligence, strict 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.
THIS WARRANTY BECOMES INVALID IF REPLACEMENT PARTS OR ACCESSORIES ARE
USED WHICH MAY IMPAIR THE SAFETY OR PERFORMANCE OF ANY THERMADYNE
PRODUCT.
THIS WARRANTY IS INVALID IF THE PRODUCT IS SOLD BY NON-AUTHORIZED
PERSONS.
This warranty is effective for the time stated in the Warranty Schedule beginning on the date that the
authorized distributor delivers the products to the Purchaser.
Warranty repairs or replacement claims under this limited warranty must be submitted by an authorized
THERMADYNE 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 Purchaser. All returned goods shall be at the Purchaser’s
risk and expense. This warranty supersedes all previous THERMADYNE warranties.
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Tweco Spool Gun Spool Gun User manual

Type
User manual

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