MK Products ELECTRIC ARC WELDING EQUIPMENT Owner`s manual

Prince® XL/Spool Gun
Owner’s Manual
Product:
Prince® XL/
Spool Gun
Manual:
091-0530
Serial:
03050001
Voltage Rating: 24 VDC
Revision:
April 2009 Rev D
Gun models:
313-XXX
316-XXX
225 Ampere Push-Pull Welding Gun
255 Ampere Push-Pull Welding Gun
Table of Contents
Safety Considerations..........................................................................................i-vi
Installation................................................................................................. Section A
Technical Specifications.....................................................................................1
Support Equipment Required.............................................................................1
Gun Lead Connections......................................................................................1
Installing Spool Assembly..................................................................................2
Interconnections.................................................................................................3
Operation.................................................................................................. Section B
General..............................................................................................................4
Barrels................................................................................................................4
Controls and Settings.........................................................................................4
Drive Roll and Idler Rolls....................................................................................5
Accessories...............................................................................................Section C
Contact Tips ......................................................................................................6
Gas Cups...........................................................................................................6
Barrel Liners.......................................................................................................6
Barrel Assemblies..............................................................................................7
Optional Barrels.................................................................................................7.
Optional Kits............................................................................................................7
Optional Accessories..........................................................................................8
Spool Gun Controls............................................................................................8
Maintenance.............................................................................................Section D
Periodic Maintenance...........................................................................................10.
Recommended Spare Parts List...........................................................................10
Troubleshooting........................................................................................ Section E
Troubleshooting Guide.....................................................................................12
Testing the Gun................................................................................................13
Appendices............................................................................................... Section F
Diagrams/Parts List..........................................................................................15
Safety Warnings
Warranty
Declaration of Conformity for
European Community (CE) Products
Note
This information is provided for units with CE certification (see rating label on unit).
Manufacturer’s Name:
MK Products, Inc.
16882 Armstrong Ave.
Irvine, CA 92606
Declares that the product:
Prince® XL
conforms to the following Directives and Standards:
Directives
Low Voltage Directive: 73/23/EEC
Electromagnetic Compatibility (EMC) Directive: 89/336/EEC
Standards
Arc Welding Equipment Part I: Welding Power Sources: IEC 60974-1
(September 1998 - Second Edition)
Arc Welding Equipment: Wirefeed Systems: IEC 974-5
(September 1997 - Draft Revision)
Degrees of Protection Provided by Enclosures (IP Code): IEC 529:1989
(November 1989 - First Edition)
Insulation Coordination For Equipment With Low-Voltage Systems:
Part I: Principles, Requirements and Tests: IEC 664-1: 1992
(October 1992 - First Edition)
Electromagnetic Compatibility, (EMC): EN 50199
(August 1995)
Torches And Guns For Arc Welding, EN 50078
SAFETY CONSIDERATIONS
ELECTRIC ARC WELDING EQUIPMENT
CAUTION : READ BEFORE ATTEMPTING INSTALLATION, OPERATION OR
MAINTENANCE OF THIS EQUIPMENT
1-1 INTRODUCTION
This equipment is intended for ultimate
application by commercial/industrial
users and for operation by persons
trained and experienced in the use and
maintenance of welding equipment.
Operation should not be undertaken
without adequate training in the use of
such equipment. Training is available
from many public and private schools or
similar facilities.
Safe practices in the installation,
operation and maintenance of this
equipment requires proper training in
the art, a careful study of the information
provided with the equipment, and the
use of common sense. Rules for safe
use are generally provided by suppliers
of welding power sources, compressed
gas suppliers, and electrode suppliers.
Careful compliance with these rules will
promote safe use of this equipment.
The following Safety Rules cover some
of the more generally found situations.
READ THEM CAREFULLY. In case of
any doubt, obtain qualified help before
proceeding.
1-2 GENERAL PRECAUTIONS
A. Burn Prevention
ELECTRIC
ARC
WELDING
PRODUCES
HIGH
INTENSITY
HEAT AND ULTRAVIOLET RADIANT
ENERGY WHICH
MAY CAUSE
SERIOUS AND PERMANENT EYE
DAMAGE AND WHICH MAY DAMAGE
ANY EXPOSED SKIN AREAS.
Wear helmet with safety goggles or
glasses with side shields underneath,
appropriate filter lenses or plates
(protected by clear cover glass). This
is a must for welding or cutting (and
chipping) to protect the eyes from radiant
energy and flying metal. Replace cover
glass when broken, pitted, or spattered.
Medical first aid and eye treatment.
First aid facilities and a qualified first aid
person should be available for each shift
unless medical facilities are close by for
immediate treatment of flash burns of
the eyes and skin burns.
Wear protective clothing - leather (or
asbestos) gauntlet gloves, hat, and high
safety-toe shoes. Button shirt collar and
pocket flaps, and wear cuffless trousers
to avoid entry of sparks and slag.
Avoid oily or greasy clothing. A spark
may ignite them.
Flammable hair preparations should not
be used by persons intending to weld or
cut.
Hot metal such as electrode stubs and
work pieces should never be handled
without gloves.
Ear plugs should be worn when working
on overhead or in a confined space. A
hard hat should be worn when others work
overhead.
B. Toxic Fume Prevention
WARNING: The use of this product may
result in exposure to chemicals known to
the State of California to cause cancer and
birth defects or other reproductive harm.
Adequate ventilation. Severe discomfort,
illness or death can result from fumes,
vapors, heat, or oxygen enrichment or
depletion that welding (or cutting) may
produce. Prevent them with adequate
ventilation. NEVER ventilate with oxygen.
Lead-,
cadmium-,
zinc-,
mercury-,
beryllium-bearing and similar materials,
when welded or cut, may produce harmful
concentrations of toxic fumes. Adequate
local exhaust ventilation must be used,
or each person in the area, as well as
the operator, must wear an air-supplied
respirator. For beryllium, both must be
used.
Metals coated with or containing materials
that emit toxic fumes should not be heated
unless coating is removed form the work
surface, the area is well ventilated, or the
operator wears an air-supplied respirator.
Work in a confined space only while it is
being ventilated and, if necessary, while
wearing an air-supplied respirator.
Gas leaks in a confined space should be
avoided. Leaked gas in large quantities
can
change
oxygen
concentration
dangerously. Do not bring gas cylinders
into a confined space.
Leaving confined space, shut OFF gas
supply at source to prevent possible
accumulation of gases in the space if
downstream valves have been accidentally
opened or left open. Check to be sure that
the space is safe before reentering it.
Vapors from chlorinated solvents can
be decomposed by the heat of the
arc (or flame) to form PHOSGENE, a
highly toxic gas, and other lung and eye
irritating products. The ultraviolet (radiant)
energy of the arc can also decompose
trichloroethylene and perchloroethylene
vapors to form phosgene.
DO NOT
WELD or cut where solvent vapors can
be drawn into the welding or cutting
atmosphere or where the radiant energy
can penetrate to atmospheres containing
even minute amounts of trichloroethylene
or perchloroethylene.
Prince® XL/Spool Gun Owner's Manual - Page i
C. Fire and Explosion
Prevention
Causes of fire and explosion are:
combustibles reached by the arc,
flame, flying sparks, hot slag, or heated
material, misuse of compressed gases
and cylinders, and short circuits.
BE AWARE THAT flying sparks or falling
slag can pass through cracks, along
pipes, through windows or doors, and
through wall or floor openings, out of
sight of the goggled operator. Sparks
can fly many feet.
To prevent fires and explosion:
Keep equipment clean and operable,
free of oil, grease, and (in electrical
parts) of metallic particles that can
cause short circuits.
If combustibles are in area, do NOT weld
or cut. Move the work if practicable, to
an area free of combustibles. Avoid
paint spray rooms, dip tanks, storage
areas, ventilators. If the work cannot
be moved, move combustibles at least
35 feet away, out of reach of sparks
and heat; or protect against ignition with
suitable and snug-fitting, fire-resistant
covers or shields.
Walls touching combustibles on
opposite sides should not be welded
on (or cut). Walls, ceilings, and floor
near work should be protected by heatresistant covers or shields.
Fire watcher must be standing by with
suitable fire extinguishing equipment
during and for some time after welding
or cutting if:
1. Appreciable combustibles (including
building construction) are within 35 feet.
2. Appreciable combustibles are further
than 35 feet, but can be ignited by
sparks.
3. Openings (concealed or visible) in
floors or walls within 35 feet may expose
combustibles to sparks.
4. Combustibles adjacent to walls,
ceilings, roofs, or metal partitions can
be ignited by radiant or conducted heat.
Hot work permit should be obtained
before operation to ensure supervisor’s
approval that adequate precautions
have been taken.
After work is done, check that area is
free of sparks, glowing embers, and
flames.
An
empty
container
that
held
combustibles, or that can produce
flammable or toxic vapors when heated,
must never be welded on or cut, unless
container has first been cleaned in
accordance with industry standards.
This includes: a thorough steam
or caustic cleaning (or a solvent of
water washing, depending on the
combustible’s solubility), followed by
purging and inerting with nitrogen or
carbon dioxide, and using protective
equipment.
Water-filling just below working level
may substitute for inerting.
A container with unknown contents
should be cleaned (see paragraph
above). Do NOT depend on sense of
smell or sight to determine if it is safe to
weld or cut.
Hollow castings or containers must be
vented before welding or cutting. They
can explode.
Explosive atmospheres.
NEVER
weld or cut where the air may contain
flammable dust, gas, or liquid vapors
(such as gasoline).
D. Compressed Gas Equipment
The safe handling of compressed gas
equipment is detailed in numerous
industry publications. The following
general rules cover many of the most
common situations.
1. Pressure Regulators
Regulator relief valve is designed
to protect only the regulator from
overpressure; it is not intended to
protect any downstream equipment.
Provide such protection with one or
more relief devices.
Never connect a regulator to a cylinder
containing gas other than that for which
the regulator was designed.
Remove faulty regulator from service
immediately for repair (first close
cylinder valve). The following symptoms
indicate a faulty regulator:
Leaks - if gas leaks externally.
Excessive Creep - if delivery pressure
continues to rise with downstream valve
closed.
Faulty Gauge - if gauge pointer does
not move off stop pin when pressurized,
nor returns to stop pin after pressure
release.
Repair. Do NOT attempt repair.
Send faulty regulators for repair to
manufacturer’s
designated
repair
center, where special techniques and
tools are used by trained personnel.
2. Cylinders
Cylinders must be handled carefully to
prevent leaks and damage to their walls,
valves, or safety devices:
Avoid electrical circuit contact with
cylinders including third rails, electrical
wires, or welding circuits. They can
produced short circuit arcs that may
lead to a serious accident. (See 1-3C)
ICC or DOT marking must be on each
cylinder. It is an assurance of safety
when the cylinder is properly handled.
Identifying
gas
content.
Use
only
cylinders with name of gas marked on
them; do not rely on color to identify gas
content.
Notify supplier if unmarked.
NEVER DEFACE or alter name, number,
or other markings on a cylinder. It is illegal
and hazardous.
that may clog orifices and damage seats
before connecting regulator. Except for
hydrogen, crack valve momentarily,
pointing outlet away from people and
sources of ignition. Wipe with a clean,
lintless cloth.
Empties: Keep valves closed, replace caps
securely; mark MT; keep them separate
from FULLS, and return promptly.
Match regulator to cylinder. Before
connecting, check that the regulator
label and cylinder marking agree, and
that the regulator inlet and cylinder outlet
match. NEVER Connect a regulator
designed for a particular gas or gases
to a cylinder containing any other gas.
Prohibited use. Never use a cylinder or its
contents for other than its intended use,
NEVER as a support or roller.
Locate or secure cylinders so they cannot
be knocked over.
Passageways and work areas. Keep
cylinders clear of areas where they may
be stuck.
Transporting cylinders. With a crane, use
a secure support such as a platform or
cradle. Do NOT lift cylinders off the ground
by their valves or caps, or by chains, slings,
or magnets.
Do NOT expose cylinders to excessive
heat, sparks, slag, and flame, etc. that
may cause rupture. Do not allow contents
to exceed 55 degrees C (130 degrees
F.) Cool with water spray where such
exposure exists.
Protect cylinders, particularly valves from
bumps, falls, falling objects, and weather.
Replace caps securely when moving
cylinders.
Stuck valve. Do NOT use a hammer or
wrench to open a cylinder valve that cannot
be opened by hand. Notify your supplier.
Mixing gases. NEVER try to mix any
gases in a cylinder.
NEVER refill any cylinder.
Cylinder fittings should never be modified
or exchanged.
3. Hose
Prohibited use. Never use hose other
than that designed for the specified gas. A
general hose identification rule is: red for
fuel gas, green for oxygen, and black for
inert gases.
Use ferrules or clamps designed for the
hose (not ordinary wire or other substitute)
as a binding to connect hoses to fittings.
No copper tubing splices.
Use only
standard brass fittings to splice hose.
Avoid long runs to prevent kinks and
abuse. Suspend hose off ground to keep
it from being run over, stepped on, or
otherwise damaged.
Coil excess hose to prevent kinks and
tangles.
Tighten connections. When assembling
threaded connections, clean and smooth
seats where necessary. Tighten. If
connection leaks, disassemble, clean,
and retighten, using properly fitting
wrench.
Adapters. Use a CGA adapter (available
from your supplier) between cylinder
and regulator, if one is required. Use
two wrenches to tighten adapter marked
RIGHT and LEFT HAND threads.
Regulator outlet (or hose) connections
may be identified by right hand threads
for oxygen and left hand threads (with
grooved hex on nut or shank) for fuel
gas.
5. Pressurizing Steps:
Drain regulator of residual gas through
suitable vent before opening cylinder
(or manifold valve) by turning adjusting
screw in (clockwise). Draining prevents
excessive compression heat at high
pressure seat by allowing seat to open
on pressurization. Leave adjusting
screw engaged slightly on single-stage
regulators.
Stand to side of regulator while opening
cylinder valve.
Open cylinder valve slowly so that
regulator pressure increases slowly.
When gauge is pressurized (gauge
reaches regulator maximum) leave
cylinder valve in following position: for
oxygen and inert gases, open fully to
seal stem against possible leak; for fuel
gas, open to less than one turn to permit
quick emergency shut-off.
Use pressure charts (available from
your supplier) for safe and efficient
recommended pressure settings on
regulators.
Check for leaks on first pressurization
and regularly thereafter. Brush with
soap solution. Bubbles indicate leaks.
Clean off soapy water after test; dried
soap is combustible.
Protect hose from damage by sharp edges,
and by sparks, slag, and open flame.
E. User Responsibilities
Examine hose regularly for leaks,
wear, and loose connections. Immerse
pressured hose in water; bubbles indicate
leaks
Remove leaky or defective equipment
from service immediately for repair.
Read and follow user manual
instructions.
Repair leaky or worn hose by cutting area
out and splicing. Do NOT use tape.
F. Leaving Equipment
Unattended
4. Proper Connections
Clean cylinder valve outlet of impurities
Follow all Safety Rules.
Close gas supply at source and drain
gas.
Prince® XL/Spool Gun Owner's Manual - Page ii
G. Rope Staging-Support
Rope staging-support should not be
used for welding or cutting operation;
rope may burn.
1-3 ARC WELDING
Comply with precautions in 1-1, 1-2,
and this section. Arc Welding, properly
done, is a safe process, but a careless
operator invites trouble. The equipment
carries high currents at significant
voltages. The arc is very bright and hot.
Sparks fly, fumes rise, ultraviolet and
infrared energy radiates, weldments
are hot, and compressed gases may
be used. The wise operator avoids
unnecessary risks and protects himself
and others from accidents.
A. Burn Protection
Comply with precautions in 1-2.
The welding arc is intense and visibly
bright. Its radiation can damage eyes,
penetrate lightweight clothing, reflect
from light-colored surfaces, and burn
the skin and eyes. Skin burns resemble
acute sunburn; those from gas-shielded
arcs are more severe and painful.
DON’T GET BURNED; COMPLY WITH
PRECAUTIONS.
1. Protective Clothing
Wear long-sleeve clothing in addition to
gloves, hat, and shoes. As necessary,
use additional protective clothing such
as leather jacket or sleeves, flameproof
apron, and fire-resistant leggings. Avoid
outer garments of untreated cotton.
Bare skin protection.
Wear dark,
substantial clothing. Button collar to
protect chest and neck, and button
pockets to prevent entry of sparks.
2. Eye and Head Protection
Protect eyes from exposure to arc. Eyes
may be damaged by radiant energy
when exposed to the electric arc, even
when not looking in the direction of the
arc. Never look at an electric arc without
protection.
Welding helmet or shield containing a
filter plate shade no. 12 or denser must
be used when welding. Place over face
before striking arc.
Protect filter plate with a clear cover
plate.
Cracked or broken helmet or shield
should NOT be worn; radiation can be
passed through to cause burns.
Cracked, broken, or loose filter plates
must be replaced IMMEDIATELY.
Replace clear cover plate when broken,
pitted, or spattered.
Flash goggles with side shields MUST
be worn under the helmet to give
some protection to the eyes should the
helmet not be lowered over the face
before an arc is struck. Looking at
an arc momentarily with unprotected
eyes (particularly a high intensity gasshielded arc) can cause a retinal burn
that may leave a permanent dark area
in the field of vision.
3. Protection of Nearby Personnel
Enclose the welding area. For production
welding, a separate room or enclosed
bay is best. In open areas, surround
the
operation
with
low-reflective,
noncombustible screens or panels. Allow
for free air circulation, particularly at floor
level.
Viewing the weld. Provide face shields for
all persons who will be looking directly at
the weld.
Others working in area. See that all
persons are wearing flash goggles.
Before starting to weld, make sure that
screen flaps or bay doors are closed.
B. Toxic Fume Prevention
Comply with precautions in 1-2B.
Generator engine exhaust must be vented
to the outside air. Carbon monoxide can
kill.
C. Fire and Explosion Prevention
Comply with precautions in 1-2C.
Equipment’s rated capacity.
Do not
overload arc welding equipment. It may
overheat cables and cause a fire.
Loose cable connections may overheat or
flash and cause afire.
Never strike an arc on a cylinder or other
pressure vessel. It creates a brittle area
that can cause a violent rupture or lead to
such a rupture later under rough handling.
D. Compressed Gas Equipment
Comply with precautions in 1-2D.
E. Shock Prevention
Exposed electrically hot conductors or
other bare metal in the welding circuit, or in
ungrounded, electrically-HOT equipment
can fatally shock a person whose body
becomes a conductor. DO NOT STAND,
SIT, LIE, LEAN ON, OR TOUCH a wet
surface when welding without suitable
protection.
To protect against shock:
Keep body and clothing dry. Never work
in damp area without adequate insulation
against electrical shock. Stay on a dry
duckboard, or rubber mat when dampness
or sweat cannot be avoided. Sweat, sea
water, or moisture between body and an
electrically HOT part - or grounded metal
- reduces the body surface electrical
resistance, enabling dangerous and
possibly lethal currents to flow through the
body.
1. Grounding the Equipment
When installing, connect the frames of
each unit such as welding power source,
control, work table, and water circulator to
the building ground. Conductors must be
adequate to carry ground currents safely.
Equipment made electrically HOT by stray
currents may shock, possibly fatally. Do
NOT GROUND to electrical conduit, or to
a pipe carrying ANY gas or a flammable
liquid such as oil or fuel.
Three-phase connection. Check phase
requirement of equipment before installing.
If only three-phase power is available,
connect single-phase equipment to only
two wires of the three-phase line. Do NOT
connect the equipment ground lead to
the third (live) wire, or the equipment will
become electrically HOT - a dangerous
condition that can shock, possibly fatally.
Before welding, check ground for
continuity. Be sure conductors are
touching bare metal of equipment
frames at connections.
If a line cord with a ground lead is
provided with the equipment for
connection to a switch box, connect
the ground lead to the grounded switch
box. If a three-prong plug is added
for connection to a grounded mating
receptacle, the ground lead must be
connected to the ground prong only. If
the line cord comes with a three-prong
plug, connect to a grounded mating
receptacle. Never remove the ground
prong from a plug, or use a plug with a
broken ground prong.
2. Connectors
Fully insulated lock-type connectors
should be used to join welding cable
lengths.
3. Cables
Frequently inspect cables for wear,
cracks, and damage. IMMEDIATELY
REPLACE those with excessively worn
or damaged insulation to avoid possibly
lethal shock from bared cable. Cables
with damaged areas may be taped to
give resistance equivalent to original
cable.
Keep cable dry, free of oil and grease,
and protected from hot metal and
sparks.
4. Terminals and Other Exposed
Parts
Terminals and other exposed parts of
electrical units should have insulating
covers secured before operation.
5. Electrode Wire
Electrode wire becomes electrically
HOT when the power switch of gas
metal-arc welding equipment is ON and
welding gun trigger is pressed. Keep
hands and body clear of wire and other
HOT parts.
6. Safety Devices
Safety devices such as interlocks
and circuit breakers should not be
disconnected or shunted out.
Before installation, inspection, or service
of equipment, shut OFF all power, and
remove line fuses (or lock or red-tag
switches) to prevent accidental turning
ON of power. Disconnect all cables from
welding power source, and pull all 115
volts line-cord plugs.
Do not open power circuit or change
polarity while welding.
If, in an
emergency, it must be disconnected,
guard against shock burns or flash from
switch arcing.
Leaving equipment unattended. Always
shut OFF, and disconnect all power to
equipment.
Power disconnect switch must be
available near the welding power
source.
Prince® XL/Spool Gun Owner's Manual - Page iii
Thank You
For selecting a quality product. We want you to take
pride in operating this product...as much pride as we
have in bringing the product to you!
Please Examine Carton and Equipment For Damage Immediately
When this equipment is shipped, title passes to the purchaser upon receipt by the
carrier. Consequently, claims for material damaged in shipment must be made by the
purchaser against the transportation company at the time the shipment is received.
Please record your equipment identification information below for future reference. This
information can be found on your machine nameplate.
Model Name & Number
_____________________
Code & Serial Number
_____________________
Date of Purchase
_____________________
Whenever you request replacements parts for, or information on this equipment always
supply the information you have recorded above.
Read this Owner’s Manual completely before attempting to use this equipment. Save this manual
and keep it handy for quick reference. Pay particular attention to the safety instructions we
have provided for your protection.
Section A
Installation
Technical Specifications
Prince® XL Gun
Wire Capacity
• .030” -.045” (0.6 - 1.2mm) solid and hard wire
• .030” - 1/16” (0.8 - 1.6mm) aluminum and cored wire
Wire Speed
• 800 ipm (20.3 mpm) max.
Duty Cycle - 60%
All ratings are at 25V using Argon Gas
• 225 Amps
­
Prince® XL Spool Gun
Wire Capacity
• .030” - .045” (0.6 - 1.2mm) solid and hard wire
• .030” - 1/16” (0.8 - 1.6mm) aluminum and cored wire
Wire Speed*
• 900 ipm (22.9 mpm) max.
Spool Size
• 4 inches (101.6mm)
Duty Cycle - 60%
All ratings are at 25V using Argon Gas
• 255 Amps
*Maximum ipm varies depending on input voltage, wire size
and the control box used.
Support Equipment Required
•
•
•
CV or CC power source of sufficient capacity for your needs.
Regulated gas supply and hoses.
Properly sized power leads from power source to wire feeder and ground.
Gun Lead Connections
Power Cable
A #2 AWG power cable is used on the Prince® XL
gun. The gun end is threaded into the gun body.
The power cable fitting connects to the power
manifold when using a Cobramatic® wire feed
cabinet. When the Prince® XL is purchased as a
spool gun; the power cable comes standard with
a lug connector.
Conduit
The Prince® XL gun comes standard with a poly-lined conduit for running
aluminum wire. The longer fitting with a shallow groove is used on the gun
end. A setscrew located on top of the gun handle secures the conduit in
place. A small spool liner (P/N 003-0198) is used on the spool gun and held
in place by the same setscrew.
Gas Hose
The gas hose is secured over the barbed gas fitting with a tie wrap. The
cabinet end of the gas hose uses our standard gas fitting (1/8” - 27 nps),
whereas the spool gun uses a 5/8” - 18 IAA RH male gas fitting.
Prince® XL/Spool Gun Owner's Manual - Page 1
Electric Cable
A seven-conductor control cable is used on the Prince® XL gun. The gun end
of the control cable is secured to the gun with a boot clamp and plugged into
the pot assembly and micro switch connectors. Slack is left in the electric
cable as it exits the back of the gun to prevent cable breakage. The cabinet
end has a seven-pin “W” clocked amphenol connector.
Installing Spool Assembly
(Kit P/N 005-0632)
Loosen the screw that secures the conduit through access hole located on
top right rear handle with a 1/16” Allen wrench.
Conduit Securing Screw
Remove conduit by pulling it out of the back of the gun.
E-Ring
Rear Wire Guide
Spool Liner
Install spool liner, and secure with screw.
Remove both rear handle screws, and secure spool canister with longer
screws provided.
2 Screws
Spool Gun Setup
Loading Electrode Wire
Unscrew, and remove spool cover.
Apply tension to drive rolls, so the wire will be picked up and fed through the
contact tip.
Straighten out the first six inches of wire and push it through the liner.
Jog the trigger until the wire is picked up by drive rolls and fed through the
contact tip.
Hold the brake assembly back towards the top of the gun; load the spool
onto shaft with the wire coming off the bottom of the spool. Release the
brake assembly to rest on the wire surface.
Replace the spool cover; making sure that the opening is over liner.
Note: The brake assembly is designed to automatically control spool
drag and keep the wire from jumping off the spool.
Disassembly of Prince® XL/Spool Gun
Remove the trigger pin with punch and remove the trigger.
Remove the six (6) handle screws and the spool adapter if installed.
Remove the barrel from the gun, loosen the barrel taper lock assembly and
slide towards the cup. Leave the barrel inserted in gun the body.
Pull the handles apart.
Prince® XL/Spool Gun Owner's Manual - Page 2
®
PRINCE XL SPOOL GUN TO WC-1 WELD CONTROL BOX
CONSTANT VOLTAGE
OR
CONSTANT CURRENT
POWER SUPPLY
WC-1 CONSTANT CURRENT
POSA START SENSING LEADS
NOT NEEDED WITH CONSTANT
VOLTAGE SUPPLIES
NOTE: The Posa Start feature permits the
WC-1 to be used in combination with any
Constant Current DC power source with an
open circuit voltage in excess of 55 volts.
TO CUSTOMER GAS SUPPLY
PRINCE XL SPOOL GUN TO COMMON POWER SUPPLIES*
®
PA-L 1 Spool Gun Adapter
14-Pin C/D Trigger
V350 PRO
120VAC Output
Power Cable and Gas Hose must
also be connected
PA-M 1 Spool Gun Adapter
14-Pin A/B Trigger
* For more power supply options, see Spool Gun Controls in Section C
Prince® XL/Spool Gun Owner's Manual - Page 3
XMT 304
120VAC Output
Section B
Operation
General Description
The Prince® XL gun was specifically designed to operate as both a push-pull
gun and spool gun. The 24 volt DC gun motor is controlled by a 3-3/4 turn
potentiometer recessed in the pistol grip. The gun trigger is so designed
that when it is partially depressed, gas flow starts via the valve located in the
gun body - prior to ignition of the arc. When the trigger is partially released
after welding (extinguishing the arc), gas flow continues until the trigger is
fully released. Built-in pre and post gas flow. The gas cups and contact tips
used on the Prince® XL air cooled barrel are the same as those used on the
Cobra Gooseneck. The drive and idler rolls are also the same as on the
Cobra Gooseneck. The modular design allows parts to be replaced in sub
assemblies for minimum spare parts inventory and less down time.
Barrels
The Prince® XL comes standard with a straight barrel assembly. An optional
curved barrel assembly (P/N 003-2152) is also available. In cases where
these barrels need to be extended or the tip threads have been damaged, a
tip extender (P/N 621-0424) can be adapted. The same tips and threads can
be used, however a longer Teflon liner (P/N 931-0137) is required.
Barrel Removal and Installation
To remove a barrel assembly, loosen the patented EZ Lock® taper lock nut
assembly 3/4 to 1 turn. This will push barrel away from the body far enough
so that it may be pulled out of the body.
To replace a barrel assembly, push the barrel assembly into the gun body
until it clicks to a stop. To assure proper seating of the barrel, open the
drive/idler roll door in the top of the handle. The rear face of the barrel should
now be flush with the gun body. Take care not to damage the “O” rings when
inserting into the body. Tighten taper lock nut assembly firmly so that barrel
cannot rotate.
Barrel Rotation
To rotate a barrel assembly, loosen the patented EZ Lock® taper lock nut
assembly no more than 1 turn. Rotate barrel to the position of your choice
and retighten taper lock nut assembly firmly so that the barrel cannot rotate.
WARNING:
Do not attempt to weld without the barrel being tightly secured
in the gun body, or damage to the barrel or body may result. Failure to
take such precaution will void your warranty.
Controls and Settings
Potentiometer
The potentiometer is located in the bottom of the pistol grip and provides
3-3/4 turns of adjustment for up to 800 ipm.
The potentiometer is mounted to one side of a PC board and is held in place
by a support plate. Both the potentiometer and the support plate have slots
that locate and secure the potentiometer in the handle. The other side
of the PC board houses the motor connectors and ribbon cable. Locking
disks behind the potentiometer knob provides a stop at the minimum and
maximum potentiometer settings.
Micro Switch
The micro switch assembly (P/N 003-0568) consists of the micro switch,
leads, and connector. The assembly is secured to the gun block with two
(2) screws. An insulator between the gun block and micro switch prevents
Prince® XL/Spool Gun Owner's Manual - Page 4
accidental shorting of the switch leads. The leads are laid in the channel
under the motor and held in place with electrical tape.
Drive and Idler Rolls
The Prince® XL gun comes standard with a knurled drive roll and a grooved
idler roll, which will handle both steel and aluminum wire with diameters from
.030-1/16 inch. Optional insulated V-groove drive rolls are also available for
aluminum wire if desired (see Optional Kits).
Drive roll tension is accomplished by means of a pressure adjusting allen
screw located on the left hand side of the gun. Proper tension is achieved
when wire does not slip if a small amount of pressure is added to the wire as
it exits the tip.
NOTE:
Over-tightening of the drive rolls will cause excessive
knurling and/or deformation of the wire.
Drive Roll Installation/Removal
NOTE:
Neither of the handles needs to be removed to access the
drive or idler rolls
1.Pull the Cam Lever away from the idler roll. This will relieve the pressure against the drive roll.
2.
Align the Drive Roll Removal Tool (P/N 931-0100) over the flats
of the drive roll. Hold the gun with one hand or on a table top, with the other hand give the Removal Tool a quick snap-turn in the CLOCKWISE DIRECTION.
3. Once the drive roll is loose, continue to spin drive roll in the clockwise direction to remove the drive roll from the gun.
4. Install a new drive roll on the left-hand threaded shaft. The drive roll will self-tighten when it is feeding wire.
Idler Roll Installation and Removal
1. Using a slot type screwdriver, loosen idler screw, taking care not to lose lock washer under idler roll.
2. Insert new idler roll and lock washer onto screw, insuring that idler groove is toward top and lock washer is beneath.
3. Tighten.
Groove Towards Top
Idler Arm
Lock Washer
NOTE:
Lock washer must be under idler roll or it will not turn freely.
Prince® XL/Spool Gun Owner's Manual - Page 5
Section C
Accessories
Contact Tips
Wire Size
Heavy Duty Contact Tip - 3/8" Diameter*
Tip ID
Arc
Tip Length
.030” (0.8mm)
.040” (1.0mm)
.035” (0.9mm)
.045” (1.1mm)
Spray
Short
Spray
1.57” (39.9mm)
1.82” (46.2mm)
1.57” (39.9mm)
.035" (0.9mm) .045" (1.1mm)
.045" (1.1mm) .054" (1.37mm)
3/64” (1.2mm) .054” (1.37mm)
Short
Short
Spray
1.82” (46.2mm)
1.82” (46.2mm)
1.57” (39.9mm)
Part No.
621-0390-25
621-0396-25
621-0391-25
621-0391-250†
621-0391-500††
621-0397-25
621-0398-25
621-0392-25
621-0392-250†
3/64” (1.2mm)
.060” (1.5mm)
Spray
1.57” (39.9mm)
1/16” (1.6mm)
.074” (1.9mm)
.085” (2.16mm)
Spray
Spray
1.57” (39.9mm)
*Use of tip removal tool is recommended
**This size tip furnished with gun
†
621-0392-500††
621-0393-25**
621-0393-250†
621-0393-500††
621-0394-25
621-0395-25
Also sold in quantities of 250
Also sold in quantities of 500
††
Finned Copper Gas Cups
Tip Extender
Finned Copper Gas Cups
Size
I.D.
Part No.
6
3/8” (9.5mm)
621-0248
8
1/2” (12.7mm)
621-0249
10
5/8” (15.8mm)
621-0250*
10 H.D.
5/8” (15.8mm)
621-0251
12 H.D.
3/4” (19.0mm)
621-0252
N/A
Tip Extender
621-0424
*Standard - furnished with gun
Gun Barrel Liners
Prince® XL Gun Barrel Liners
Barrel P/N
003-2152
--
Description
Part No.
Curved, air cooled, steel wire only .030”-.065”
(.8-1.6mm)
615-0343
Teflon liner package, 5 pieces
931-0137
Prince® XL/Spool Gun Owner's Manual - Page 6
Barrel Assemblies
Standard 003-2151
225 Amp, Air Cooled
Standard 003-2152
225 Amp, Air Cooled
Optional 6”, 12” and 18” Straight and Curved
Barrel Assemblies
6” Straight Air Cooled Barrel Assembly.............................................. 003-2151
6” Curved 45° Air Cooled Barrel Assembly......................................... 003-2152
12” Straight Air Cooled Barrel Assembly ........................................... 003-2332
12” Curved Air Cooled Barrel Assembly............................................. 003-2333
18” Straight Air Cooled....................................................................... 003-2334
18” 45° Air Cooled.............................................................................. 003-2335
Optional Kits
Insulated drive roll kits are used to prevent preheating of the wire which may
soften it and clog the liner. This picking up of current at the drive rolls rather
than at the contact tip is usually not a problem unless using too large of a
contact tip or excessively oxidized aluminum wire.
Insulated Groove Drive Roll Kit....................................................... 005-0640
For .030" (0.8mm) dia. aluminum wire.
Includes insulated groove drive roll and insulated idler roll assy.
Insulated Groove Drive Roll Kit....................................................... 005-0716
For .035" (0.9mm) dia. aluminum wire.
Includes insulated groove drive roll and insulated idler roll assy.
Insulated Groove Drive Roll Kit....................................................... 005-0717
For .040" (1.0mm)dia. aluminum wire.
Includes insulated groove drive roll and insulated idler roll assy.
Insulated Groove Drive Roll Kit....................................................... 005-0718
For .045" (1.2mm) dia. aluminum wire.
Includes insulated groove drive roll and insulated idler roll assy.
Insulated Groove Drive Roll Kit....................................................... 005-0644
For .062" (1.6mm) dia. aluminum wire.
Includes insulated groove drive roll and insulated idler roll assy.
Prince® XL Handle Kit....................................................................... 005-0633
Includes left and right handle with door, trigger and pin,and all handle screws.
Spool Adapter Kit............................................................................. 005-0632
Includes left and right handle with door, trigger and pin, and all handle
screws. Used to change a standard 313-xxx series Prince® XL gun into a
spool gun.
Barrel Insulator Kit........................................................................... 005-0696
Heavy Duty Spool Gun Brake Spring for Hardwires..................... 005-0682
25’ 7 Pin Amphenol Extension Cable.............................................. 005-0660
Used to extend the spool gun. Two cables may be joined together for 50’
extension. Power & gas cables not included.
Prince® XL/Spool Gun Owner's Manual - Page 7
Optional Accessories
Conduits
Flat Spiral Steel Conduit for steel and cored wire
15ft./4.5m............................................................................................ 615-0208
25ft./7.6m............................................................................................ 615-0216
35ft./10.7m.......................................................................................... 615-0218
50ft./15.2m.......................................................................................... 615-0219
Snake Skin Zipper Cover
Leather Snake Skin protective covers are now standard on all guns. You
may order replacement covers to protect the lead assembly of the gun when
the original factory cover becomes damaged or worn. The Velcro® closure
makes it easy to replace in the field.
13' cover fits 15' lead............... 931-0110
23' cover fits 25' lead............... 931-0122
33’ cover fits 35’ lead............... 931-0132
48’ cover fits 50’ lead............... 931-0123
Gas Valve Removal Tool
Gas valve removal is performed by using P/N 931-0105 Gas Valve Removal
Tool. This multifunctional tool has been slotted on one side to encompass
and conform to the gas valve stem and seat into the slotted gas valve body
as seen in Figures 1 and 2. Removal of the gas valve can be accomplished
by turning the gas valve tool counter clockwise. Reinstall by turning clockwise. The tool doubles as a bottle opener.
Gas Valve Removal Tool
Figure 1
Figure 2
Prince® XL Spool Gun Controls
WC-1
P/N 001-3062
The WC-1 is desinged to hookup to any CV or CC
power supply having its own contactor. CC Posa Start
“run-in speed” is included as a standard feature. The
control operates on 115VAC, 50-60hz power. For
machines such as gas drives that do not have contactors, the MK200 Contactor Box (P/N 001-3066) must be
used.
WC-1
MK200 Contactor Box
P/N 001-3066
MK200 Contactor Box
PA-L1 Spool Gun Control - Lincoln
P/N 005-0676
Connects directly to Lincoln Electric power supplies (42V
system) with 14-Pin (X-clocked) amphenol
connectors, such as:
CV 250
CV 655
DC 655
Range 275
CV 300
DC 400
V350-Pro (factory model)
Ranger 305G
CV 400
DC 600
Ranger 250
Prince® XL/Spool Gun Owner's Manual - Page 8
Spool Gun Control - Lincoln
PA-M1 Spool Gun Control - Miller
P/N 005-0261
Connects directly to Miller power supplies (24V system)
that are classified with 14-Pin amphenols as type 6 or 9
and to Thermal Arc units, such as:
MILLER SUPPLIES
Millermatic 200 Deltaweld's
Shopmaster
CP Series
XMT's & Maxtron Trailblazer 250, 251
Regency's
Spool Gun Control - Miller
THERMAL ARC
Thermal Arc 300GMS CC/CV
Fabricator 210, 250, 300 LF
Any Gas-drive that has a CV tap and contactor installed with a 14 pin amphenol.
PA-G1 Spool Gun Control - Generic
P/N 005-0264
This Generic Torpedo is designed to hook-up to CV
power supplies that supply an auxiliary 26 VAC @ 1.7
amps and uses a closing contact signal. The unit is
supplied with bare wires that must be connected to the
power supply. Some examples of power supplies that
can be hooked-up are:
Spool Gun Control - Generic
Lincoln SP-250, 255 & Wirematic 250 & 255
Beta-Mig 200 & Beta-Mig LF
Airco Dip-Pak 200, 225 & 250
ESAB (L-TEC) / MigMaster 250
P/N 005-0206
An amphenol adaptor cable and gas/power lug
are all that is needed to connect to the Migmaster.
Adaptor kit includes everything needed.
ESAB (L-Tec-Linde) MigMaster 250
MillerMatic 250 & Vintage / Hobarts BetaMig 2510
P/N 005-0205
This easy to install, plug in module fits the Millermatic 250, Miller
Vintage machine, or Hobart Betamig 2510. It and a Prince® Spool
Gun are all that is needed to get your customer up and running.
MillerMatic 250, Vintage
and BetaMig 2510
Panasonic Gunslinger 260
P/N 005-0617
Easy to install adapter cable using Gunslinger speed
control.
Panasonic Gunslinger 260
ESAB MigMaster 251
P/N 005-0624
A panel kit plugs directly into the front of the MigMaster
251 and includes everything that is needed to interface the
spool gun.
ESAB MigMaster 251
MillerMatic 250X/251
P/N 005-0629
Easy to install adapter cable using MillerMatic 250X
speed control. Reference Tech Bulletin TB 2112
found at mkproducts.com for Millermatic/Prince XL
spool gun compatibility.
MillerMatic 250X &
Fabricator 250
Fabricator 250
P/N 005-0689
Easy to install adapter cable using Thermal Arc Fabricator 250.
Prince® XL/Spool Gun Owner's Manual - Page 9
NOTE: For further information on spool gun adaptability, see the weld
control selector guide or contact MK Products.
Section D Maintenance
Maintenance of the gun will normally consist of a general cleaning of the wire
guide system, including tubes, drive rolls, and conduit at regular intervals.
Remove spatter build-up from inside of nozzles with a hardwood stick.
The only parts on the gun that are subject to normal wear are the conduit,
contact tips, gas cups, drive and idler rolls and barrel liners. A supply of
those parts should be maintained on hand.
If repairs do become necessary, qualified shop maintenance personnel can
easily replace any parts.
Your Cobramatic® system is designed to provide years of reliable service.
Normal wear and component failure may require occasional service.
The number of units in operation and the importance of minimal “down time”
will determine to what extent spare parts should be stocked on hand. See
the “Recommended Spart Parts List” for the mose commonly replaced parts.
Maintenance Tools
Tool
Part Number
Gas Valve Removal Tool
Contact Tip Removal Tool
Drive Roll Removal Tool
931-0105
931-0002
931-0100
Recommended Spart Parts List
Part Number
Description
615-0601-15
615-0601-25
615-0601-35
615-0601-50
005-0661
003-0568
005-0633
511-0101
005-0686
325-0206
333-0082
003-0585
431-3117
003-0198
003-2072
003-2071
Conduit 15’
Conduit 25’
Conduit 35’
Conduit 50’
Potentiometer Kit
Micro Switch
Handle Kit
Drive Roll
Idler Roll Kit
Idler Roll Screw
Idler Roll Washer
Trigger Assy
Door
Wire Guide-Spool Gun
Brake Assy - Spool Gun
Cover Assy - Spool Gun
Idler Roll
005-0686
Drive Roll
511-0101
Micro Switch Assy
(switch with leads)
003-0568
Prince® XL/Spool Gun Owner's Manual - Page 10
Section E
Troubleshooting
All MK Products push-pull guns operate on the same principle. The 115
VAC or 42VAC slave motor in the feeder runs at a fast, constant speed, but
has very low torque; it is always trying to feed more wire than the gun motor
wants, and when the gun motor gets all it wants, it slows the slave motor,
preventing a bird’s nest. Because of the low torque produced by the slave
motor, a brake system is used to prevent wire overrun rather than tension.
The drag adjustment in the spindle is used simply to keep the wire slightly
taut, so it will not unspool while feeding wire.
The 24 VDC gun motor is controlled by a solid state speed control and a
pot located in the gun. The gun motor, potentiometer, and micro switch are
connected to the cabinet/control box via a control cable and an amphenol
connector. If this cable becomes damaged, a variety of symptoms can occur,
depending on which wire(s) break. To test, check each wire for continuity
and shorts.
With the increased torque rating in the current Prince® XL motor, P/N 2110071, it now draws about twice as much current on start-up as the original
Prince® motors P/N’s 211-0054 & 211-0056. Even though the duration of
start-up is very short, about 15msec, it is too much for the standard 2A fuse
to handle. For this reason, all 2A fuses in the motor circuitry (F1) should be
changed to a 3AG 4A fast blow 250V fuse, P/N 151-0043. This new 4A fuse
is sufficient for use on all model welding guns on the wire feeders, while still
providing protection for the circuitry from any shorts in the motor or motor
leads.
This fuse change includes all Cobramatic, Cobramatic II and CobraMig
250/260, WC-1, Torpedo’s, and any other motor circuits powering Prince® XL
or Spool Guns using motor P/N 211-0071.
Remember the micro switch in the gun activates both the 115 VAC or 42
VAC and 24 VDC circuits in the cabinet. Therefore, if the slave motor and
brake solenoid operate, but the gun does not, look more toward the 24 VDC
circuits, speed control, control cable, or the gun motor. If nothing operates,
look more toward the 115 VAC or 42 VAC input, micro switch leads, or micro
switch.
Prince® XL/Spool Gun Owner's Manual - Page 11
Troubleshooting Guide
Trouble
No wire feed at gun,
feeder not operating,
i.e. no slave motor or
brake solenoid
No wire feed at gun,
feeder operating
properly.
Wire feeds, but
welding wire is not
energized.
Remedy
Cause
115/42 VAC control fuse
in feeder.
Replace fuse.
Micro-switch defective/
not being activated.
Replace switch. Check switch for
operation.
Broken electrical cable.
Check micro-switch wires for continuity.
4 amp fuse (F1) in
feeder/Control box
blown.
Check motor leads for shorts, then
replace fuse.
Bad potentiometer.
Check potentiometer with meter.
Broken electrical cable.
Check motor and potentiometer wires for
continuity.
Bad speed control/PCB.
See specific cabinet/control box owners
manual for speed control operation.
Loose or no cable
connections.
Check all power connections.
Contactor control cable
loose or in wrong
position.
Check power supply owners manual
for location and type of contactor signal
required, i.e., closing or 115 VAC.
Welding power source.
Check power source manual.
Dirty or worn conduit.
Blow out or replace conduit.
Incorrect pressure on
drive rolls.
Adjust pressure at both feeder and gun.
Idler roll stuck.
Check for lock washer under idler roll, or
replace if damaged.
Wrong size contact tip.
See contact tip table.
Bad potentiometer.
Check with meter.
Broken electrical cable.
Check potentiometer wires for continuity
or short.
Bad speed control
See specific cabinet/control owners
manual for speed control operation.
Idler roll upside-down.
Place groove in idler roll toward top.
Rear wire guide missing.
Replace wire guide.
Incorrect placement of
barrel insulator.
To replace a barrel assembly, push the
barrel assembly into the gun body until it
clicks to a stop. To assure proper seating
of the barrel, open the drive/idler roll door
in the top of the handle. the rear face of
the barrel should now be flush with the
gun body.
Wire feeds erratically.
Wire feeds one
speed only.
Wire walks out of
drive rolls.
Poor gas/water flow.
Prince® XL/Spool Gun Owner's Manual - Page 12
Testing The Gun
Motor Check
Remove the gun connector from the cabinet.
Using the gun Amphenol, check the resistance across pins “A” and “B”
(motor leads). The resistance across the motor should be between 5-10
ohms.
If an open circuit or short exist, check the motor leads and motor
independently.
Testing the Potentiometer
Using the gun Amphenol, check the resistance across pin “D” (wiper) and pin
“C”. The resistance should vary from 0 - 5K ohms.
Check the resistance across pin “D” (wiper) and pin “G”. The resistance
should vary from 5K - 0 ohms.
Testing the Micro Switch
Using the gun Amphenol, check for continuity across pins “E” and “F” when
the trigger is pressed.
E
F
D
G
A
C
B
"W" Clocked
Amphenol Connector
Viewed from front of connector
Prince® XL/Spool Gun Owner's Manual - Page 13
THIS PAGE INTENTIONALLY BLANK
Section F
Prince® XL/Spool Gun Diagrams/Parts List
Exploded View...........................................................................16
Head Body, Exploded View........................................................17
Spool Gun, Exploded View........................................................18
Straight Barrel Assembly............................................................19
Curved Barrel Assembly............................................................20
Spool Assembly, Exploded View................................................21
Lead Assembly...........................................................................22
Spool Gun Lead Assembly.........................................................23
Electrical.....................................................................................24
Prince® XL/Spool Gun Owner's Manual - Page 15
Part No.
001-1143
001-1144
001-1276
001-1145
Prince® XL/Spool Gun Owner's Manual - Page 16
Description
15ft
25ft
35ft
50ft
Lead Assembly
No. Qty.
1
1
1
1
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
1
1
1
1
1
1
7
1
1
1
3
4
2
2
2
2
1
1
1
1
1
1
1
1
1
1
1
1
No. Qty.
437-0237 Spacer Handle PXL
511-0101 Drive Roll Gold
751-0020 Cap Plug 0.218 ID x 0.50 LG
Assy Potentiometer PXL
Assy Trigger PXL
Assy Body PXL
Clamp Leads PXL
Assy Barrel Str A/W PXL
Pin
Connector Molex 2 Pos
Connector Molex 5 Pos
Motor
Screw Shc 4-40 x 0.50
Wshr Spr Lk #4
Wshr Spr Lk #6
Screw Pnhd Ph 4-40 x 0.625 St
Screw Pnhd Ph 4-40 x 1.50 St
Screw Pnhd Ph 6-32 x 1.50
Label Serial Number
Tie Wrap
Pin Dowel 0.093 x 2.00 LG
Pin Dowel 0.093 x 1.25 LD
Door PXL
Spring Door PXL
Handle Kit: Includes line items
005-0633 3,12,13,14,15,16,20,23,24,25
Lead
Description
Exploded View
Part No.
REF
TABLE
005-0661
003-0585
003-1972
003-1974
003-2151
153-0852
153-0856
153-0857
211-0071
328-0003
333-0003
333-0005
336-0049
336-0056
336-0070
405-0706
411-0045
421-0408
421-0409
431-3117
435-3124
Prince® XL Exploded View
Prince XL/Spool Gun Head Body, Exploded View
P/N 003-1972
®
APPLY PIPE SEALANT TO MALE
PIPE THREADS
Note: If Cobramatic Wire Feeder is
equipped with a gas solenoid kit, a
modified gas valve stem (p/n 431-1080)
must be installed in gun to allow gas flow
from cabinet valve.
Head Body
Items #2, 5, & 11 can
be purchased as a kit,
P/N 005-0686
No. Qty. Part No.
Description
1
1
431-2013 Wire Guide
2
1
333-0082 Washer, #10 Split Lock
3
1
419-0020 Spr. Comp., 0.29 OD x 0.047
4
1
321-1074 Set Screw, Mod 6-32 x 1/2
5
1
325-0206 Scr, Pnh, Sltd, 10-24 x 3/8
6
-7
-8
1
431-1427 Pin, Pivot
9
1
421-0129 Pin, Spring, 0.063 x 0.437
10 1
003-0568 Micro Switch Assy
11
1
511-0001 Idler Roll, Cobra
12 1
431-1424 Idler Arm
13 1
001-0562 Gas Valve, Cobra
14 2
431-1886 Ftg, 3/16 Hose, 1/16-27NPT
15 1
313-0008 E-ring, Int 0.188
16
--17
-Not Available Separately
18 1
002-0583 Adjust Screw, Idler Arm
Prince® XL/Spool Gun Owner's Manual - Page 17
Spool Gun Assembly
No.Qty. Part No.
Description
1 1 001-1317 Lead 25ft Spool Gun 7W
1 1 001-1318 Lead 50ft Spool Gun 7W
2 1 003-0567 Assy potentiometer
3 1 003-0585 Assy Trigger
4 1 003-1972 Assy Body
5 1 003-1974 Clamp Leads
6 1 003-2021 Assy Spool (see break down)
7 1 003-2151 Assy Barrel Str A/W
8 7 153-0852 Pin
9 1 153-0856 Connector Molex 2 Pos
10 1 153-0857 Connector Molex 5 Pos
11 1 211-0071 Motor
12 3 328-0003 Screw Shc 4-40 x 0.50
13 4 333-0003 Wshr Spr Lk #4
14 2 336-0049 Screw Pnhd Ph 4-40 x 0.625 St.
15 2 336-0056 Screw Pnhd Ph 4-40 x 1.50 St.
16 1 405-0706 Label Serial Number
17 1 411-0045 Tie Wrap
Handle Kit: Includes line items
18 1
005-0633 3,12,13,14,15,16,20,23,24,25
19 1
20 1 431-3117 Door
21 1 435-3124 Spring Door
22 1 436-0136 Handle Right SS
23 1 436-0137 Handle Left SS
24 1 511-0101 Driveroll Gold
25 1 751-0020 Cap Plug
Prince XL Spool Gun Assembly
®
Prince® XL/Spool Gun Owner's Manual - Page 18
Prince XL/Spool Gun Straight Barrel Assembly
P/N 003-2151
®
Straight Barrel Assembly
No.
Qty.
Part No.
1
1
-
Not Available Separately
2
1
-
Not Available Separately
Description
3
4
303-0010
O-Ring 0.489 ID x 0.629 OD
4
2
303-0094
O-Ring 0.301 ID x 0.070 Width
5
1
931-0137
Teflon Liner Package, 5 pieces
6
1
621-0250
Assy Cup Copper Finned #10
7
1
621-0393
Tip Hd Spray 0.060 ID
8
-
-
-
9
1
005-0696
Insulator Replacement Kit: Includes items 2, 9,10
10
1
431-1774
Cup Insulator
11
1
313-0091
Retaining Ring 5/8 Shaft
Prince® XL/Spool Gun Owner's Manual - Page 19
Prince XL/Spool Gun Curved Barrel Assembly
P/N 003-2152
®
Curved Barrel Assembly
No. Qty.
Part No.
Description
1
1
-
Not Available Separately
2
1
-
Not Available Separately
3
4
303-0010
O-Ring 0.489 ID x 0.07 W
4
2
303-0094
O-Ring 0.301 ID x 0.07 W
5
1
931-0137
Teflon Liner Package, 5 pieces
6
1
621-0250
Assy Cup Cpr Finned #10
7
1
621-0393
Tip Hd Spray 0.060 ID
8
-
-
9
1
10
11
-
005-0696
Insulator Replacement Kit:
Includes items 2, 9,10
1
431-1774
Cup Insulator
1
313-0091
Retaining Ring 5/8 Shaft
Prince® XL/Spool Gun Owner's Manual - Page 20
Prince XL 1 lb Spool Assembly
P/N 003-2021
®
Spool Gun Assembly
No.
Qty.
Part No.
1
1
437-0235
Spindle
2
1
003-2072
Assy Brake
2
REF
005-0682
HD Brake Spring for Hard Wires (optional)
3
1
003-2071
Assy Cover
4
2
336-0073
Scr pan Hd Phil 6-32 x 2.00 St
5
2
333-0005
Washer Split #6
6
1
003-0198
Wire Guide
Description
Prince® XL/Spool Gun Owner's Manual - Page 21
Prince XL Lead Assembly
®
Lead Assembly
Length
#2 Power
Cable
Conduit
Electrical
Cable
Gas Hose
Snake Skin
15’/4.6m
615-0601-15
001-2527
005-0268
001-0537
931-0110
25’/7.6m
615-0601-25
001-2528
005-0269
001-0538
931-0122
35’/10.7m
615-0601-35
001-3812
005-0307
552-0181
931-0132
50’/15.2m
615-0601-50
001-1042
005-0272
001-0665
931-0123
Prince® XL/Spool Gun Owner's Manual - Page 22
Prince XL Spool Gun Lead Assembly
®
Spool Gun Lead Assembly
Length
#2 Power Cable
Electrical Cable
Gas Hose
Snake Skin
25’/7.6m
843-0484
005-0269
552-0202
931-0122
50’/15.2m
843-0485
005-0272
552-0203
931-0123
Prince® XL/Spool Gun Owner's Manual - Page 23
Prince XL/Spool Gun
Electrical Schematic/ Connector Pinout
®
E
F
D
G
A
C
B
"W" Clocked
Amphenol Connector
Viewed from front of connector
5 Pin Female Connector
P/N 153-0857
5 Pin Male Connector
P/N 153-0855
Electric Cable
Female pins (7 total)
P/N 153-0853
Male pins (7 total)
P/N 153-0852
2 Pin Female Connector
P/N 153-0856
Cabinet End
Amphenol Connector
Torch Connectors
Inside Handles
Torch Lead
A
B
G
D
C
E
F
2 Pin Male Connector
P/N 153-0854
Red
Pin 1
Torch Functions
Pin 1
Black
Red
White
Grey
Green
Grey
Blue
Grey
Brown
-
+
Grey
Pin 1
Pin 1
Yellow/Orange
Prince® XL/Spool Gun Owner's Manual - Page 24
1
5K
TORCH
MOTOR
3
2
TORCH
POT
Red
Red
TORCH
TRIGGER
LIMITED WARRANTY
Effective August 1, 2008
This warranty supersedes all previous MK Products warranties and is
exclusive, with no other guarantees or warranties expressed or implied.
LIMITED WARRANTY - MK Products Inc., Irvine, California warrants
that all new and unused equipment furnished by MK Products is free
from defects in workmanship and material as of the time and place of
delivery by MK Products. No warranty is made by MK Products with
respect to trade accessories or other items manufactured by others.
Such trade accessories and other items are sold subject to the warranties of their respective manufacturers, if any.
MK Products’ warranty does not apply to components having normal
useful life of less than one (1) year, such as relay points, wire conduit,
tungsten, and welding gun parts that come in contact with the welding
wire, including gas cups, gas cup insulators, and contact tips where
failure does not result from defect in workmanship or material.
MK Products shall, exclusively remedy the limited warranty or any
duties with respect to the quality of goods, based upon the following
options:
(1) repair
(2) replacement
(3) where authorized in writing by MK Products, the reasonable cost
of repair or replacement at our Irvine, California plant.
As a matter of general policy only, MK Products may honor an original
user’s warranty claims on warranted equipment in the event of failure
resulting from a defect within the following periods from the date of
delivery of equipment to the original user:
1. Power Supplies and Wire Feed Cabinets ..................3 years
2. Weldheads, CobraCooler, Positioners, Prince XL and
Prince XL Spool Guns, Python, CobraMAX, Cobra SX,
Cobra MX ....................................................................1 year
3. Sidewinder Spool Gun, Prince SG Spool Guns, Modules ......
............................................................................... 180 days
4. Repairs/Exchanges/Parts/Accessories .................. 90 days
16882 Armstrong Ave.
Irvine, CA 92606
Tel (949) 863-1234
Fax (949) 474-1428
www.mkproducts.com
16882 Armstrong Ave.
Irvine, CA 92606
Tel (949)863-1234
Fax (949)474-1428
www.mkproducts.com
Classification of any item into the foregoing categories shall be at the
sole discretion of MK Products. Notification of any failure must be made
in writing within 30 days of such failure.
A copy of the invoice showing the date of sale must accompany products
returned for warranty repair or replacement.
All equipment returned to MK Products for service must be properly
packaged to guard against damage from shipping. MK Products will
not be responsible for any damages resulting from shipping.
Normal surface transportation charges (one way) for products returned
for warranty repair or replacement will be borne by MK Products, except
for products sold to foreign markets.
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED
WARRANTY, GUARANTY, OR REPRESENTATION AS TO PERFORMANCE,
AND ANY REMEDY FOR BREACH OF CONTRACT WHICH, BUT FOR
THIS PROVISION, MIGHT ARISE BY IMPLICATION, OPERATION OF
LAW, CUSTOM OF TRADE, OR COURSE OF DEALING, INCLUDING ANY
IMPLIED WARRANTY OF MERCHANTABILITY OR OF FITNESS FOR
PARTICULAR PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT
FURNISHED BY MK PRODUCTS, IS EXCLUDED AND DISCLAIMED BY
MK PRODUCTS.
EXCEPT AS EXPRESSLY PROVIDED BY MK PRODUCTS IN WRITING,
MK’s PRODUCTS ARE INTENDED FOR ULTIMATE PURCHASE BY COMMERCIAL/INDUSTRIAL USERS AND FOR OPERATION BY PERSONS
TRAINED AND EXPERIENCED IN THE USE AND MAINTENANCE OF
WELDING EQUIPMENT AND NOT FOR CONSUMERS OR CONSUMER
USE. MK PRODUCTS’ WARRANTIES DO NOT EXTEND TO, AND NO
RE-SELLER IS AUTHORIZED TO EXTEND MK PRODUCTS’ WARRANTIES
TO ANY CONSUMER.
USE OF OTHER THAN GENUINE MK PRODUCTS’
CONSUMABLES, PARTS, AND ACCESSORIES MAY INVALIDATE YOUR
PRODUCT WARRANTY.
August 1, 2008
Rev. A
August 1, 2008
Rev. A
www.mkproducts.com
16882 Armstrong Ave..
Irvine, California 92606
Tel (949) 863-1234 Fax (949) 474-1428