Tweco SP 2001 User Manual
SP-2001
SPOOL GUN ASSEMBLY
For the Following Specs:
407838B-1 — SP-2001 Spool Gun
•
•
•
407838B-2 — SP-2001 Spool Gun
•
•
with 50 Ft. Cable Assembly
with 25 Ft. Cable Assembly
OWNER’S MANUAL Number 430429-287
Revised April 6, 1998
IMPORTANT: Readtheseinstructionsbeforeinstalling,operating, or servicing this system.
THERMAL ARC INC., TROY, OHIO 45373-1085, U.S.A.
430429-287
TABLE OF CONTENTS
INTRODUCTION 1
How To Use This Manual ..................................1-1
Equipment Identification ..................................1-1
Receipt Of Equipment ...................................1-1
ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS 2
DESCRIPTION OF EQUIPMENT 3
General ...........................................3-1
Product Specifications ...................................3-1
Spool Gun Components ..................................3-1
Power Source Compatibility ................................3-2
INSTALLATION 4
Overview ..........................................4-1
Connections .........................................4-1
OPERATION 5
Prewelding Procedure ...................................5-1
Welding Procedure .....................................5-1
PARTS LIST 6
Equipment Identification ..................................6-1
How To Use This Parts List .................................6-1
DIAGRAMS
April 6, 1998 Revised
INTRODUCTION
430429-287
INTRODUCTION
How To Use This Manual:
This Owner’s Manual usually applies to just the
underlined specification or part numbers listed on
the cover. If 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 annotationsareeasily recognized as follows:
WARNING gives information regarding possible personal injury. Warnings will be enclosed
in a box such as this.
CAUTION refers to possible equipment
damage. Cautions will be shown in bold
type.
NOTEoffershelpfulinformationconcerning
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 attached to the machine is identified only by the
specification or part number printed on theshipping
container. Record these numbers for future reference.
Receipt Of Equipment:
When you receive the equipment, check it against
the invoice to make sure it is complete and inspect
theequipmentforpossibledamageduetoshipping.
If there is any damage, notify the carrier immediately to file a claim. Furnish complete information
concerning damage claims or shipping errors to
Thermal Arc, Order Department, 2200 Corporate
Drive, Troy, Ohio 45373-1085. Include all equipment identification numbers as described above
along with a full description of the parts in error.
Additional copies of this manual may be purchased 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
ARC WELDING can be hazardous.
PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER
WEARERSKEEPAWAY UNTILCONSULTINGYOUR DOCTOR.DONOT LOSETHESEINSTRUCTIONS. READOPERATING/INSTRUCTION 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
trainingbeforeusingthis equipment. Anyone not havingextensivetraining in welding andcuttingpracticesshould 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 Z49.1 entitled:
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.
Touchingliveelectrical parts can causefatalshocks
or severe burns. The electrode and work circuit is
electricallylivewhenevertheoutputison. The input
power circuit and machine internal circuits are also
livewhen poweris on.Insemiautomaticorautomatic
wire welding, the wire, wire reel, drive roll housing,
and all metal parts touching the welding wire are
electrically live. Incorrectly installed or improperly
grounded equipment is a hazard.
1. Do not touch live electrical parts.
2. Wear dry, hole-free insulating gloves and body protection.
3. Insulate yourselffromwork and ground using dryinsulatingmats
or covers.
4. Disconnect input power or stop engine before installing or servicing this equipment. Lock input power disconnect switch open,
or remove line fuses so power cannot be turned on accidentally.
5. Properly install and ground this equipment according to its
Owner’s Manual and national, state, and local codes.
SAFETY IN WELDING AND CUTTING. This publication and
6. Turn off all equipment when not in use. Disconnect power to
equipment if it will be left unattended or out of service.
7. 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
touch holders connected to two welding machines at the same
time or touch other people with the holder or electrode.
8. Do notuse worn, damaged,undersized,or poorlysplicedcables.
9. Do not wrap cables around your body.
10. Ground the workpiece to a good electrical (earth) ground.
11. Do not touch electrode while in contact with the work (ground)
circuit.
12. Use only well-maintainedequipment. Repairorreplacedamaged
parts at once.
13. In confined spaces or damp locations, do not use a welder with
AC output unless it is equipped with a voltage reducer. Use
equipment with DC output.
14. Wear a safety harness to prevent falling if working above floor
level.
15. Keep all panels and covers securely in place.
ARC RAYS can burn eyes and skin;
NOISE can damage hearing.
Arc rays from the welding process produce intense
heat and strong ultraviolet rays that can burn eyes
and skin. Noise from some processes can damage
hearing.
Eye protection filter shade selector for welding or cutting (goggles or helmet), from AWS A6.2-73.
Welding or Cutting
Operation
Torch soldering
Torch brazing
Oxygen cutting
Light
Medium
Heavy
Gas welding
Light
Medium
Heavy
Shielded metal-arc welding
(stick) electrodes
Electrode Size
Metal Thickness
or Welding Current
—
—
Under 1 in., 25 mm
1 to 6 in., 25-150 mm
Over 6 in., 150 mm
Under 1/8 in., 3 mm
1/8 to 1/2 in., 3-12 mm
Over 1/2 in., 12 mm
Under 5/32 in., 4 mm
5/32 to 1/4 in., 4 to 6.4 mm
Over 1/4 in., 6.4 mm
Filter
Shade
No.
2
3or4
3or4
4or5
5or6
4or5
5or6
6or8
10
12
14
1. Wear a welding helmet fitted with a proper shade of filter (see
ANSI Z49.1 listed in Safety Standards) to protect your face and
eyes when welding or watching.
2. Wear approved safety glasses. Side shields recommended.
3. Use protective screens or barriers to protect others from flash
and glare; warn others not to watch the arc.
4. Wear protective clothing made from durable, flame-resistant
material (wool and leather) and foot protection.
5. Use approved ear plugs or ear muffs if noise level is high.
Welding or Cutting
Operation
Gas metal-arc welding (MIG)
Non-ferrous base metal
Ferrous base metal
Gastungstenarcwelding (TIG)
Atomic hydrogen welding
Carbon arc welding
Plasma arc welding
Carbon arc air gouging
Light
Heavy
Plasma arc cutting
Light
Medium
Heavy
Electrode Size
Metal Thickness
or Welding Current
All
All
All
All
All
All
Under 300 Amp
300 to 400 Amp
Over 400 Amp
May 8, 1996 2-1
Filter
Shade
No.
11
12
12
12
12
12
12
14
9
12
14
ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS
Instruction 830001
FUMES AND GASES can be hazardous
to your health.
Weldingproduces fumesandgases.Breathingthese
fumes and gases can be hazardous to your health.
1. Keep your head out of the fumes. Do not breath the fumes.
2. If inside, ventilate the area and/or use exhaust at the arc to
remove welding fumes and gases.
3. 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 workpiece, and hot equipment cancausefiresandburns.
Accidental contact of electrode or welding wire to
metal objects can cause sparks, overheating, or fire.
1. Protect yourself and others from flying sparks and hot metal.
2. Do not weld where flying sparks can strike flammable material.
3. Remove all flammables within 35 ft (10.7 m) of the welding arc.
If this is not possible, tightly cover them with approved covers.
4. Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
4. Read the Material Safety Data Sheets (MSDSs) and the manufacturer’s instruction for metals, consumables, coatings, and
cleaners.
5. Work in a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Shielding gases used for
welding can displace air causing injury or death. Be sure the
breathing air is safe.
6. Do not weld in locations near degreasing, cleaning, or spraying
operations. The heat and raysof thearccanreactwithvapors to
form highly toxic and irritating gases.
7. 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.
6. Be aware that welding on a ceiling, floor, bulkhead, or partition
can cause fire on the hidden side.
7. Do not weld on closed containers such as tanks or drums.
8. 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.
9. Do not use welder to thaw frozen pipes.
10. Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
11. Wear oil-free protective garments such as leather gloves, heavy
shirt, cuffless trousers, high shoes, and a cap.
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 cylinderscontaingasunderhighpressure. If damaged, a cylinder can explode. Since gas
cylinders are normally part of the welding process,
be sure to treat them carefully.
1. Protectcompressed gascylindersfromexcessiveheat, mechanical shocks, and arcs.
2. Install and secure cylinders in an upright position by chaining
themtoastationarysupportorequipmentcylinderracktoprevent
falling or tipping.
ENGINE EXHAUST GASES can kill.
Engines produce harmful exhaust gases.
1. Wear approved face shield or safety goggles. Side shields recommended.
2. Wear proper body protection to protect skin.
3. Keep cylindersawayfrom any welding orotherelectrical circuits.
4. Never allow a welding electrode to touch any cylinder.
5. Use only correct shielding gas cylinders, regulators, hoses, and
fittings designed for the specific application; maintain them and
associated parts in good condition.
6. Turn face away from valve outlet when opening cylinder valve.
7. Keep protective cap in place over valve except when cylinder is
in use or connected for use.
8. Read and follow instructionsoncompressedgas cylinders, associated equipment, and CGA publication P-1 listed in Safety
Standards.
ENGINES can be hazardous.
1. Use equipment outside in open, well-ventilated areas.
2. 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,suchasfans, rotors, and belts cancut
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.
SPARKS can cause BATTERY GASES
TO EXPLODE; BATTERY ACID can
burn eyes and skin.
Batteriescontain acidand generateexplosivegases.
STEAM AND PRESSURIZED HOT
COOLANT can burn face, eyes, and
skin.
The coolantinthe radiator can beveryhot and under
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 & Safety Code Sec. 25249.5 et seq.)
NOTE: Considerations About 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,
of Power Frequency Electric & 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.
2. Arrange cables to one side and away from the operator.
2. Do not addfuelwhile smokingor if unitis near anysparks oropen
flames.
3. Allow engine to cool before fueling. If possible, check and add
fuel to cold engine before beginning job.
4. Do not overfill tank — allow room for fuel to expand.
5. Do not spillfuel.Iffuelisspilled,clean up before starting engine.
3. Have only qualified people remove guards or covers for mainte-
nance and troubleshooting as necessary.
4. To prevent accidentalstartingduring servicing,disconnectnega-
tive (-) battery cable from battery.
5. Keep hands, hair, loose clothing, and tools away from moving
parts.
6. Reinstall panels or guards and close doors when servicing is
finished and before starting engine.
1. Always wear a face shield when working on a battery.
2. Stop engine before disconnecting or connecting battery cables.
3. Do not allow tools to cause sparks when working on a battery.
4. Do not use welder to charge batteries or jump start vehicles.
5. Observe correct polarity (+ and –) on batteries.
1. Do not remove radiator cap when engine is hot. Allow engine to
cool.
2. Wear gloves and put a rag over cap area when removing cap.
3. Allow pressure to escape before completely removing cap.
Biological Effects
3. Do not coil or drape cables around the body.
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 information.
PRINCIPAL SAFETY STANDARDS
Safety inWeldingandCutting,ANSI Standard Z49.1, from American
Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33126.
SafetyandHealthStandards, OSHA 29 CFR1910,fromSuperintendent of Documents, U.S. Government Printing Office, Washington,
D.C. 20402.
Recommended Safe Practices for the Preparation for Welding and
Cuttingof ContainersThatHaveHeldHazardousSubstances, American Welding Society Standard AWS F4.1, from American Welding
Society, 550 N.W. LeJeune Rd., Miami, FL 33126.
National Electrical Code, NFPA Standard 70, from National Fire
Protection Association, Batterymarch Park, Quincy, MA 02269.
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet
P-1, from Compressed Gas Association, 1235 Jefferson DavisHighway, Suite 501, Arlington, VA 22202.
Code forSafetyin Welding and Cutting,CSAStandard W117.2, from
Canadian Standards Association, Standards Sales, 178 Rexdale
Boulevard, Rexdale, Ontario, Canada M9W 1R3.
Safe Practices for Occupation and Educational Eye and Face Protection, ANSI Standard Z87.1, from American National Standards
Institute, 1430 Broadway, New York, NY 10018.
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
PRECAUTIONS DE SECURITE EN SOUDAGE A L'ARC
Instruction 830002
PRECAUTIONS DE SECURITE EN SOUDAGE A L′ARC
LE SOUDAGE A L′ARC EST DANGEREUX
PROTEGEZ-VOUS,AINSI QUE LES AUTRES, CONTRE LES BLESSURESGRAVES POSSIBLES OU LA MORT. NE LAISSEZ PAS LES
ENFANTSS’APPROCHER,NILES PORTEURSDE STIMULATEURCARDIAQUE (AMOINSQU’ILS N’AIENTCONSULTE UNMEDECIN).
CONSERVEZ CES INSTRUCTIONS.LISEZLEMANUELD’OPERATION OU LES INSTRUCTIONS AVANT D’INSTALLER, UTILISER OU
ENTRETENIR CET EQUIPEMENT.
Les produits et procédés de soudage peuvent sauser des blessures graves ou la mort, de même que des dommages au reste du matériel
et à la propriété,sil’utilisateur n’adhère pas strictement à toutes les règles de sécurité et ne prend pas les précautions nécessaires.
En soudage et coupage, des pratiques sécuritaires se sont développées suite à l’expérience passée. Ces pratiques doivent être apprises
parétude ou entraînement avant d’utiliserl’equipement. Toute personne n’ayant pas suivi un entraînement intensif en soudage et coupage
ne devrait pas tenter de souder. Certaines pratiques concernent les équipements raccordés aux lignes d’alimentation alors que d’autres
s’adressent aux groupes électrogènes.
La norme Z49.1 de l’American National Standard, intitulée “SAFETY IN WELDING AND CUTTING” présente les pratiques sécuritaires à
suivre. Ce document ainsi que d’autres guides que vous devriez connaître avant d’utiliser cet équipement sont présentés à la fin de ces
instructions de sécurité.
SEULES DES PERSONNES QUALIFIEES DOIVENT FAIRE DES TRAVAUX D’INSTALLATION, DE REPARATION, D’ENTRETIEN ET
D’ESSAI.
L’ELECTROCUTION PEUT ETRE
MORTELLE.
Une décharge électrique peut tuer ou brûler gravement. L’électrode et le circuit de soudage sont sous
tension dès la mise en circuit. Le circuit d’alimentation et les circuits internes de l’équipement sont
aussi sous tension dès la mise en marche. En
soudage automatique ou semi-automatique avec
fil, ce dernier, le rouleau ou la bobine de fil, le
logement des galets d’entrainement et toutes les
pièces métalliques en contact avec le fil de soudage
sont sous tension. Un équipement inadéquatement
installé ou inadéquatement mis à la terre est dangereux.
1. Ne touchez pas à des pièces sous tension.
2. Portez des gants et des vêtements isolants, secs et non troués.
3. Isolez-vous de lapièce à souderetde lamiseà laterreau moyen
de tapis isolants ou autres.
4. Déconnectez la prise d’alimentation de l’équipement ou arrêtez
le moteur avant de l’installer ou d’en faire l’entretien. Bloquez le
commutateurencircuit ouvertou enlevezlesfusibles del’alimentation afin d’éviter une mise en marche accidentelle.
5. Veuillez à installer cet équipement et à le mettre à la terre selon
le manuel d’utilisation et les codes nationaux, provinciaux et
locaux applicables.
LE RAYONNEMENT DE L′ARC PEUT
BRÛLER LES YEUX ET LA PEAU; LE
BRUIT PEUT ENDOMMAGER L′OUIE.
L’arc de soudage produit une chaleur et des
rayons ultraviolets intenses, susceptibles de
brûler les yeux et la peau. Le bruit causé par
certains procédés peut endommager l’ouïe.
1. Portez une casque de soudeur avec filtre oculaire de nuance
appropriée (consultez la norme ANSI Z49 indiquéeci-après)
6. Arrêtez tout équipement après usage. Coupez l’alimentation de
l’équipement s’il est hors d’usage ou inutilisé.
7. N’utilisez quedes porte-électrodesbienisolés.Nejamaisplonger
les porte-électrodes dans l’eau pour les refroidir. Ne jamais les
laisser traîner par terre ou sur les pièces à souder. Ne touchez
pas aux porte-électrodes raccordés à deux sources de courant
en même temps. Ne jamais toucher quelqu’un d’autre avec
l’électrode ou le porte-électrode.
8. N’utilisez pas de câbles électriques usés, endommagés, mal
épissés ou de section trop petite.
9. N’enroulez pas de câbles électriques autour de votre corps.
10. N’utilisez qu’une bonne prise de masse pour la mise à la terre
de la pièce à souder.
11. Ne touchez pas à l’électrode lorsqu’en contact avec le circuit de
soudage (terre).
12. N’utilisez que des équipements en bon état. Réparez ou remplacez aussitôt les pièces endommagées.
13. Dans des espaces confinés ou mouillés, n’utilisez pas de source
de courant alternatif, à moins qu’il soit muni d’un réducteur de
tension. Utilisez plutôt une source de courant continu.
14. Portez un harnais de sécurité si vous travaillez en hauteur.
15. Fermez solidement tous les panneaux et les capots.
pour vous protéger le visage et lesyeuxlorsquevoussoudezou
que vous observez l’exécution d’une soudure.
2. Portez des lunettesde sécurité approuvées.Desécrans latéraux
sont recommandés.
3. Entourez l’aire de soudage de rideaux ou de cloisons pour
protéger les autres des coups d’arcoudel’éblouissement;
avertissez les observateurs de ne pas regarder l’arc.
4. Portez des vêtements en matériaux ignifuges et durables (laine
et cuir) et des chaussures de sécurité.
5. Portez un casque antibruit ou des bouchons d’oreilleapprouvés
lorsque le niveau de bruit est élevé.
8-V-96 2-1
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