Operation Manual - Weld Revolution

Operation Manual - Weld Revolution
Weld Revolution LLC
19511 Wied Rd Ÿ Suite E Ÿ Spring Ÿ TX 77388 Ÿ USA
Phone: +1-832-585-1244 Ÿ Fax: +1-832-585-1109 Ÿ [email protected]
www.weldrevolution.com
Operation Manual
Model #:
MA-400TM
A ir-C o o le d , M e ch a n ize d
SpinArc T M Welding Torch
Patents Pending
Operation Manual
MA-400, Machine Air-Cooled
SpinArcTM Welding Torch
Doc #: OM-MA-400-07
Revision 1.7 1-28-2016
Thank You for Choosing Weld Revolution®
Thank you for selecting a Weld Revolution product. The SpinArcTM welding torch you have purchased is a
breakthrough in new technology that has been carefully assembled and is ready to weld. Each torch is factory
tested prior to shipment to ensure high performance. Before installing, compare the equipment received
against the invoice to verify that the shipment is complete and undamaged. It is the responsibility of the
purchaser to file all claims of damage or loss that may have occurred during transit with the carrier.
This Operation Manual contains general information, instructions and maintenance to help better maintain
your specialized SpinArc welding torch. Please read, understand and follow all safety precautions.
While every precaution has been taken to assure the accuracy of this owner’s manual, Weld Revolution
assumes no responsibility for errors or omissions. Weld Revolution assumes no liability for damages resulting
from the use of information contained herein. The information presented in this owner’s manual is accurate to
the best of our knowledge at the time of printing. Please reference weldrevolution.com for updated material.
For customer support and special applications, please call the Weld Revolution Customer Service Team at +1832-585-1244 or email us at [email protected] Our trained Customer Service Team is available
Monday – Friday, between 8:00 a.m. and 5:00 p.m. CST, and will answer your product application or repair
questions.
For more information on other Weld Revolution products visit us on the web at weldrevolution.com. For
additional support materials such as spec sheets, troubleshooting information, how-to guides and videos,
animations, online configurators and much more, please visit weldrevolution.com.
Serial Number: ________________________________
Date of Purchase: _____________________________
The serial number can be found on the body of the torch under the lower cap.
Subject to Change – The information presented in this manual is accurate to the best of our knowledge at the time of
printing. Please visit weldrevolution.com for the most up-to-date information.
Page 2 of 28
C o n te n ts
SAFETY PRECAUTIONS – READ BEFORE USING ....................................................................................................................4
Introduction ................................................................................................................................................................................ 10
How it Works ............................................................................................................................................................................... 10
What’s Included .......................................................................................................................................................................... 10
Available Models ........................................................................................................................................................................ 10
Additional Required Parts ....................................................................................................................................................... 10
Optional Accessories ................................................................................................................................................................ 10
Consumables & Replacement Parts .................................................................................................................................... 10
Specifications ............................................................................................................................................................................. 11
Installation ................................................................................................................................................................................. 12
Operation .................................................................................................................................................................................... 14
Control Box Settings ................................................................................................................................................................. 14
Torch Adjustments .................................................................................................................................................................... 15
Application Notes ....................................................................................................................................................................... 17
Consumables .............................................................................................................................................................................. 18
Contact Tips ................................................................................................................................................................................. 18
Nozzles .......................................................................................................................................................................................... 18
Wire Liners ................................................................................................................................................................................... 18
Replacement Parts ................................................................................................................................................................... 19
Control Cables ............................................................................................................................................................................ 20
Contact Tip Extension .............................................................................................................................................................. 20
Replacement Cable Assembly .............................................................................................................................................. 20
Power Pins .................................................................................................................................................................................... 21
Maintenance ............................................................................................................................................................................. 22
Wire Liners .................................................................................................................................................................................. 22
Shielding Gas Nozzles ............................................................................................................................................................. 22
Flexure Nuts ................................................................................................................................................................................ 22
Flexure Replacement ................................................................................................................................................................23
Optional Accessories & Parts ................................................................................................................................................23
Hand Welding Kit ........................................................................................................................................................................23
Control Box Mounting Kit ........................................................................................................................................................23
Heat Shield ...................................................................................................................................................................................23
Flexure Nut Tool .........................................................................................................................................................................23
Control Box Bump Guard .........................................................................................................................................................23
O-Ring Kit ......................................................................................................................................................................................23
Trouble Shooting ..................................................................................................................................................................... 24
Limited Warranty ...................................................................................................................................................................... 27
Service ........................................................................................................................................................................................... 27
Page 3 of 28
S A F E T Y P R E C A U T IO N S – R E A D B E F O R E U S IN G
Welding is not particularly hazardous when certain safety practices are followed. Everyone using this
equipment should be thoroughly trained in safe welding practices. Failure to observe safe practices may cause
serious injury.
Handling welding torches presents no danger if the
appropriate safety regulations are strictly adhered
to. For example:
• Starting procedures must be reserved for those
fully conversant with processes relating to arc
welding equipment.
• Arc welding can prove damaging to eyes, skin, and
hearing! It is therefore imperative that both
management and operators understand and follow
the ANSI Standard Z49.1, SAFETY IN WELDING AND
CUTTING. All Personal Protective Equipment (PPE)
shall be in place in accordance with this referenced
specification and all other applicable and governing
regulations.
• The operating data provided in the Specifications
are maximum values. Overloading the welding
torch will inevitably damage the product and void
any and all warranties.
• Before changing any parts on the torch or control
box, disconnect the torch from the welding power
source and disconnect the control box input power
source. Unplug the control box from the electrical
outlet.
• The operating instructions for all other welding
components - e.g. power source, wire feed and
cooling unit must be followed per the
manufacturer’s recommendations.
• Never pull the cable assembly across sharp edges
or set down on a hot surface.
• Never move the torch by pulling or dragging by the
welding torch or cable.
• Curtains or partitions shall be installed to protect
other workers or observers from arc radiation.
• When handling gas cylinders, consult the
instructions issued by the manufacturers and the
suppliers of the pressurized gas.
• Work pieces that have been degreased using
chlorinated solvents must be sprayed down with
clean water before welding starts to avoid the risk
of phosgene forming. For the same reason, no
degreasing baths containing chlorine must be
placed close to the welding point.
• All vapors given off by metals can cause harm and
a special warning is attached to lead, cadmium,
copper, zinc, and beryllium. Take appropriate
precautions to ensure that the legal maximum
levels of toxic concentrations are not exceeded.
Page 4 of 28
• Do not touch the welding torch with bare skin until
it has had adequate time to cool down.
• Wait to adjust the rotation diameter until the torch
has cooled to room temperature.
Fume and Gases
FUMES AND GASES can be
hazardous. Welding and cutting
produces
fumes
and
gases.
Breathing these fumes and gases
can be hazardous to your health.
• Keep your head out of the fumes. Do not breathe
the fumes.
• If inside, ventilate the area and/or use local forced
ventilation at the arc to remove welding and cutting
fumes and gases. The recommended way to
determine adequate ventilation is to sample for the
composition and quantity of fumes and gases to
which personnel are exposed.
• If ventilation is poor, wear an approved air-supplied
respirator.
• Read and understand the Safety Data Sheets (SDSs)
and the manufacturer’s instructions for adhesives,
coatings,
cleaners,
consumables,
coolants,
degreasers, fluxes and metals.
• Work in a confined space only if it is well ventilated,
or while wearing an air-supplied respirator. Always
have a trained watch-person nearby. Welding
fumes and gases can displace air and lower the
oxygen level causing injury or death. Be sure the
breathing air is safe.
• Do not weld or cut in locations near degreasing,
cleaning, or spraying operations. The heat and rays
of the arc can react with vapors to form highly toxic
and irritating gases.
• Do not weld or cut 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 while wearing an airsupplied respirator. The coatings and any metals
containing these elements can give off toxic fumes
if welded.
Arc Rays
ARC RAYS can burn eyes and skin.
Arc rays from welding and cutting
processes produce intense visible
and invisible (ultraviolet and
infrared) rays that can burn eyes
and skin. Sparks fly off from the weld.
• Wear an approved welding helmet fitted with a
proper shade of filter lenses to protect your face
and eyes from arc rays and sparks when welding,
cutting, or watching (see ANSIZ49.1 and Z87.1 listed
in Safety Standards).
• Wear approved safety glasses with side shields
under your helmet.
• Use protective screens or barriers to protect others
from flash, glare and sparks; warn others not to
watch the arc.
• Wear body protection made from durable, flame
resistant material (leather, heavy cotton, wool).
Body protection includes oil-free clothing such as
leather gloves, heavy shirt, cuffless trousers, high
shoes and a cap.
Welding and Cutting
Welding or cutting on closed
containers such as tanks, drums or
pipes, can cause them to blow up.
Sparks can fly off from the welding
or cutting arc. The flying sparks,
hot work piece and hot equipment can cause fires
and burns. Accidental contact of electrode to metal
objects can cause sparks, explosion, overheating or
fire. Check and be sure the area is safe before doing
any welding or cutting.
• Remove all flammables within 35 ft. (10.7 m) of the
welding or cutting arc. If this is not possible, tightly
cover them with approved covers.
• Do not weld or cut where flying sparks can strike
flammable material.
• Protect yourself and others from flying sparks and
hot metal.
• Be aware that welding sparks and hot materials
from welding and cutting can easily go through
small cracks and openings to adjacent areas.
• Watch for fire, and keep a fire extinguisher nearby.
• Be aware that welding or cutting on a ceiling, floor,
bulkhead or partition can cause fire on the hidden
side.
• Do not weld or cut on containers that have held
combustibles, or on closed containers such as
tanks, drums, or pipes unless they are properly
prepared according to AWS F4.1 and AWS A6.0 (see
Safety Standards).
• Do not weld or cut where the atmosphere may
contain flammable dust, gas, or liquid vapors (such
as gasoline).
• Connect work cable to the work as close to the
welding or cutting area as practical to prevent
welding or cutting current from traveling long,
possibly unknown paths and causing electric shock,
sparks and fire hazards.
• Do not use welder to thaw frozen pipes.
• Remove stick electrode from holder or cut off
welding wire at contact tip when not in use.
• Remove any combustibles, such as a butane lighter
or matches, from your person before doing any
welding or cutting.
• After completion of work, inspect area to ensure it
is free of sparks, glowing embers, and flames.
• Use only correct fuses or circuit breakers. Do not
oversize or by-pass them.
• Follow requirements in OSHA 1910.252 (a) (2) (iv)
and NFPA 51B for hot work and have a fire watcher
and extinguisher nearby.
• Read and understand the Safety Data Sheets (SDSs)
and the manufacturer’s instructions for adhesives,
coatings,
cleaners,
consumables,
coolants,
degreasers, fluxes and metals.
Electric Shock
Touching live electrical parts can
cause fatal shocks or severe burns.
The electrode and work circuit is
electrically live whenever the output
is on. The input power circuit and
machine internal circuits are also live
when power is on. In gas metal arc
welding (GMAW), 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.
• Do not touch live electrical parts.
• Wear dry, hole-free insulated gloves and body
protection.
• Insulate yourself from work and ground using dry
insulating mats or covers big enough to prevent any
physical contact with the work or ground.
• Do not use AC output in damp areas, if movement is
confined, or if there is danger of falling.
• Use AC output ONLY if required for the welding or
cutting process.
• If AC output is required, use remote output control
if present on unit.
• Additional safety precautions are required when
any of the following electrically hazardous
Page 5 of 28
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
conditions are present: in damp locations or while
wearing wet clothing; on metal structures such as
floors, gratings or scaffolds; when in cramped
positions such as sitting, kneeling or lying; or when
there is a high risk of unavoidable or accidental
contact with the workpiece or ground. For these
conditions, use the following equipment in order
presented: 1) a GMAW DC constant voltage (wire)
welder, 2) a DC manual (stick) welder or 3) an AC
welder with reduced open circuit voltage. In most
situations, use of a DC, constant voltage wire
welder is recommended. And, do not work alone!
Disconnect input power or stop engine before
installing or servicing equipment. Lockout/tagout
input power according to OSHA 29 CFR 1910.147 (see
Safety Standards).
Properly install, ground, and operate this
equipment according to its Owner’s Manual and
national, state/provincial and local codes.
Always verify the supply ground – check and be
sure that input power cord ground wire is properly
connected to ground terminal in disconnect box or
that cord plug is connected to a properly grounded
receptacle outlet.
When making input connections, attach proper
grounding conductor first and double-check
connections.
Keep cords dry, free of oil and greases and
protected from hot metal and sparks.
Frequently inspect power cord for damage or bare
wiring. Replace cord immediately if damaged. Bare
wiring can kill.
Turn off all equipment when not in use.
Do not use worn, damaged, undersized or poorly
spliced cables.
Do not drape cables over your body.
If earth grounding of the workpiece is required,
ground it directly with a separate cable.
Do not touch electrode if you are in contact with the
work, ground or another electrode from a different
machine.
Do not touch electrode holders connected to two
welding machines at the same time since double
open circuit voltage will be present.
Use only well-maintained equipment. Repair or
replace damaged parts at once. Maintain unit
according to manual.
Wear a safety harness if working above floor level.
• Keep all panels and covers securely in place.
Clamp work cable with good metal-to-metal
contact to workpiece or worktable as near the weld
as practical.
Insulate work clamp when not connected to
workpiece to prevent contact with any metal object.
Do not connect more than one electrode or work
cable to any single weld output terminal.
Disconnect cable for process when not in use.
Page 6 of 28
Cylinders
•
•
•
•
•
•
•
•
•
•
•
Compressed gas cylinders contain gas
under high pressure. If damaged, a
cylinder can explode. Since gas
cylinders are normally part of the
welding process, be sure to treat them
carefully.
Protect compressed gas cylinders from excessive
heat, mechanical shocks, physical damage, slag,
open flames, sparks and arcs.
Install cylinders in an upright position by securing
to a stationary support or cylinder rack to prevent
falling or tipping.
Keep cylinders away from any welding, cutting or
other electrical circuits.
Never drape a welding electrode or cutting torch
over a gas cylinder.
Never allow a welding electrode or cutting torch to
touch any cylinder.
Never weld on a pressurized cylinder – explosion
will result.
Use only the correct compressed gas cylinders,
regulators, hoses and fittings designed for the
specific application; maintain them and associated
parts in good condition.
Turn face away from valve outlet when opening
cylinder valve. Do not stand in front of or behind the
regulator when opening the valve.
Keep protective cap in place over valve except when
cylinder is in use or connected for use.
Use the right equipment, correct procedures and
sufficient number of persons to lift and move
cylinders.
Read and follow instructions on compressed gas
cylinders, associated equipment, and Compressed
Gas Association (CGA) publication P-1 listed in
Safety Standards.
Additional Safety Warnings for Installation,
Operation and Maintenance
HOT PARTS can burn
Ÿ Do not touch hot parts bare handed.
Ÿ Allow cooling period before working
on equipment.
Do not attempt to adjust the rotation
diameter setting until the torch is cool
to the touch.
Ÿ While handling hot parts, use proper tools and/or
wear heavy, insulated welding gloves and clothing to
prevent burns.
FLYING METAL OR DIRT can injure or kill
Ÿ Welding, cutting, chipping, wire
brushing and grinding cause sparks and
flying metal. As welds cool, they can
throw off slag.
Ÿ Wear approved safety glasses with
side shields even under your welding helmet.
BUILDUP OF GAS can injure or kill
Ÿ Shut off compressed gas supply when
not used.
Ÿ Always ventilate confined spaces or
use approved air-supplied respirator.
ELECTRIC AND MAGNETIC FIELDS (EMF) can
affect implanted Medical Devices
Ÿ Wearers of Pacemakers and other
Implanted Medical Devices should keep
away.
Ÿ Implanted Medical Device wearers
should consult their doctor and the
device manufacturer before going near arc welding,
spot welding, gouging, plasma arc cutting or
induction.
NOISE can damage hearing
Ÿ Noise from some processes or
equipment can damage hearing.
Ÿ Wear approved ear protection if noise
level is high.
FIRE OR EXPLOSION hazard
Ÿ Do not install or place unit on, over, or
near combustible surfaces.
Ÿ Do not install unit near flammables. Do
not overload building wiring – be sure
power supply system is properly sized, rated and
protected to handle this unit.
MOVING PARTS can injure
Ÿ Keep away from moving parts such as
the rotating mechanism in the torch and
the rotating contact tip. Keep away
from moving fans.
Ÿ Keep all doors, panels, covers and
guards closed and securely in place.
Ÿ Have only qualified persons remove
doors, panels, covers or guards for
maintenance and troubleshooting as
necessary.
Ÿ Reinstall doors, panels, covers or guards when
maintenance is finished and before reconnecting
input power. Keep away from pinch points such as
drive rolls.
FLYING SPARKS can injure
Ÿ Wear a face shield to protect eyes and
face.
Ÿ Shape tungsten electrode only on
grinder with proper guards in a safe
location wearing proper face, hand and body
protection.
Ÿ Sparks can cause fires – keep flammables away.
READ INSTRUCTIONS
Ÿ Read and follow all labels and the
Owner’s Manual carefully before
installing, operating, or servicing the
unit.
Ÿ Read the safety information at the
beginning of the manual and each
section.
Ÿ Use only genuine replacement parts from the
manufacturer.
Ÿ Perform maintenance and service according to the
Owner’s Manual, industry standards and national,
state/provincial and local codes.
WELDING WIRE can injure
Ÿ Do not press gun trigger until
instructed to do so.
Ÿ Do not point gun toward any part of
the body, other people or any metal
when threading welding wire.
COMPRESSED AIR can injure or kill
Ÿ Before working on compressed air •
system, turn off and lockout/tagout
unit, release pressure and be sure air
pressure cannot be accidentally applied.
Ÿ
Relieve
air
pressure
before
disconnecting or connecting air lines. Ÿ
Check
compressed
air
system
components and all connections and
hoses for damage, leaks and wear
before operating unit.
Ÿ Do not direct air stream toward self or others.
Ÿ Wear protective equipment such as safety glasses,
hearing protection, leather gloves, heavy shirt and
trousers, high shoes, and a cap when working on
compressed air system.
Ÿ Use soapy water or an ultrasonic detector to search
for leaks – never use bare hands. Do not use
equipment if leaks are found.
Page 7 of 28
TRAPPED AIR PRESSURE AND WHIPPING
HOSES can injure
Ÿ Release air pressure from tools and
system before servicing, adding or
changing attachments or opening
compressor oil drain or oil fill cap.
H.F. RADIATION can cause interference
Ÿ High-frequency (H.F.) can interfere
with radio navigation, safety services,
computers
and
communications
equipment.
Ÿ Have only qualified persons familiar
with electronic equipment perform this
installation. The user is responsible for having a
qualified
electrician
promptly
correct
any
interference problem resulting from the installation.
Ÿ Have the installation regularly checked and
maintained.
Ÿ If notified by the FCC about interference, stop using
the equipment at once.
Ÿ Keep high-frequency source doors and panels
tightly shut, keep spark gaps at correct setting, and
use grounding and shielding to minimize the
possibility of interference.
ARC WELDING AND PLASMA CUTTING can
cause interference
Ÿ Electromagnetic energy can interfere
with sensitive electronic equipment
such as computers and computerdriven equipment such as robots.
Ÿ Be sure all equipment in the welding
area is electromagnetically compatible.
Ÿ To reduce possible interference, keep cables as
short as possible, close together, and down low, such
as on the floor.
Ÿ Locate welding or cutting operation 100 meters from
any sensitive electronic equipment.
Ÿ Be sure welding machine or plasma cutter is
installed and grounded according to its Owner’s
Manual.
Ÿ If interference still occurs, the user must take extra
measures such as moving the welding or cutting
machine using shielded cables, using line filters or
shielding the work area.
OVERUSE CAN CAUSE OVERHEATING
Ÿ Allow cooling period; follow rated duty
cycle.
Ÿ Reduce current or reduce duty cycle •
before starting to weld again.
Ÿ Do not block or filter air flow to unit.
Page 8 of 28
IMPORTANT: Be sure to follow your
facility’s lock out / tag out procedures.
California Proposition 65 Warnings
Welding or cutting equipment produces fumes or
gases that contain chemicals known to the State of
California to cause birth defects and in some cases,
cancer. (California Health & Safety Code Section
25249.5 et seq.) This product contains chemicals
known to the State of California to cause cancer and
birth defects or other reproductive harm. Wash your
hands after using.
EMF Information
Electric current flowing through any conductor
causes localized electric and magnetic fields (EMF).
The current from arc welding (and allied processes
including spot welding, gouging, plasma arc cutting,
and induction heating operations) creates an EMF
field around the welding circuit. EMF fields may
interfere with some medical implants, e.g.
Pacemakers. Protective measures for persons
wearing medical implants have to be taken. For
example, restrict access for passersby or conduct
individual risk assessment for welders. All welders
should use the following procedures in order to
minimize exposure to EMF fields from the welding
circuit:
1. Keep cables close together by twisting or taping
them, or using a cable cover.
2. Do not place your body between welding cables.
Arrange cables to one side and away from the
operator.
3. Do not coil or drape cables around your body.
4. Keep head and trunk as far away from the
equipment in the welding circuit as possible.
5. Connect work clamp to workpiece as close to the
weld as possible.
6. Do not work next to, sit or lean on the welding power
source.
7. Do not weld while carrying the welding power
source wire feeder.
About Implanted Medical Devices:
Implanted Medical Device wearers should consult
their doctor and the device manufacturer before
performing or going near arc welding, spot welding,
gouging, plasma arc cutting, or induction heating
operations. If cleared by your doctor, then following
the above procedures is recommended.
Safety Standards
• ANSI Standard Z49.1, SAFETY IN WELDING AND
CUTTING, American Welding Society, 2501 N.W. 7th
St., Miami, FL 33125.
Free download at
http://www.aws.org/technical/AWS_Z49.pdf
• ANSI Standard Z41.1, STANDARD FOR MEN’S SAFETY
- TOE FOOTWEAR obtainable from the American
National Standards Institute, 1430 Broadway, New
York, NY 10018.
• ANSI Standard Z49.2, FIRE PREVENTION IN THE USE
OF CUTTING AND WELDING PROCESSES obtainable
from the American National Standards Institute,
1430 Broadway, New York, NY 10018.
• OSHA, SAFETY AND HEALTH STANDARDS, 29CRF
1910, obtainable from the U.S. Government Printing
Office, Washington, D.C. 20402.
• OSHA, PERSONAL PROTECTIVE EQUIPMENT, OSH
3151-12R
2003.
Free
download
at
https://www.osha.gov/Publications/osha3151.pdf
• AWS Standard A6.0, WELDING AND CUTTING
CONTAINERS WHICH HAVE HELD COMBUSTABLES
obtainable from the American Welding Society, 2501
N.W. 7th St., Miami, FL 33125.
• NFPA Standard 70-1978, NATIONAL ELECTRICAL
CODE obtainable from the National Fire Protection
Association, 470 Atlantic Avenue, Boston, MA 02210.
• ANSI Standard Z88.2, “Practice for Respiratory
Protection” obtainable from the American National
Standards Institute, 1430 Broadway, New York, NY
10018.
• ANSI Standard Z87.1, SAFE PRACTICES FOR
OCCUPATION AND EDUCATIONAL EYE AND FACE
PROTECTION obtainable from the American
National Standards Institute, 1430 Broadway, New
York, NY, 10018.
• NIOSH, SAFETY AND HEALTH IN ARC WELDING AND
GAS WELDING AND CUTTING obtainable from the
Superintendent of Documents, U.S. Printing Office,
Washington, D.C. 20402.
• American Welding Society Standard AWSF4.1
“Recommended Safe Practices for the Preparation
for Welding and Cutting of Containers and Piping
That Have Held Hazardous Substances”, obtainable
from the American Welding Society, 2501 N.W. 7th
St., Miami, FL 33125
Page 9 of 28
In tro d u ctio n
This manual provides basic instructions for Weld Revolution’s MA-400TM Mechanized Air-Cooled Welding
Torch. This product delivers the benefits of Weld Revolution’s innovative and patented SpinArc welding
technology in a mechanized torch that can also be used semi-automatically with the optional hand welding kit.
This welding torch can be easily used with any modern welding power source and wire feeder. Simply select
and install the appropriate power pin (wire feeder adapter) for the specific wire feeder. Refer to the list of
power pins in the Spare Parts section of this manual.
How it Works
Weld Revolution’s patented technology rotates the welding wire in a circular motion at a high rate of speed.
Centrifugal force propels the molten droplets across the arc creating a consistent and sound weld bead. This
enables high deposition rate welding for significant increases in productivity. The innovative torch design
allows easy adjustment of the wire rotation diameter and rotational speed to optimize weld quality and
performance.
What’s Included
Additional Required Parts
The MA-400 includes the following items:
• Cable Assembly
• Torch Body
• Control Box (CB-115)
• Control Cable (CC-15)
• Trigger Control Cable (TC-15)
• Flexure Nut Tool (PN 1087)
The following items must also be purchased:
• Power Pin (adaptor specific to wire feeder)
• Contact Tips
• Nozzles
• Liner
Available Models
Optional Accessories
Model #
Length, ft. (m)
MA-400-6
6 ft. (1.8 m)
MA-400-10
10 ft. (3.0 m)
MA-400-15
15 ft. (4.6 m)
MA-400-XX
XX ft.
Special Order 3 - 15 ft.
(1.8 - 4.6 m)
The following items are also available:
• Hand Welding Kit (PN HWK-1)
• Control Box Mounting Kit (PN CB-MK1)
• Lower Cap Heat Shield (PN 1036)
• O-Ring Kit (PN 1750)
Consumables & Replacement Parts
Contact tips, shielding gas nozzles, wire liners, flexures and other maintenance parts are listed later in the
manual. Additional contact tips, nozzles and power pins are available by special request through our Customer
Service Team.
Page 10 of 28
S p e cifica tio n s
Max Amperage
400 Amp @ 100% duty cycle with 80/20 Ar/CO2*
Rotation Diameter
1 – 8 mm (0.039 - 0.315 in.) at the contact tip,
tool-free adjustability in increments of approximately 1 mm
Spin Direction
Clockwise & Counter-Clockwise
Spin Start Delay
0 – 5 seconds
Rotation Speed
1,000 – 5,000 rpm
Operating Environment
32 – 104oF (0 – 40oC)
Wire Diameters
0.035 – 1/16” (0.90 - 1.6 mm)
Welding Processes
GMAW, GMAW-P, FCAW
Control Box Input Power
110 – 240 VAC, 50/60 Hz
Cable Length
Available in 6, 10 & 15 ft. (1.8, 3.0 & 4.6 m)
Custom lengths available by special order between 3 – 15 ft.
(1.8 – 4.6 m)
* Rating based on tests that comply with IEC 60974-7 specifications for Arc Welding Torches.
For further information or help with Weld Revolution products, please visit our website at
www.weldrevolution.com, or contact Customer Service at +1-832-585-1244.
Page 11 of 28
In sta lla tio n
Step 1:
Install Power Pin (detailed instructions with each power pin)
The power pin attaches to the feeder end of the cable. This required part enables the torch to
connect to the specific wire feeder model in use. Power pins are sold separately (see
Replacement Parts).
Welding Cable Assembly
Power Pin
Wire Liner
Contact Customer Service at +1-832-585-1244 for help selecting the right power pin.
Step 2:
Install the Wire Liner (see also pg. 22)
The proper wire liner must be ordered separately. With the torch lying flat on the floor or table,
unscrew the tip of the power pin and insert the liner. Insert the liner through the cable. The
liner should be sticking out 1-1/4” (32 mm) from the end of the brass end piece. Make sure the
liner seats fully inside the torch and is flush inside the power pin. There may be a slight
resistance as the liner enters the torch body. It is important that the liner is inserted fully and
the back flange and O-ring are properly seated in the power pin.
Step 3:
Connect Torch to Feeder
Insert the power pin into the wire feeder bushing and tighten the screw on the wire feeder.
Make sure that the control cable connection on the torch is facing down to protect it.
Step 4:
Mount the Torch
Mount the welding torch into existing mechanized systems by holding the middle section of the
torch body. A hand welding kit (PN HWK-1 sold separately) is also available. This allows the
torch to be used semi-automatically giving the welder greater flexibility to weld by hand.
Step 5:
Mount the Control Box
The optional mounting kit (PN CB-MK1 sold separately) can be used to attach the control box to
the wire feeder or other magnetic surface. There are also mounting tabs on the case. With the
box secure and in the OFF position, plug it into a grounded input power circuit. Do not remove
the grounding plug from the cable. Isolate the control box from all sources of high frequency.
Page 12 of 28
Step 6:
Control Cable
Connect the orange control cable to both the torch and the control box. Be careful to fully hand
tighten both ends. Protect the cable from potential damage.
Step 7:
Turn Control Box ON
First, make sure the spin switch is set to OFF. Verify the control cables and power cord are
securely connected. Make sure the torch is mounted and connected to the wire feeder. Now,
turn ON the control box. Verify the LEDs are illuminated.
Step 8:
Feed Wire
On the wire feeder, use the jog function to run the wire through the cable. As it approaches the
torch, slow the wire speed down to ensure smooth feeding through the torch. HINT: It is
helpful to turn ON the spin to about 1,000 rpm when feeding wire.
Step 9:
Install Contact Tip
Two tools are needed to install or remove a contact tip. While holding the Contact Tip
Extension with a 5/16” (8 mm) wrench or small crescent wrench, use Welper® pliers to remove
or tighten the contact tip. Be careful not to damage the threads or to twist the spinner. Clip
the wire to the desired wire stick out, which will be approximately the same as conventional
MIG welding without rotation, and you’re ready to weld.
Welper® is a registered trademark of Kabushikigaisha Taimu Kemikaru Joint Stock Company, Japan.
Page 13 of 28
O p e ra tio n
Control Box Settings
The control box is an integral part of the MA-400 SpinArc Welding System. This is the user interface for setting
the Mode Setting, Spin Speed (RPM), the Spin Direction (CW or CCW) and the Spin Start Delay (0 – 5 seconds).
The actual spin speed is displayed while rotating.
Mode Setting (ON, OFF, REMOTE)
•
ON/OFF: Set the 3-position mode selector switch to either OFF, ON or AUTO. In the ON position, the
contact tip rotates. Toggle between the OFF (center toggle position) and ON position to manually
enable rotation. NOTE: Remember to turn off the spin when not welding.
•
REMOTE: The REMOTE mode is used to remotely start the wire rotation. This feature is helpful when
using the torch in other mechanized/robotic systems and with the Optional Hand Welding Kit. A thirdparty system can initiate the arc start and rotation start simultaneously. For this mode, install the
Trigger Control Cable (TC-15) between the box and the wire feeder trigger connection. The TC-15 has
two flying leads to enable the user to attach the appropriate Amphenol or other connector to the wire
feeder trigger connection. Note: When the optional Hand Welding Kit is used, set the Mode to REMOTE,
and install the Trigger Control Cable (TC-15).
Spin Speed
Display
Mode
Selector
Power
Switch
Mounting
Holes
Spin
Direction
Input
Power Cord
Spin Speed
Control Knob
Page 14 of 28
Spin Delay
Knob
Trigger Control
Cable Fitting
Control Cable
Fitting
Spin Direction (CC/CCW)
The spin direction is determined from the welder’s perspective while it is welding. The clockwise (CW) or
counterclockwise (CCW) rotation is orientated looking down at the weld from the torch. In other words, looking
into the shielding gas nozzle would be opposite of the spin direction setting.
The spin direction may be arbitrary in many situations. However, there may be particular applications where
the direction of rotation is important. For example, in a horizontal fillet weld the relative direction of the arc
may be important. If traveling from left to right with a CW spin, the arc traverses from the top leading edge to
the bottom. Changing to CCW in this case, puts the arc on the bottom edge first. This may or may not affect
the final results; however, it is a factor to consider.
Spin Start Delay
The Spin Start Delay knob is located on the bottom of the unit. This can be used to delay the start of the
rotation, which may be helpful in certain applications. This feature works in both the ON and Auto modes.
Verify that the knob is fully turned to the left (counter clockwise) direction if an immediate rotation is desired.
Torch Adjustments
Spin Diameter
HOT SURFACES can burn.
Do not attempt to
adjust the rotation
diameter setting until
the torch is cool to
the touch.
C A UT I O N
MOVING PARTS can injure.
Turn OFF the control
box before opening the
torch and attempting
to adjust the spin
diameter
The spin diameter is easily adjusted by changing the “gear” position on the crank assembly. This is accessible
by removing the lower cap and nozzle together, exposing the crank window. There are eight diameter settings
for a range of approximately 0.10 – 0.33 in. (1 to 8 mm).
Changing Spin Diameter
To change the spin diameter, first verify that the torch is cool to the touch and is able to be handled without
gloves. Then,
(1) Unlock lower cap – twist left
(2) Slide the cap down
(3) Hold the numbered part stationary
(4) Turn the aluminum piece using the thumb
and forefinger of the other hand
(5) Align the position indicator with the desire
setting on the brass part
1
2
3
4
5
Page 15 of 28
When using a standard contact tip (PN CT403-21-45) and contact tip extension (PN 1043-00), the spin diameter
increases by approximately 0.039 in. (1.0 mm) with each setting (1 to 8).
Due to the design of the spinning mechanism, the spin diameter at the end of the electrode will be larger than
the spin diameter at the contact tip. As shown in the figure below, the contact tube assembly has a fixed pivot
point and the tube is driven in a circular motion by an eccentric rotational drive system.
The effective spin diameter is considered to be the outside rotational diameter of the electrode. The effective
spin diameter is a function of the contact tip-to-work distance (CTWD), electrode wire stiffness, and rotational
speed. For example, simply increasing the rotational speed for a given CTWD and electrode will increase the
effective spin diameter due to centrifugal forces on the wire.
The table below is an example of effective spin diameter at different crank positions using a teach tip with 1 in.
(25 mm) CTWD rotating at 1,000 RPM. These are approximate dimensions.
Spin&Drive&
Pivot&Point&
CTWD&
Effec3ve&Spin&
Diameter&
Effective Spin Diameter
with 1 in. (25 mm) CTWD at 1,000 rpm
Crank
Position
Approx. Spin
Diameter, in. (mm)
1
0.04 (1)
2
0.08 (2)
3
0.12 (3)
4
0.16 (4)
5
0.20 (5)
6
0.24 (6)
7
0.28 (7)
8
0.32 (8)
Measuring the effective spin diameter is outlined in the following section.
For multiple pass groove welds, different spin diameters can be utilized. For example, a smaller spin diameter
may work better on the root and first fill passes. The spin diameter can be increased for the fill and cap
passes.
Measuring Effective Spin Diameter
Method 1: Install the optional Teach Tip (PN CT403-20-075) in place of the contact tip. Set the rotation speed
to the desired RPM. Using a set of high quality calipers, measure the rotation diameter at the end of the Teach
Tip wire. (HINT: Use a small flashlight to illuminate the circular wire path. The wire should just slightly touch
the calipers.) The actual welding wire can also be used, along with the approximate Contact-Tip-to-Work
distance, to estimate the spin diameter.
Method 2: Use the welding electrode for the given welding procedure. Extend the wire to the desired ContactTip-To-Work distance (CTWD). Measure the outside diameter of the wire rotation at the specified CTWD with a
set of high quality calipers.
Page 16 of 28
Application Notes
The following variables are not set on the welding torch; however, they are important to consider for each
application:
Weld Bead Width
There are several variables that can affect the width of the deposited weld bead, including:
• Spin Diameter Setting
• Contact Tip-to-Work Distance (CTWD)
• Welding Voltage
• Spin Speed (RPM)
• Welding Wire Diameter and Wire Stiffness
Travel Speed
The travel speed range that can be utilized is a function of welding position, welding electrode type/size,
amperage, voltage, joint type, spin speed and targeted heat input needed to achieve the required mechanical
properties
Vertical Welding Progression
In general, the SpinArc welding process is better suited for vertical down welding.
Gas Nozzles & Joint Geometry
The gas nozzle must be selected in relation to the weld joint details. For example, in a narrow gap joint it may
prove favorable to use a contact tip that is extended beyond the end of the nozzle. This extension can be
obtained by using the contact tip extension (PN 1043-00) or by using a shortened nozzle. Additionally, a joint
with a compound bevel can enable the nozzle to be inserted into the joint for thicker materials.
Nozzles with narrow openings can also be used with relatively small spin diameters to avoid crashing the
spinner into the nozzle.
Page 17 of 28
C o n su m a b le s
Contact Tips
Bag
Quantities
Wire Dia.
Part #
.035” (0.9 mm)
CT403-27-35
100
CrZr Extended Life HD for 0.035 in. (0.9 mm)
CT403-21-45
100
Tapered Tip for .045 in. (1.2 mm) wire
CT403-20-45
100
Heavy Duty for .045 in. (1.2 mm) Wire
CT403-27-45
100
CrZr Ext. Life HD for .045 in. (1.2 mm) wire
CT403-21-1.0
100
Tapered Tip for 1.0 mm (0.040”) Wire
CT403-27-1.0
100
CrZr Extended Life Tip, for 1.0 mm (0.040”)
Wire
CT403-20-52
100
Heavy Duty for 0.052 in (1.3 mm) wire
CT403-20-116
100
Heavy Duty for 1/16 in. (1.6 mm) wire
CT603-20-116
100
Extra HD Tip for 1/16 in. (1.6 mm) wire
CT403-20-075
1
.045” (1.2 mm)
1.0 mm (0.040”)
0.052” (1.3 mm)
Description
1/16” (1.6 mm)
Teach Tip
Teach Tip
Note: CrZr tips are specially formulated with Chromium and Zirconium to handle high amperage welding
Nozzles
N401-5-75
Bag
Quantities
10
N401-4-75
10
Nozzle, 3/4 in. (19 mm) Bore - 1/8 in. (3 mm) Recessed
N401-6-75
10
Nozzle, 3/4 in. (19 mm) Bore - 1/8 in. (3 mm) Recessed Copper
N401-7-75
10
HD Nozzle, 3/4 in. (19 mm) Bore - 1/8 in. Recessed
N401-48-62
10
HD Bottleneck Nozzle, 5/8 in. Bore - Flush
N401-81-62
10
HD Nozzle, 5/8 in. Bore - 1/8 in. Stick-Out
Part #
Description
HD Nozzle, 3/4 in. (19 mm) Bore - 1/4 in. (6 mm) Recessed
Wire Liners
Wire Dia.
0.035 – 0.045 in.
(0.9 – 1.1 mm)
0.045 – 1/16 in.
(1.1 – 1.6 mm)
Page 18 of 28
L415-35-6
Bag
Quantities
1
L415-35-10
1
10 ft. (3 m)
L415-35-15
1
15 ft. (4.6 m)
L415-116-6
1
6 ft. (1.8 m)
L415-116-10
1
10 ft. (3 m)
L415-116-15
1
15 ft. (4.6 m)
Part #
Length
6 ft. (1.8 m)
R e p la c e m e n t P arts
The following parts can be ordered by calling our Customer Service Team at +1-832-585-1244.
Item
1
2
3
2
4
14
5
Description
Part #
1
Cable Assembly
CA-6
(6 ft.)
CA-10 (10 ft.)
CA-15 (15 ft.)
2
Upper Cap
1028
3
O-Ring, Power Stud
1037
4
Power Stud
1053
5
O-Ring, Outer Body
1038
6
O-Ring, Insulator Lower
1039
7
Flexure
1032
8
Contact Tip Extension
9
Contact Tip
10
Lower Cap
1012
11
O-Ring, Lower End Cap
1042
12
Nozzle Retaining Ring
1041
13
Shielding Gas Nozzle
14
Control Cable
15
Power Pin
16
Control Box
6
15
7
8
See Table
Below
See Table
Below
See Table
Below
See Table
Below
See Table
Below
CB-115
9
10
11
12
16
5
13
Page 19 of 28
Control Cables
The CC-15 or CC-6 cables connect from the back of the torch to the control box.
NO TI CE
Do not extend the orange control cable beyond 15 ft. (4.6 m).
The TC-15 is used to close the wire feeder trigger circuit for arc start. This is required when running in the
“REMOTE” mode as described in the Operation section of this manual. It is also included in the optional Hand
Welding Kit (HWK-1). The cable has an Amphenol connection on one end (connects to the control box) and two
bare (“flying”) leads on the other end for connecting to the wire feeder trigger connection.
Part #
Description
CC-15
Control Cable, 15 ft. (4.6 m)
CC-6
Control Cable, 6 ft. (1.8 m)
TC-15
Trigger Cable, 15 ft. (3.0 m)
Contact Tip Extension
Control Cable
CC-15 or CC-6
The standard contact tip extension is 1.9 in (48.5 mm) long. Extended tip holders are available to extend the
contact tip beyond the end of the shielding nozzle, which can be used in deeper groove welds or for wider spin
diameters.
Part #
Description
1043-00
Standard, 1.9 in. (48.5 mm)
1043-25
0.25 in. (6 mm) extension
1043-50
0.50 in. (12 mm) extension
1045-75
0.75 in. (19 mm) extension
1045-100
1.00 in. (25 mm) extension
Replacement Cable Assembly
In the event the cable is damaged it can be replaced by ordering a replacement from our Customer Service
Team by calling +1-832-585-1244.
Part #
Description
CA-6
Replacement Cable Assembly, 6 ft. (1.8 m)
CA-10
Replacement Cable Assembly, 10 ft. (3.0 m)
CA-15
Replacement Cable Assembly, 15 ft. (4.6 m)
Replacement Cable Assembly, designate length
of cable at time of order
Note: This does not include the Power Pin, Wire Liner or Torch Body.
CA-XX
Page 20 of 28
Power Pins
The correct power pin (wire feeder adaptor) is required to connect the torch to the wire feeder. Below is a list
of the most common feeders and corresponding power pin part number.
Manufacturer
Airco
Cloos
Wire Feeder Model
Auto-Pack 130, Dip-Pack 200 (New), Dipstick 160 (New), System, Universal,
MIGhty 1, Med20, Med20 Synergic, Med40, Med40 Synergic
Euro Style
Part #
PP-EURO1
PP-EURO2
Med30, MIG 2E, MIG 4HD, MIG 4HD Dual, Mobile Master, ESAB MIG C420
PP-EURO1
Feeders with "MT"-Style Quick Connect Block
PP-E1
ThruArm Style: VR 1500 M, VR 1500 PAP VR15000
PP-F1
"North American" Style
PP-F2
F++ Connector
Power-MIG 255, 200, 250, 300, 350 MC, Power-Feed 10M, 25M, DH-10, LN-10
(New Style), LN-25 PRO, STT-10
LN4, LN5, LN6, LN7, LN8, LN9, LN22, LN25, LN742 , NA5R, Power-Feed 10
(Robotic), Power Wave 450/455, Synergic 7
LN7, LN8, LN9, LN22, LN25, LN742, Synergic 7
PP-F3
Power Wave 450, Synergic 7
PP-EURO1
Power Wave 4R Series
PP-L4
MIGMaster 250, 4HD, MIG2E
Millermatic 250MP, 300, MM-35 (New), MM90, New Automatic 1, PortaMIG, S32P,
S42GL, S52A, S54A, Swing Arc Dual Swing, S32S, 52D, 54D, 52E, 54E, Shop
Master 300, 22 Series, 60 Series, 70 Series, Millermatic 130XP, Challenger 172,
185, Vintage, 250X, Suitcase 8VS, 12VS, R115
Firefly 130
PP-EURO1
OTC Daihen
CM741, CMRE741, AF4001, New D Series
PP-OTC
OXO
PS-60Q, AVC-30Q
PP-OXO
Tweco #4
PP-TW4
Tweco #5
PP-TW5
ESAB
Fronius
Lincoln
Linde / L-Tec
Miller
Tweco
PP-TW4
PP-L2
PP-L3
PP-M1
PP-M3
Additional power pins may be available by special request through our Customer Service Team by calling
+1-832-585-1244.
Page 21 of 28
M ain ten an ce
Wire Liners
The wire liner runs the entire length of the welding cable from the power pin at the
wire feeder end to the torch body. Having a properly functioning liner is critical to
good wire feeding and acceptable welding performance. It’s important to replace
the liner as needed, depending on the amount and type of welding electrodes used. In some case, this is daily
or multiple times per day. Throughout the day, liners collect debris and restrict the wire from moving smoothly
through the cable. This restriction leads to wire feeding issues, including burning back the wire to the contact
tip if not addressed in time.
NO TI CE
How to Change the Liner
1.
2.
3.
4.
5.
6.
7.
Remove the contact tip and back out the welding wire from the cable assembly.
Remove the cable assembly from the feeder.
Lay the cable out straight on a flat surface.
Loosen and remove the liner holding cap on the back of the power pin (wire feeder end).
Pull out the old liner.
Cut the new liner to the same length as the old liner.
Insert the new liner. The liner should extend out 1-1/4” (32 mm) from the end of the brass end piece on the
welding end of the cable. Make sure the liner seats fully inside the torch, flush against power pin.
8. Install and tighten the liner cap by hand.
Shielding Gas Nozzles
NO TI CE
It is important to keep the gas nozzle clear from weld spatter. If spatter is allowed
to build up inside the nozzle, this can interfere with the rotation. As needed,
remove the nozzle and use Welpers® to clear any weld spatter buildup.
Flexure Nuts
It is important that both flexure nuts remain tight. These keep the flexure from
rotating, which is key to efficient power transfer and a stable welding arc. Gently
grab the contact tip holder and try to spin it about its centerline axis. If the flexure
rotates, then the flexure nuts must be tightened. Remove the contact tip and contact tip extension, then
tighten the Inner Flexure Nut [B] to 25 in. lbs. (2.8 Nm) with a 12 mm, deep socket and a torque wrench. Hand
tighten the Outer Flexure Nut [A] with the Flexure Nut Tool (PN 1087). This tool is provided with each MA-400.
NO TI CE
A
B
C - Flexure Nut Tool
(PN 1087)
Page 22 of 28
Flexure Replacement
NO TI CE
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
The flexure (PN 1032) should be inspected for cracks occasionally. The life of this
part depends on the spin diameter setting on the crank and spin speed (rpm). This
part is considered a maintenance part.
Remove the lower cap on the torch
Inspect the flexure for cracking
Remove Contact Tip Extension (PN 1043-XX) from Flicker (PN 1004)
Remove Outer Flexure Nut with tool (PN 1087)
Slide out and remove Flicker assembly from torch body
Place Flicker in non-marring vice
Remove Inner Flexure Nut with 12 mm deep socket
Remove old Flexure and replace with new one (PN 1032)
Thread Inner Nut on Flicker
Tighten Inner Flexure Nut (PN 1034) to 25 in. lbs. with 12 mm deep socket & torque wrench
Slide Flicker assembly back into torch body
Thread Outer Flexure Nut (PN 1033) and hand tighten with tool (PN 1087)
O p tio n a l A cce s s o rie s & P a rts
Hand Welding Kit
Part # HWK-1
The mechanized torch can be used by hand with the optional
Hand Welding Kit. Part # HWK-1
Control Box Mounting Kit
The Control Box can be easily attached to existing welding
equipment, carts, or other parts with our mounting kit.
Includes heavy-duty magnetic base. Part # CB-MK1
Heat Shield
For high amperage and high temperature applications, a
heat shield can be installed over the lower cap. Part # 1036
Flexure Nut Tool
The Flexure Nut Tool is a specialized tool used to tighten the
outer flexure nut (see Maintenance Section above).
Part # 1087
Part # CB-MK1
Heat Shield
Part # 1036
Flexure Nut Tool
Part # 1087
Control Box Bump Guard
The bump guard is designed to protect the control box.
Part # CB-BG1
Part # CB-BG1
O-Ring Kit
Includes all the O-rings, clips and grommet used in the torch.
Part # K1750
Page 23 of 28
T ro u b le S h o o tin g
Problem
1. Electrode does
not feed
2. Contact tip
burn back
Possible Cause
Corrective Action
1.
Feeder relay
1.
2.
Broken control lead
2. Check continuity on the optional trigger control
cable or other cable controlling the feeder trigger
circuit and replace
3.
Poor adaptor connection
3. Test and replace leads and/or pins
Consult feeder manufacturer
4. Improper or worn drive rolls
4. Replace drive rolls
5.
Drive roll tension
misadjusted
5. Adjust tension at feeder
6.
Burn back to contact tip
6. See “Contact tip burn back”
7.
Wrong size liner
7. Replace with correct size
8. Buildup inside liner
8. Replace liner
1.
Improper voltage and/or
wire feed speed
1.
2.
Erratic wire feeding
2. See “Erratic wire feeding”
3.
Improper tip stickout
3. Adjust nozzle/tip relationship
Adjust parameters
4. Improper electrode stickout
4. Adjust wire stickout
5.
Faulty work connection
(ground)
5. Replace cables and/or connections
3. Flexure is
broken
1.
Exceed design life of the
part
1.
4. Short contact
tip life
2.
Loose contact tip
2. Tighten contact tip
3.
Improper contact tip size
3. Replace with proper size
Page 24 of 28
See Maintenance Section for replacement
instructions
4. Electrode eroding tip
4. Inspect and/or change drive rolls
5.
Exceeding duty cycle
5. Replace with properly rated tips or torch
6.
Overheating tips
6. Replace with heavy duty or extended life contact
tips
Problem
5. Erratic wire
feeding
6. Porosity in
weld
Possible Cause
Corrective Action
1.
Buildup inside liner
1.
2.
Wrong size liner
2. Replace with new liner of proper size
3.
Improper drive roll size
3. Replace with proper size drive rolls
Replace liner, check condition of electrode
4. Worn drive rolls
4. Replace with new drive rolls
5.
Improper guide tubes
5. (a) Replace and adjust guides as close to drive rolls
as possible on the feeder
(b) Eliminate all gaps in electrode path
6.
Gaps at liner junctions
6. Replace with new liner, trimming as per the
“Changing the liner” section
7.
Feeder malfunction
7. Consult feeder manufacturer
8. Worn contact tip
8. Inspect and replace
9.
9. Provide a larger radius for the wire to feed through,
especially important on larger and stiffer
electrodes
Tight bend or loops in the
cable
10. Cable assembly is too long
10. Replace with shorter cable assembly, especially
important with stiff electrodes (e.g., stainless steel
and nickel alloys)
11. Flexure is loose
11. The flexure should not turn (even when the contact
tip is rotating). Remove welding wire, remove
contact tip, remove lower cap, turn on spin and
verify flexure is not turning. If loose, tighten [A]
Outer Flexure Nut with tool (PN 1087) and tighten
Inner Flexure Nut [B] to 25 in. lbs. (2.8 Nm) with a 12
mm deep socket. See Maintenance Section.
1.
Extreme heat or duty cycle
1.
2.
No shielding gas
2. Install full tanks, check for hose leaks, check
regulator/flowmeter for proper function
3.
Flow improperly set
3. Adjust flow
Use heavy duty consumables
4. Poor gas flow
4. Clean or replace nozzle, check for gas hose leaks (a
turbine flow meter at the nozzle works best to
measure the actual flow rate), check
regulator/flowmeter for proper function
5.
Ruptured gas hose
5. Replace or repair the line or hoses
6.
Worn, cut or missing
O-rings
6. Replace O-rings
7.
Loose fittings
7. Tighten torch and cable connections
Page 25 of 28
Problem
Possible Cause
Corrective Action
7. Control box not
working
1.
No input power
1.
Check to make sure the power cord is plugged in to
110 or 240 VAC and is in good working condition
8. Electrode does
not spin
1.
Broken motor control lead
1.
(a) Check continuity in eight control wires in the
orange control cable. Replace the control cable if
necessary.
(b) Check continuity in the welding cable assembly
control leads between feeder and torch head
connection. Replace cable assembly if needed.
(c) Contact Customer Service.
2.
Nozzle clogged with slag
2. Remove slag and/or replace nozzle
3.
Spin Delay set knob is
turned
3. Verify that the Spin Delay knob on the bottom of
the unit is set to zero or the desired time
1.
Electrical interference (EMI)
1.
2.
Loose motor control lead
2. Check motor wiring harness connections for lose
wires (under plastic housing on feeder end and
under aluminum cap on torch).
3.
Damaged control cable
3. Replace the control cable
1.
Worn contact tip
1.
2.
Buildup inside liner
2. Replace liner, check electrode
3.
Wrong tip size
3. Replace with correct tip size
9. Erratic spin
speed
10. Erratic arc
(a) Move control box and welding cable away from
sources of electrical noise, e.g. high frequency TIG.
(b) use a shorter control cable. Do not extend the
orange control cable longer than 15 ft. (3 m).
(c) use a shorter welding cable.
(d) verify that the grounding pin is in place on the
control box input power cable.
Replace contact tip
4. Tight bends or loops in the
cable
4. Provide a larger radius for the wire to feed through,
especially important on larger and stiffer
electrodes
5.
5. Poor work connection is the most common cause
of unstable welding. Inspect ground cable for
loose connections, fraying and cuts. Connect
ground clamp directly to the work piece, and not
through paint or other coatings.
Faulty Work Connection
Any service beyond the routine maintenance or troubleshooting defined in this manual must be performed at
the factory or by a factory authorized service facility. Disassembly of the torch, beyond removing the upper or
lower end caps, or opening the control box voids the warranty. Please contact our Customer Service Team at
+1-832-585-1244 for assistance.
Page 26 of 28
L im ite d W a rra n ty
Statement of Limited Liability
Weld Revolution LLC warrants to the end user (purchaser) of all new products that it will be free of defects in
workmanship and material. This warranty is void if the equipment has been subjected to improper installation,
improper care or abnormal operations.
Warranty Period
Weld Revolution will assume both the parts and labor expense of correcting defects during the warranty
period. The warranty period starts from the date of purchase to the original end user or from the date of
manufacture if proof of purchase is not available and is as follows:
180 Days
•
•
All SpinArc welding systems, including the MA-400. This includes the originally supplied control box,
welding cable assembly, and torch body.
Consumables, control cables and replacement parts are NOT COVERED under this warranty. This
includes contact tips, nozzles, O-rings, liners, flexure and all other replacement parts.
Conditions of Warranty to Obtain Warranty Coverage
The purchaser must contact Welding Revolution directly at +1-832-585-1244.
Warranty Repair
If Weld Revolution or an authorized service facility confirms the existence of a defect covered by this warranty,
the defect will be corrected by repair of replacement at Weld Revolution’s option. At Weld Revolution’s
request, the purchaser must return, to Weld Revolution any “Goods” claimed defective under Weld Revolution’s
warranty.
Freight Costs
The purchaser is responsible for shipment to and from Weld Revolution.
WARRANTY LIMITATIONS
WELD REVOLUTION WILL NOT ACCEPT RESPONSIBILITY OR LIABILITY FOR REPAIRS MADE OUTSIDE OF A WELD
REVOLUTION AUTHORIZED SERVICE FACILITY. WELD REVOLUTION’S LIABILITY UNDER THIS WARRANTY SHALL
NOT EXCEED THE COST OF CORRECTING THE DEFECT OF THE WELD REVOLUTION PRODUCT. WELD REVOLUTION
WILL NOT BE LIABLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES (SUCH AS LOSS OF BUSINESS, ETC.)
CAUSED BY THE DEFECT OR THE TIME INVOLVED TO CORRECT THE DEFECT. THIS WRITTEN WARRANTY IS THE
ONLY EXPRESS WARRANTY PROVIDED BY WELD REVOLUTION WITH RESPECT TO ITS PRODUCTS. WARRANTIES
IMPLIED BY LAW SUCH AS THE WARRANTY OF MERCHANTABILITY ARE LIMITED TO THE DURATION OF THIS
LIMITED WARRANTY FOR THE EQUIPMENT INVOLVED. THIS WARRANTY GIVES THE PURCHASER SPECIFIC LEGAL
RIGHTS. THE PURCHASER MAY ALSO HAVE OTHER RIGHTS WHICH VARY FROM STATE TO STATE.
Service
Any service beyond the routine maintenance or troubleshooting defined in this manual must be performed at
the factory or by a factory authorized service facility. Disassembly of the torch beyond removing the upper or
lower end caps voids the warranty. Opening the Control Box voids the warranty. Please contact our Customer
Service Team at +1-832-585-1244 for assistance.
Page 27 of 28
Customer Assistance Policy
Weld Revolution LLC does not warrant or guarantee or assume any liability with respect to any information or
advice given. Our employees are not in a position to verify the information provided or to evaluate the
engineering requirements for any customer. Additionally, the provision of any information or advice does not
create, expand, or alter any warranty on our products. Any express or implied warranty that might arise from
the information or advice, including any implied warranty of merchantability or any warranty of fitness for any
customers’ particular purpose is specifically disclaimed. The selection and use of specific products sold by the
Company is solely within the control of, and remains the sole responsibility of the customer. Many variables
beyond the control of the Company affect the results obtained in applying these types of fabrication methods
and service requirements.
Weld Revolution LLC
19511 Wied Road, Suite E
Spring, TX 77388 USA
www.weldrevolution.com
Phone: +1-832-585-1244
Fax:
+1-832-585-1109
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