Thermion 500 User manual

MANUAL August 24, 2007
OWNER’S MANUAL
(OPERATIONS AND MAINTENANCE)
Thermion Metalizer
Thermion
Thermion Spray Master
Thermion 500
MANUFACTURED BY
SILVERDALE, WASHINGTON, USA
Phone: [phone] or
1-877-884-3428
FAX: [phone]
Email: [email protected]
file 50115 US 1.098
T
TH HE ER RM MI IO ON N I IN NC C. .
ARC SPRAY METALIZING SYSTEMS

ii
The US Thermal-Spray Standards Program:
Thermal-spray standards in the United States are developed by several professional
societies that include American Society for Testing and Measurement (ASTM) for test &
measurements methods and composition specifications; American Welding Society
(AWS) for feedstock, equipment acceptance, application process, training &
certification; American Water Works Association (AWWA) for thermal-spray zinc
potable water tank linings; International Association of Corrosion Engineers (NACE) for
corrosion application processes and inspection; and Society of Protective Coatings
(SSPC) for test & measurement methods, application specification & inspection in
regards to protective coatings for the protection of steel.
US Published Standards:
C2.16-92, Guide for Thermal-Spray Operator Qualification.
This guide sets forth recommended thermal-spray operator qualification procedures. It
covers applicable documents relating to thermal-spray equipment, consumables, and
safety. It also contains operator qualification and coating system analysis forms.
AWS C2.18-93, Guide for the Protection of Steel with Thermal Sprayed Coatings
of Aluminum and Zinc and Their Alloys and Composites.This guide sets forth
recommended thermal-spray operator qualification procedures. It covers applicable
documents relating to thermal-spray equipment consumables, and safety. It also
contains operator qualification and coating analysis forms. Note: This standard is being
incorporated into ANSI/AWS C2.18A-XX/SSPC CS 23.00A-XX/NACE TPC #XA, Guide
for the Application of Thermal Spray Coatings (Metalizing) of Aluminum, Zinc, and Their
Alloys & Composites for the Corrosion Protection of Steel, in preparation.
SSPC CS 23.00, Guide for Thermal Spray Metallic Coating Systems.
This guide covers the requirements of thermal-spray metallic coatings, with and without,
sealers and topcoats, as a means to prevent the corrosion of steel surfaces. Types of
metallic coatings include pure zinc, pure aluminum and zinc/aluminum alloy, 85%
zinc/15%luminum by weight. Note: This standard is being incorporated into ANSI/AWS
C2.18A-XX/SSPC CS 23.00A-XX/NACE TPC #XA, Guide for the Application of Thermal
Spray Coatings (Metalizing) of Aluminum, Zinc, and Their Alloys & Composites for the
Corrosion Protection of Steel, in preparation.
ASTM C 633, Test Method for Adhesion or Cohesive Strength of Flame-Sprayed
Coatings.
This test method covers the determination of the degree of adhesion (bonding strength)
of a coating to a substrate, or the cohesive strength of the coating in a tension normal
to the surface. The test consists of coating one face of a loading fixture, and subjecting
this assembly of coating and fixtures to a tensile load normal to the plane of the coating.

iii
US Published Standards:
ASTM D 4541, Test Method for Pull-Off Strength of Coating Using Portable
Adhesion Testers.
This test method covers a procedure for evaluating the pull-off strength (commonly
referred to as adhesion) of a coating by determining either the greatest perpendicular
force (in tension) that a surface area can bear before a plug of material is detached, or
whether the surface remains intact at a prescribed force (pass/fail). Failure will occur
along the weakest plane within the system comprised of the test fixture, adhesive,
coating system, and substrate. This test method maximized tensile stress as compared
to the shear stress applied by other methods, such as a scratch or knife adhesion, and
the results may not be comparable. Further, pull-off strength measurements depend
upon both material and instrumental parameters. Results obtained using different
devices or results for the same coating on substrates having different stiffness may not
be comparable.
MIL-STD-1687A(SH), Thermal spray processes for naval ship machinery
applications, 2/11/87.
This standard covers thermal-spray processes for machinery element repair of ferrous
and non-ferrous substrates. Included are requirements for the qualification of thermal
spray procedures and operators, requirements and guidance for use of thermal spray
material and equipment, quality assurance requirements, and descriptions of applicable
qualification tests. Note: This standard is being revised.
MIL-STD-2138A(SH), Metal Sprayed Coatings for Corrosion Protection Aboard
Naval Ships.
This standard covers the requirements for the use of metal-sprayed coatings
(Aluminum) for corrosion control applications on board naval ships. This standards
covers certification of facilities, certification of operators, application procedures, metal-
spray procedures, and production quality assurance (including test procedures and
records). Note: This standard is being incorporated into ANSI/AWS C2.18A-XX/SSPC
CS 23.00A-XX/NACE TPC #XA, Guide for the Application of Thermal Spray Coatings
(Metalizing) of Aluminum, Zinc, and Their Alloys & Composites for the Corrosion
Protection of Steel, in preparation.
MIL-P-85856, Powder Materials, 7 December 1988.
This specification describes three (3 material categories for use in constructing thermal-
spray coatings, consisting of metallic and/or non-metallic components. These powder
materials may be suitable for application using wither plasma arc or combustion gas
(flame spray) techniques.

iv
US Standards In-Preparation
ANSI/AWS A5.33/A5.33M:199X, Specification for Solid and Composite Wires, and
Ceramic Rods for Thermal Spraying, 01/19/99 (ballot to publish).
This specification defines the as manufactured, chemical composition classification
requirements for solid and composite wires and ceramic rods for thermal spraying.
Requirements for standard sizes, marking, manufacturing, and packaging are included.
ANSI/AWS C2.16A, Guide for Thermal-Sprayer Qualification, WD #2, March 5,
1999.
This standard contains the thermal sprayer (operator) performance qualification tests
for thermal sprayers. Qualification tests are included for job knowledge, flame
spraying, arc spraying, plasma spraying, and high velocity oxygen fuel (HVOF)
spraying.
ANSI/AWS C2.18A-XX/SSPC CS 23.00A-XX/NACE TPC #XA, Guide for the
Application of Thermal Spray Coatings (Metallizing) of Aluminum, Zinc, and Their
Alloys & Composites for the Corrosion Protection of Steel, WD-2, February 25,
1999.
This standard is a procedure for the application of metallic thermal spray coatings
(TSC) of aluminum, zinc, and their alloys and composites for the corrosion protection of
steel. Required equipment, application procedures, and in-process quality control (QC)
checkpoints are specified.
ANSI/AWS C2.18B-XX/SSPC CS 23.00B-XX/NACE TPC #XB, Specification for the
Application of Thermal Spray Coatings (Metallizing) of Aluminum, Zinc, and Their
Alloys & Composites for the Corrosion Protection of Steel, WD-2, February 25,
1999.
This standard is a specification for the application of thermal spray coating (TSC)
systems for the corrosion protection specifies procedures for surface preparation and
the application of the TSC with in-process quality control (QC) check points. Annexes
provide amplifying information which include safety, job reference standards and job
control record, selection of TSC’s, TSC operator and inspector qualification, inspection,
material and equipment, and maintenance and repair of TSC’s. This standard may be
used as a procurement document.
ANSI/AWS C2.19-XX, Machine Element Repair with Thermal-Spray Coatings, in
preparation.
This standard covers thermal-spray processes for machinery element repair of ferrous
and non-ferrous substrates. Included are requirements for the qualification of thermal
spray procedures and operators, requirements and guidance for use of thermal spray
material and equipment, quality assurance requirements, and descriptions of applicable
qualification tests. Note: NAVSEA (Charles Null) requested AWS incorporate MIL-STD-
1687A(SH) into an AWS standard, April 1998.

v
US Standards In-Preparation
ANSI/AWS C2.20-9X, Specification for Thermal Spraying Zinc Anodes on Steel
Reinforced Concrete, Committee Draft #2, February 18, 1999. Ballot CD-205,
Approval to publish. Due 03/31/99.
This AWS standard is a specification for thermal spraying zinc anodes on steel
reinforced concrete. This standard is formatted as an industrial process instruction.
The scope includes: job description, safety, pass/fail job reference standards, feedstock
materials, equipment, a step-by-step process instruction for surface preparation,
thermal spraying, and quality control. There are three annexes: job control record,
operator qualification, and portable adhesion testing.
ANSI/AWS C2.21-9X, Specification for Thermal Spray Equipment Acceptance
Inspection, WD-4, May 15, 1998.
This standard specifies the thermal spray equipment acceptance requirements for
plasma, arc-wire, flame-powder, -wire, -rod, and -cord, and high-velocity-oxygen-fuel
(HVOF) equipment. Proof of suitability shall be provided by the equipment supplier.
Example inspection reports are provided in four non-mandatory appendices.
ANSI/AWS C2.22-9X, Guide for Metallographic Sample Preparation and Evaluation
of Thermal Spray Coatings. Note: No comparable ISO standard. Inactive
This guide presents the recommend practices for the metallographic techniques and
procedures for characterizing thermal spray coatings. Cutting, mounting, grinding, and
polishing materials and procedures are summarized. Coating analysis covers the
interpretation of the microstructure (percentage of porosity, oxides, and other phases)
and the correlation of that information with the overall properties of the thermal spray
coating by comparison with a standard using the Line-Intercept Method and the Grid
Area Method.
SSPC/NACE/AWS Tri-Society on Corrosion Protection of Steel with
Thermal Spray Coatings (TSTSC)
The SSPC/NACE/AWS Tri-Society on Corrosion Protection of Steel with Thermal Spray Coatings was
formed November 1996, at the SSPC C.1.2.B meeting, Dallas, TX. Membership inducted from the AWS
C2B, SSPC C2.1.B, and NACE T-6H-45 thermal spray committees on corrosion protection of steel. Two
Task Groups were formed:
TG-A, for developing a process specification for the protection of steel with thermal spray coatings of
aluminum and zinc and their alloys. The scope of TG-A is to develop a process specification updating
and merging the content AWS C2.18, SSPC CS 23.00, and MIL-STD-2138.
TG-B, for developing a guide for the inspection of thermal spray coatings on steel. The TG-B
inspection guide is a necessary complement to TG-A process specification.

vi
ISO Standards of TC 107 SC 5, Thermal Spraying
(12 standards issued)
ISO 2063:1991 Metallic and other inorganic coatings -- Thermal spraying -- Zinc, aluminum and their
alloys
ISO/DIS 14231 Thermal spraying -- Acceptance inspection of thermal spraying equipment
ISO/DIS 14232 Thermal spraying -- Powders -- Composition -- Technical supply conditions
ISO/DIS 14916 Thermal spraying -- Determination of tensile adhesive strength
ISO/DIS 14917 Thermal spraying -- Terminology, classification
ISO/DIS 14918 Thermal spraying -- Approval testing of thermal sprayers
ISO/DIS 14919 Thermal spraying -- Wires, rods and cords for flame and arc spraying -- Classification --
Technical supply conditions
ISO/DIS 14920 Thermal spraying -- Spraying and Fusing of thermally sprayed coatings of self-fluxing
alloys
ISO/DIS 14922-1 Thermal spraying -- Quality requirements of thermally sprayed structures --
Part 1: Guidance for selection and use
ISO/DIS 14922-2 Thermal spraying -- Quality requirements of thermally sprayed structures --
Part 2: Comprehensive quality requirements
ISO/DIS 14922-3 Thermal spraying -- Quality requirements of thermally sprayed structures --
Part 3: Standard quality requirements
ISO/DIS 14922-4 Thermal spraying -- Quality requirements of thermally sprayed structures --
Part 4: Elementary quality requirements
ISO 2063:1991, Metallic and other inorganic coatings -- Thermal spraying -- Zinc, aluminum and
their alloys. Edition: 2 (monolingual) -- Number of pages: 10 --Price code: E-- ICS:25.220.40
Descriptors: aluminum plating, classification, coatings, iron and steel products, metal coatings, metal
spraying, protective coatings, specifications, tests, zinc coatings. Last updated on 1998-01-17.
ISO/DIS 14231, Thermal spraying -- Acceptance inspection of thermal spraying equipment. Edition:
1 (monolingual) -- ICS: 25.220.20 Descriptors: acceptability, coating processes, coatings, equipment,
inspection, quality control, specifications, spraying, thermal spraying -- Last updated on 1998-01-17.
ISO/DIS 14232, Thermal spraying -- Powders -- Composition -- Technical supply conditions.
Edition: 1 (monolingual) -- ICS: 25.220.20 -- Descriptors: certificates of conformity, chemical composition,
chemical properties, classification, coating processes, coatings, delivery condition, designation,
microstructure, physical properties, powdery materials, size classification, specifications, spraying, thermal
spraying -- Last updated on 1998-01-17.
ISO/DIS 14916, Thermal spraying -- Determination of tensile adhesive strength.
Edition: 1 (monolingual) ICS: 25.220.20 Descriptors: adhesion tests, adhesive strength, coating
processes, coatings, determination, spraying, tension tests, tests, thermal spraying
Last updated on 1998-01-17
ISO/DIS 14917, Thermal spraying -- Terminology, classification. Edition: 1 (monolingual) -- ICS:
01.040.25, 25.220.20 -- Descriptors: classification, coating processes, coatings, spraying, thermal
spraying, vocabulary -- Last updated on 1998-01-17.
ISO/DIS 14918, Thermal spraying -- Approval testing of thermal sprayers. Edition: 1 (monolingual) --
ICS: 25.220.20 -- Descriptors: coating processes, coatings, instructions, personnel, procedure,
qualification, qualification approval, spraying, thermal spraying -- Last updated on 1998-01-17.
ISO/DIS 14919, Thermal spraying -- Wires, rods and cords for flame and arc spraying --
Classification -- Technical supply conditions. Edition: 1 (monolingual)--ICS: 25.220.20 -- Descriptors:
certificates of conformity, classification, coating processes, coatings, cordages, delivery condition,
designation, diameters, dimensions, marking, metal bars, packaging, properties, specifications, spraying,
thermal spraying, wire -- Last updated on 1998-01-17.
ISO/DIS 14920, Thermal spraying -- Spraying and fusing of thermally sprayed coatings of self-
fluxing alloys. Edition: 1 (monolingual) -- ICS: 25.220.20 -- Descriptors: coating processes, coatings,
melting, specifications, spraying, thermal spraying -- Last updated on 1998-01-17.

vii
ISO Standards of TC 107 SC 5, Thermal Spraying
ISO/DIS 14922-1, Thermal spraying -- Quality requirements of thermally sprayed
structures -- Part 1: Guidance for selection and use. Edition: 1 (monolingual) -- ICS:
25.220.20 -- Descriptors: coating processes, coatings, quality, rules (instructions),
specifications, spraying, thermal spraying -- Last updated on 1998-01-17.
ISO/DIS 14922-2, Thermal spraying -- Quality requirements of thermally sprayed
structures -- Part 2: Comprehensive quality requirements. Edition: 1 (monolingual)
-- ICS: 25.220.20 -- Descriptors: coating processes, coatings, inspection, personnel,
qualification, quality, specifications, spraying, thermal spraying -- Last updated on 1998-
01-17.
ISO/DIS 14922-3, Thermal spraying -- Quality requirements of thermally sprayed
structures -- Part 3: Standard quality requirements. Edition: 1 (monolingual) -- ICS:
25.220.20 -- Descriptors: coating processes, coatings, inspection, personnel,
qualification, quality, specifications, spraying, thermal spraying -- Last updated on 1998-
01-17.
ISO/DIS 14922-4, Thermal spraying -- Quality requirements of thermally sprayed
structures -- Part 4: Elementary quality requirements. Edition: 1 (monolingual) --
ICS: 25.220.20 -- Descriptors: coating processes, coatings, inspection, personnel,
qualification, quality, specifications, spraying, thermal spraying -- Last updated on 1998-
01-17.

viii
Important Safeguards
Means Warning! Watch out!
There are possible hazards with this procedure! The possible hazards are
shown in the below symbols. Your end user (applicator, operator or helper)
should read and understand these safeguards. The operator should read
and understand the operating and installation instructions provided with this Thermion
Arc Spray System.
The arc spray process and Thermion Arc Spray equipment share similarities with
welding processes and equipment. Improper use or maintenance may cause serious
injury or death. Your end user should have training or experience in safe practices for
the arc spray process before operating the arc spray equipment.
WARNING-ELECTRIC SHOCK MAY KILL
DO NOT touch bare conductors or terminals when energized. DO NOT work in
wet or damp areas. Wear dry insulated gloves and dry protective clothing. Remember
that when the power source is on, the electrode (wire) is electrically hot. DO NOT touch
the wire with bare skin while touching the electrical ground. Install and maintain your
electrical equipment using the correct electrical code standards appropriate for your
requirements, a certified electrician should always hook primary leads to the electrical
grid source with the appropriate safety disconnects.
WARNING-ARC RAYS MAY INJURE EYES AND BURN SKIN
The arc spray process produces extreme heat and strong ultraviolet rays.
Never try to arc spray without a welding helmet equipped with the proper lens. Protect
helpers, observers and bystanders. Failure to protect may cause permanent damage to
eyes. Also, protect skin from both arc rays and burns from heat. Always where
protective clothing which does not allow skin to become exposed.
WARNING-FUMES AND GASES MAY BE DANGEROUS TO YOUR HEALTH
Follow the precautions specified by the wire material manufacturers.
Breathing any fumes created by the arc spray process may cause illness or death when
there is not proper ventilation and protection. Keep your head out of the fumes. If
ventilation is not adequate, wear approved respiratory protection.
WARNING-WIRE FEED ROLLS CAN INJURE
Keep clear of wire feed rolls, these gears are hazardous during operation.
Keep clear of all moving parts, moving wire and rolling wire spools.
WARNING-NOISE CAN BE DAMAGING TO YOUR HEARING
Wear ear protection at all times. In some conditions double ear protection
may be required.

ix
Warranty Information
A. Limited Warranty
1) Subject to the terms and conditions hereof, Thermion Inc. warrants to the
user that all new and unused equipment furnished by Thermion Inc. is free
from defect in workmanship and materials as of the time and place of delivery
by Thermion Inc. or its agent. With respect to trade accessories or other
items manufacture by others, such items are sold subject to the warranties of
their respective manufacturers, if any.
2) Thermion Inc. will honor an original user's warranty claim on warranted
equipment in the event of failure resulting from a defect for a period of 90
(ninety) days from date of purchase.
3) Thermion Inc. will honor an original user's warranty claim on component and
any defects in workmanship on the wire feed unit for a period of 90 (ninety)
days from date of purchase.
B. Express Warranty
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 the 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
Thermion Inc. is excluded and disclaimed by Thermion Inc..
C. Consumer
Except as expressly provided by Thermion Inc. in writing, Thermion Inc. products
are intended for purchase and use by commercial/industrial users and for
operation by persons trained and experienced in the use and maintenance of
Thermal Arc Spray equipment and not for domestic use. Thermion Inc.
warranties do not extend to, and no reseller is authorized to extend, Thermion
Inc. warranties to any consumer.

x
Preface
This manual has been designed for experienced Thermal Arc Spray operators
and must be read completely before using the equipment. If you lack experience
or are unfamiliar with the practices and safe operation of welding equipment,
please consult your foreman. Do not attempt to install, operate, or perform
maintenance on this equipment unless you are qualified and have read and
understood this manual. If in doubt about installing or operating this equipment,
contact your distributor.
For the safe and successful use of this equipment, be sure the information
contained in this manual reaches the operator. Extra copies of this manual are
available upon request. Specify Part Number 51088 and your machine serial
number.
This manual is divided into nine sections:
Section 1: Introduction
Section 2: Safety
Section 3: System Assembly
Section 4: Controls and Their Functions
Section 5: Operation (General)
Section 6: Principals of Operation
Section 7: Liner Replacement
Section 8: Parts for Various Wire Sizes
Section 9: Parts Diagrams
The information contained in this manual represents our best judgment;
however, Thermion Inc. assumes no liability for its use.

xi
Service Notice
If, after reading this manual, and consulting with your distributor you have
additional questions regarding the operation of this piece of equipment, please
call, fax, or write:
Thermion
P.O. Box 0780
4955 N.W. Uff Da Lane
Silverdale, WA 98383 USA
[phone]
Fax [phone]
www.thermioninc.com
[e-mail]

xii
Table of Contents
Page Section Contents
2 1 Introduction
1.1 General Information and Safety
1.2 Receiving and Handling
1.3 General Description
1.3.1 Wire Feeder
1.3.2 Spray Gun
1.3.3 Arc Shorting Control
1.3.4 Remote Control
4 2 Safety Measures
2.1 Reduction of Fire and Explosive Hazards
2.2 Reduction of Respiratory Hazards
2.3 Threshold Limits for Air Concentration of
Hazardous Material
2.4 Personal Protection
2.5 Eye Protection
8 System Assembly
3.1 Location
3.2 Power Supply
3.3 Component Interconnection
3.3.1 Wire Feeder Hook Up to Power Supply
3.3.2 Gun Hook Up
3.3.3 Gun Tip/Air Nozzle Alignment
3.3.4 Service Air
10 4 Controls (START UP PROCEDURES)
4.1 Voltage
4.2 Amperage
4.3 Wire Inch
4.4 Fuse Holder & Indicator Light
4.5 Gun Switch
4.6 Air Sweep
4.7 Wire Runback

xiii
Table of Contents, continued
Page Section Contents
13 5 Operation (General)
5.1 Power Supply
5.2 Wire Loading and Drive Adjustment
14 6 Principles of Operation
6.1 Operating Parameters
6.2 Air Nozzle Alignment (Bridge Master Head)
6.2.1 Angle Spray Nozzle (Bridge Master Head)
6.3 Air Nozzle Alignment (Thermion 500 Head)
6.3.1 Air Nozzle Alignment (Hard Wire)
6.3.2 Angle Spray Nozzle (Thermion 500 Head)
6.4 Maintenance
6.4.1 Spray Head
6.4.2 Combination Leads
6.4.3 Feeder Unit
6.4.4 Control Cables
23 6.5 Maintenance Schedule
25 7 Replacing Wire Liner
7.1 Replacing/ Installation Small Wire Liners
28 8 Parts Required for Various Wire Sizes
29 9 Components Section
9.1 Cable Components
9.2 Feeder Components
9.3 Lead Components
9.3.1 Small Wire Lead Components
9.4 5100 Spray Head Components (Bridge Master
Head)
9.4.1 5000 Spray Head Components (Thermion 500
Head)
9.5 Wire Drive Components
9.6 Motor Components
9.7 System Wiring

2
1 Introduction
1.1 General Information and Safety
A. General Information presented in this manual and in the Power Supply
Manual, and on labels, tags and plates provided on the unit pertains to
equipment design, installation, operation, maintenance, and
troubleshooting which should be read, understood, and followed for the
safe and effective use of the equipment.
B. The installation, operation, maintenance and troubleshooting of the arc
spray equipment requires practices and procedures which ensure personal
safety and the safety of others. Therefore, this equipment is to be installed
and operated only by qualified persons in accordance with the manual and
all applicable codes.
Safety instructions pertaining specifically to this equipment appear throughout
this manual and the Power Supply Manual, highlighted by signal words
DANGER, WARNING, CAUTION, and IMPORTANT, which identify different
levels of hazards.
DANGER indicates an operational procedure, which, if not followed, will
cause SEVERE injury to the operator, service personnel or
bystanders.
WARNING statements include hookup, operating and maintenance
instructions and procedures which, if not followed carefully, could
result in SEVERE personal injury or damage to the equipment.
CAUTION indicates an operation procedure, which, if not followed, may cause
MINOR injury to the operator, service personnel and/or bystanders.
IMPORTANT highlights instructions, which need special emphasis to obtain the
most efficient and safe operation of this equipment.

3
1.2 Receiving and Handling
Prior to installing this equipment, remove all packing material from around the
unit and carefully inspect for any damage, which may have occurred during
shipment. Any claims for loss or damage that may have occurred during transit
must be filed by the purchaser with the carrier.
When requesting information concerning this equipment, model description and
serial number of the equipment must be supplied.
1.3 General Description
The Thermion Inc. arc spray machine is a pusher type arc spray system that has
a patented feature which controls arc shorting. This equipment is designed to
spray most wires, i.e., stainless, low alloy steels, bronzes, aluminum, zinc, zinc-
aluminum, babbitt, etc.
1.3.1 Wire Feeder:
The feeder is compact with a carrying handle. The meters, dials, and switches
are located on the front of the feed unit for ease of viewing and operation. The
drive assembly is a four-roll heavy-duty drive unit. A shop or field caddie is
available for easy mounting of the wire feed unit.
1.3.2 Spray Gun:
The spray gun is simple, durable, and lightweight. The patented combination
leads carry the atomization air, spray wire, and power to the spray gun from the
feeder.
1.3.3 Arc Shorting Control:
Arc spray systems typically have an inherent problem of arc shorting. This
condition occurs on all systems; the larger the wire diameter, the more severe
the problem. A patented feature of the Thermion system controls arc shorting.
As the arc attempts to short, a sensor detects a change in arc conditions, and
the patented feature compensates, recreating atomization. This feature has
allowed continuous usage of 3/16" aluminum and zinc wires producing over 40
lbs. and 150 lbs., per arc hour spray rate at a power level of 400 amperes.
1.3.4 Remote Control of Power Source:
The standard Thermion Inc. system includes a welding-type power source. All
functions of the system are remotely controlled at the wire feeder; the power
supply can be located remote from the work area. Refer to the power supply
manual for methods used to activate remote capabilities.

4
2 Safety Measures
WARNING Arc spraying can be hazardous because it requires the use of
electric voltages and currents, hoses under high pressure, and potentially
irritating or toxic spray materials. It may involve air contaminated by dusts,
fumes, etc,. However, it can be a completely safe process when performed by a
capable operator with proper understanding of arc spraying practices and
knowledge of the equipment, one who takes care in operation and follows the
recommended precautionary measures.
2.1 Reduction of Fire and Explosive Hazards
WARNING Remember that the stream of sprayed metal is HOT. Point the gun
away from yourself and away from flammable materials. Carelessness in
pointing the gun at paper, wood, or oily rags can result in fire.
CAUTION Be especially careful not to spray on the hoses when
operating the gun. Hoses will burn. Keep them out of the way. All air lines,
compressors, regulators, etc., should be inspected regularly for leaks and loose
connections.
EQUIPMENT MAINTENANCE: Maintain the arc spray equipment in first-class
condition. Follow the maintenance recommendations in this Thermion Inc.
instruction manual.
DANGER: All dust, having considerable caloric value, can be explosive. This
dust includes: flour, starch, hard rubber dust, wood flour, aluminum dust, and
the dust of other metals. Aluminum and magnesium dusts are particularly
hazardous. The greatest care should be used in handling them. To minimize the
danger of a dust explosion in an arc spray booth or other confined spaces,
prevent the accumulation of fumes and dust. Ventilation and good
housekeeping in the work area is essential. Inspect and clean regularly to
assure that there is no potentially dangerous accumulation of dust.
Dust Collectors must be suitable for metal spray dust. All closed collectors
should be provided with blowout holes or relief panels. All fans, pipes, dust
arresters and motors should be electrically grounded. Motors should be external
to the dust system.
When cleaning booths, pipes, etc., the ventilating fan should be kept running to
prevent the accumulation of fumes or dust in the system. Non-sparking tools
should be used in cleaning and repair operations.
When emptying the collector, all sources of ignition in the area should be
eliminated. When making repairs on the ventilating or dust collecting equipment,
no welding or cutting should be done before the equipment is washed down and
all metal dust removed.

5
2.2 Reduction of Respiratory Hazards
WARNING For shop work, being performed by an operator, without an air
fed hood, A suitable spray booth and an adequate exhaust system are required
to avoid the toxic or noxious effects of dust, fumes, and mists which may be
generated by arc spraying. The following is for information only; your
Governmental Safety and Health Agency should determine the actual
requirements.
For ordinary arc spray work, air at a velocity of 200 FPM (1.0m/s) should pass
into the opening of the spray booth. With the arc spray gun at the booth
opening, the exhaust system must be able to exhaust 200 CFM (0.1m3/s) of air
for every square foot of booth opening. If the booth has an opening of four
square feet, (.37m²), a system that will exhaust 4  200 or 800 CFM (0.4m
3/s)
should be provided. If there is any question as to the effectiveness of the
ventilating and exhaust system or as to the presence of airborne particles, which
the operator might inhale, consult a competent industrial hygienist.
Because any finely divided material may damage the respiratory system,
respirators are recommended for all Thermal Spraying.
IMPORTANT It is strongly recommended that complete and current information
be obtained from your Governmental Health Agency.
Some materials, such as beryllium, tellurium, and their oxides, are dangerous to
the respiratory system and should not be used at all except under the
supervision of a competent safety engineer.
BLASTING and SPRAYING both produce dust. Blasting of toxic materials
should be considered to be hazardous, as is spraying such materials.
Completely sealed mask-type pressurized respirators are recommended for all
applications of Thermal Spray. However, with proper ventilation that maintains
proper threshold limits of hazardous material, element type filters of the proper
type will protect satisfactorily.

6
2.3 Threshold Limits for Air Concentration of
Hazardous Material
WARNING Obtain up to date, exact figures from your governmental health
agency.
CERTAIN SOLVENTS: Certain solvents may decompose when exposed to
ultra violet rays. Avoid exposing solvents, or parts when wet with solvent, to the
radiation from the arc.
When the electric arc spray system is set up and operated in accordance with
the instructions in this manual, the metalizing wires are electrically energized
only when the gun is spraying. When the spray is shut off, electrical charge is
removed from both metalizing wires.
DANGER If, while the gun is spraying, a person should touch both energized
wires, or any part that the wire is in contact with, that person could receive an
electrical shock, the volume and current of which are capable of developing a
harmful or fatal electric shock or burns.
Do not clean the inside of the power supply unit with a wire brush or any other
tool. Use clean, dry compressed air only.
2.4 Personal Protection
WARNING The electric arc generated at the front of the gun is very bright
and emits ultraviolet light rays. The eyes and skin must be guarded against
these rays. Standard air fed welding, or sand blasting, personal protection
equipment fitted with a dark lenses, has proven to provide adequate protection
for thermal spraying.
Possible allergic reaction of dust, fumes, and the like, or other unknown causes
of health impairment due to contact with the body cannot, in most cases, be
predicted. To avoid such reaction, never permit spray dust to enter the eyes,
mouth, cuts, scratches, or open wounds. After spraying, and especially before
eating or handling foods, wash hands thoroughly. Wear fireproof or flame
resistant protective clothing if available. Protect eyes, ears, and skin through use
of gloves, facemask, ear, and body protectors that are standard in the welding
industry.
REDUCTION OF NOISE HAZARDS:
Noise from a THERMION INC. arc spray gun range between 80 and 120
decibels. At this level, most Governmental Health Agencies require ear
protection and sometimes double ear protection.

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2.4 Personal Protection (cont’.)
WARNING The noise made by the arc spray gun is loud enough to cause the
operator discomfort and can cause hearing damage. Adequate protection should
always be used.
The operator and other personnel close to the arc spray operation must be
protected from excessive noise. If possible, the spray operation should be
isolated. Hearing protection should be used. Do not rely on wads of cotton for
hearing protection. They are ineffective against high-intensity noise.
Noise level at any location depends on factors such as equipment operating
parameters, background noise, work area size, and wall, floor, and ceiling
materials. To determine the exact noise level, it is necessary to measure the
sound level to determine the method needed for adequate protection.
2.5 Eye Protection (Standard Welding Shields & Lens)
CAUTION The hardened green (Shade 9) lens is within the shade range
recommended for arc spraying. However, the choice of lens shade may be
based on visual sensitivity and sharpness (acuity) and may vary widely from one
individual to another. Check with your Government Health Agency for current
and complete shade number recommendations.
Always wear proper eye protection when operating or watching the arc spray
operation. Inspect the lens and cover plates frequently. Lenses and cover
plates that are scratched, pitted, or damaged can impair vision and seriously
reduce protection.
3. Environment
DANGER The Thermal Spraying operation can produce materials that are
hazardous for plants, animals, fish, or water quality. Precautions must be taken
to prevent any danger to the environment. Collect all residues from the metal
spray operation and dispose of as hazardous material or determine that it is safe
to the environment prior to disposal.

8
3 System Assembly