ESAB Spool Gun User manual

Issue Date: January, 2012

Manual No: 89210002Revision: B

ART# A-11080

Safety and Operating

Instructions

SPOOL GUN

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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; SG200TA-25-3545

Set-up and Safe Operating Procedures

Instruction Guide Number 89210002

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

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: January 2012

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

3.02 Adjusting wire feed pressure and speed ........................... 3-6

3.03 Installing the wire spool ................................................... 3-6

3.04 Wire feed speed calibration .............................................. 3-8

SECTION 4: CARE AND MAINTENANCE ................................................................ 4-13

4.01 Changing the contact tip ................................................. 4-13

4.02 Changing the wire conduit ..............................................4-14

4.03 Changing the drive rolls .................................................4-15

SECTION 5: TROUBLESHOOTING CHECK LIST ...................................................... 5-17

SECTION 6: REPLACEMENT PARTS LIST .............................................................. 6-18

STATEMENT OF WARRANTY ................................................................................. 6-20

SET-UP AND SAFE OPERATING PROCEDURES

1-1

89210002

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

89210002Safety 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, ﬂ ame, ﬂ 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

89210002

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

89210002

SECTION 2:

MODEL SPECIFICATIONS

ART# A-11080

Figure 2-1: Spool Gun

Description Rating

Rated Welding Current

C0

2

200A

Mixed Gas 160A

Duty Cycle 60%

Wire Diameter (Normal) 0.023-0.045 (Normal)

Wire Diameter (Stainless Steel) 0.023-0.030 (Stainless Steel)

Maximum Wire Feed Speed 630 in./min. (16m./min.)

Maximum Wire Spool Size

Diameter: 4” (100mm)

Width: 1.75” (45mm)

Motor Voltage 24V DC

Net Weight 12.79 lbs. (5.8kg)

Table 2-2: Speciﬁ cations

Model Speciﬁ cations

SET-UP AND SAFE OPERATING PROCEDURES

3-5

89210002

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. Connect the male Dinse style cable

connector to the female Dinse

receptacle on the machine.

3. Connect gas supply ﬁ tting and tighten with a wrench.

3A. Inlet - USA model 3B. Inlet - UK model 3C. Outlet

4. Align Control Plug to panel ﬁ tting and

tighten securely.

Installation and Operation

3-6

SET-UP AND SAFE OPERATING PROCEDURES

89210002

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. Turn the speed control knob (bottom

of handle) to adjust the wire feed

speed.

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

89210002

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

89210002

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.

3.04 WIRE FEED SPEED CALIBRATION

NOTE

The Thermal Arc 252i machine must be calibrated to the spool gun before operating to

ensure optimum welding characteristics.

Wire Feed Speed Calibration

Procedure

WARNING

DO NOT TOUCH the electrode wire

while it is being fed through the

system. The electrode wire will be

at welding voltage potential.

Required Equipment/Tools:

• Appropriate personal protective gear:

gloves, safety glasses, etc.

• Tape measure

• Spool of desired ﬁ ller metal

• Spool Gun

• T15 (Torx) driver (supplied)

NOTE

To perform the wire feed speed

calibration procedure the end of

the Spool wire needs to be trimmed

back to the contact tip of the Spool

Gun before and after feeding wire

out for measurement.

NOTE

This calibration procedure does

not affect the calibration of the

wirefeeder inside the 252i. To re-

calibrate the wirefeeder inside the

252i all remote devices must be

disconnected from it.

Installation and Operation

SET-UP AND SAFE OPERATING PROCEDURES

3-9

89210002

1. Disconnect the input power to the

Thermal Arc 252i welding power supply.

2. Disconnect all Dinse polarity connectors

on the lower front of the Thermal Arc

252i power supply. Leave the control

cable connected.

Disconnect Polarity

Connection(s)

+

-

Front View 252i

Art # A-11081

Figure 3-1: Disconnect Work Lead

3. Remove (4) front panel screws on the

Thermal Arc 252i.

Art # A-10406

Figure 3-2: Front Panel Removal

4. Locate the SERVICE DIP switch on the

back of the control board and set the

number “1” DIP switch to the “ON”

position.

12

ON

Figure 3-3: Setting DIP Switch

5. Temporarily place the board back in

the unit. The DIP switch will need to be

returned to the “OFF” position when the

calibration process is complete.

6. Re-connect the input power to the

welding power supply and turn it ON. The

left and right displays should show “ERR

30” which means the normal welding

output has been prevented.

NOTE

From this point forward unless

noted all adjustments will be made

using the controls on the Thermal

Arc 252i.

7. Enter Advanced Features Mode by

pressing & releasing Advanced Features

Button.

Advanced

Features

8. Using the left knob, scroll through the

menu list to ﬁ nd and select “WFS CAL

PROC”.

WIRESPEED

A

Left Knob

9. Press and release the left knob to

enter the Wire Feed Speed Calibration

Installation and Operation

3-10

SET-UP AND SAFE OPERATING PROCEDURES

89210002

Procedure. At this point, the left display

will show “SET / SPD1”,

(Low speed value) and the right display

will show the Factory set low speed wire

feed calibration value.

WIRESPEED

A

Left Knob

NOTE

The power supply requires two

values to properly calibrate wire

feed speed. A low feed speed

value and a high feed speed value.

Default speeds span the most

typical jobs. You may choose

alternates that better represent

your work. The closer an upper

or lower speed is to an actual

procedure, the better the accuracy.

NOTE

To perform the wire feed speed

calibration procedure the end of

the Spool wire needs to be trimmed

back to the contact tip of the Spool

Gun before and after feeding wire

out for measurement.

10. Using the right knob on the 252i, adjust

wire feed speed value in the right

display to read 250 for the lower wire

feed speed calibration speed (in units/

minute).

ARC CONTROL

V

Right Knob

11. Turn the left knob clockwise until the left

display shows “PULL / TRIG”.

And the right display shows “LOWR”.

WIRESPEED

A

Left Knob

WARNING

Ensure that all Dinse polarity

connections have been removed

from the front of the unit or live ﬁ ller

metal wire will be present during

this part of the procedure.

12. Pull the gun trigger and hold until wire

feeding stops (Approximately 1 meter

of wire will be spooled out). If trigger

is released before wire stops feeding

on its own, the procedure needs to be

started over. When the wire has stopped

spooling and the left display is showing

the “MEAS / WIRE” message, release the

Spool Gun trigger.

13. Measure its length. Cut off wire at the

same location as when it started.

14. Using the right control knob on the 252i,

adjust the value in the right display to

match the value that was just measured.

ARC CONTROL

V

Right Knob

15. Turn the left control knob until the left

display shows “SET SPD2”.

Installation and Operation

SET-UP AND SAFE OPERATING PROCEDURES

3-11

89210002

The right display will show the default

nominal upper wire feed calibration

speed.

WIRESPEED

A

Left Knob

16. Using the right knob on the 252i, adjust

wire feed speed value in the right display

to read 600 for the upper wire feed speed

calibration speed (in units/minute).

ARC CONTROL

V

Right Knob

NOTE

The speed which is selected should

also be significantly ABOVE the

value used for the lower wire feed

speed calibration.

17. Turn the left knob clockwise until the left

display shows “PULL / TRIG”.

And the right display shows “UPPR”.

WIRESPEED

A

Left Knob

18. Pull the gun trigger and hold until wire

feeding stops (Approximately 1 meter

of wire will be spooled out) If trigger

is released before wire stops feeding

on its own, the procedure needs to be

started over. When the wire has stopped

spooling and the left display is showing

the “MEAS / WIRE” message, release the

Spool Gun trigger.

19. Measure its length. Cut off wire at the

same location as when it started.

20. Using the right control knob, adjust the

value in the right display to match the

value that was just measured.

ARC CONTROL

V

Right Knob

21. Turn the left knob clockwise until the left

display shows “WFS / CAL”.

The right display will show the word

“SAVE”.

WIRESPEED

A

Left Knob

22. Press and release the left knob to save

the new calibration settings. If the

calibration data passes the internal

data checks, the calibration data will

be saved.

NOTE

If the new calibration values pass

internal checks and are accepted,

the operator will brieﬂ y observe the

ﬂ ashing decimal points pattern in

the left hand display when pressing

the knob to save the data.

If the new values do NOT pass

internal checks, the original/

previous data is retained and the

ﬂ ashing decimal point is not shown.

WIRESPEED

A

Left Knob

Installation and Operation

3-12

SET-UP AND SAFE OPERATING PROCEDURES

89210002Installation and Operation

NOTE

This will save the values that were

entered for the length of wire.

23. Turn unit OFF.

24. Disconnect the input power to the

welding power supply.

25. Remove (4) front panel screws.

26. Locate the SERVICE DIP switch on the

back of the control board and set the

number “1” DIP switch to the “OFF”

position.

27. Reinstall the control panel with all (4)

screws.

Art # A-10406

Figure 3-4: Front Control Panel

28. Re-connect the Dinse polarity cable and

the Work Lead to the Thermal Arc 252i.

29. Re-connect the input power to the

welding power supply. Calibration is

complete.

SET-UP AND SAFE OPERATING PROCEDURES

4-13

89210002

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

4-14

SET-UP AND SAFE OPERATING PROCEDURES

89210002

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

4-15

89210002

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.

Care and Maintenance

4-16

SET-UP AND SAFE OPERATING PROCEDURES

89210002

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.

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

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