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Prince™ XL/Spool Gun - Owner's Manual Page 15

NOTE:
The Posa Start feature permits the WC-1 to be used in
combination with any Constant Current DC power source
with an open circuit voltage in excess of 55 volts.

Section 15

Interconnections

POWER CABLE

GAS HOSE

CUSTOMER

SUPPLIED

Ground Lead

WC-1 CONSTANT CURRENT

POSA START SENSING LEADS.

NOT NEEDED WITH CONSTANT VOLTAGE

SUPPLIES

red

green

COUPLER - AW-430-RH

M.K. P/N 753-3377

CONSTANT VOLTAGE

OR

CONSTANT CURRENT

POWER SUPPLY

+

_

CONTACTOR LEADS

PRINCE™XL SPOOL GUN

TO

WC-1 WELD CONTROL BOX

115VAC PLUG

WATER

POWER CABLE

PRINCE™XL TORCH

TO

COBRAMATIC I CABINET

(150-003, 150-203)

Weld Control Box

ELECTRICAL CABLE

ELECTRICAL

CABLE

WIRE CONDUIT

GAS HOSE

WATER HOSE -

OPTIONAL

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Summary of Contents for Prince XL

Page 1: ... 1428 Product Description Prince XL Spool Gun MK Manual Part Number 091 0384 MK Form Number PXL G SG NWSA Form Number 550 Effective with Serial Number 98100011 Voltage Rating 24 VDC Printing Revision Date July 2000 E This manual applies to the following torch model numbers 212 XXX 213 XXX 216 XXX ...

Page 2: ...ontaining materials that emit toxic fumes should not be heated unless coating is removed form the work surface the area is well ventilated or the operator wears an air supplied respirator Work in a confined space only while it is being ventilated and if necessary while wearing an air supplied respirator Gas leaks in a confined space should be avoided Leaked gas in large quantities can change oxyge...

Page 3: ... to mix any gases in a cylinder NEVER refill any cylinder Cylinder fittings should never be modified or exchanged 3 Hose Prohibited use Never use hose other than that designed for the specified gas A general hose identification rule is red for fuel gas green for oxygen and black for inert gases Use ferrules or clamps designed for the hose not ordinary wire or other substitute as a binding to conne...

Page 4: ...in ungrounded electrically HOT equipment can fatally shock a person whose body becomes a conductor DO NOT STAND SIT LIE LEAN ON OR TOUCH a wet surface when welding without suitable protection To protect against shock Keep body and clothing dry Never work in damp area without adequate insulation against electrical shock Stay on a dry duckboard or rubber mat when dampness or sweat cannot be avoided ...

Page 5: ...THIS PAGE INTENTIONALLY BLANK ...

Page 6: ...5 INTERCONNECTIONS 15 Section 16 OPERATION 16 Section 17 INSTALLING SPOOL ASSEMBLY 19 Section 18 SPOOL GUN SETUP 20 Section 19 MAINTENANCE 20 Section 20 TROUBLESHOOTING 21 Section 21 TESTING THE TORCH 23 Section 22 Prince XL Head Body Exploded View 25 Section 23 Prince XL Exploded View 26 Section 24 Prince XL Spool Gun 25ft 27 Section 25 Air Cooled Straight Barrel Assy 7 Exploded View 28 Section 2...

Page 7: ...the King Cobra torch A rotating water cooled barrel assem bly P N 003 1987 is available as a spare part The wire speed control knob is located on the bottom of the torch handle and provides 3 3 4 turns of rotation with a maximum speed of 900 ipm An important feature of the Prince XL spool gun assembly is that it can be converted from a spool gun into a Push Pull system to be used with the Cobramat...

Page 8: ... Volts Water cooled using optional W C Cup P N 621 0065 All above Duty Cycle ratings are with Argon Gas Torch weight less leads Air cooled 36 4 oz 1 02 kilogram Water cooled 38 4 oz 1 08 kilogram PRINCE XL SPOOL GUN Wire Capacity 023 045 0 6 1 2mm solid and hard wire 030 1 16 0 8 1 6mm aluminum and cored wire Wire Speed 900 ipm 22 9 mpm max Spool Size 4 inches 101 6mm Duty Cycle 150 Amps 25 Volts ...

Page 9: ...3 4 44mm 621 0002 045 1 2mm 053 1 3mm Spray 1 1 2 38mm 621 0327 045 1 2mm or 052 1 3mm 060 1 5mm Spray 1 1 2 38mm 621 0003 060 1 5mm Short 1 3 4 44mm 621 0286 1 16 1 6mm 075 1 9mm Spray 1 1 2 38mm 621 0075 1 16 1 6mm 085 2 1mm Spray 1 1 2 38mm 621 0153 085 2 1mm Short 1 3 4 44mm 621 0154 Standard Furnished with torch All tips stamped with tip I D contact tbl NOTE As a rule of thumb use the smaller...

Page 10: ...3mm 1 7 8 47 6mm 621 0157 621 0166 045 1 2mm 053 1 35mm Spray Short 1 5 8 41 3mm 1 7 8 47 6mm 621 0161 621 0167 052 1 4mm 060 1 5mm Spray Short 1 5 8 41 3mm 1 7 8 47 6mm 621 0162 621 0168 063 1 6mm 075 1 9mm Spray Short 1 5 8 41 3mm 1 7 8 47 6mm 621 0163 621 0169 063 1 6mm 085 2 16mm Spray 1 5 8 41 3mm 621 0164 093 2 3 mm 113 2 8 mm Spray 1 5 8 41 3mm 621 0215 Standard furnished with torch To remo...

Page 11: ...1973 Straight Water All Wires 030 063 8 1 6mm 615 0323 003 1973 Straight Water Optional All Wires 030 035 8 9mm 615 0545 003 1986 Curved Air All Wires 030 063 8 1 6mm 615 0539 003 1986 Curved Air Optional All Wires 030 035 8 9mm 615 0546 003 1986 Curved Air Steel Wire Only 030 063 8 1 6mm 615 0547 003 1987 Curved Water All Wires 030 063 8 1 6mm 615 0539 003 1987 Curved Water Optional All Wires 030...

Page 12: ...for Kool Cup Adapter 1 621 0386 10 Gas Cup for Kool Cup Adapter 2 see page 9 Use standard Prince tips 3 003 1487 Kool Cup adapter H D 4 449 0193 Nut Cup Retainer koolcup tbl 48 Degree PrinceXL Air Cooled Torch Cup and Tips Must be used with Kool Cup Adapter H D and Cup Retaining Nut Part No Item Description Wire Size 003 1487 3 Kool Cup Adapter H D N A 449 0193 4 Cup Retaining Nut N A 621 0375 1 4...

Page 13: ... used to prevent preheating of the wire which may soften it and clog the liner This picking up of current at the drive rolls rather than at the contact tip is usually not a problem unless using too large of a contact tip or excessively oxidized aluminum wire Prince XL Handle Kit 005 0633 Includes left and right handle with door trigger and pin and all handle screws Spool Adaptor Kit 005 0632 Inclu...

Page 14: ... 10 Gas Cup for Kool Cup Adapter 621 0386 All three items are needed to make Prince XL air cooled torch 200 amps 25 volts 100 duty cycle 8 Gas Cup for Kool Cup Adapter 621 0388 25 7 Pin Amphenol Extension Cable 005 0660 Used to extend the spool gun Two cables may be joined together for 50 extension Power gas cables not included Snake skin zipper cover 14 cover fits 15 lead 931 0110 24 cover fits 2...

Page 15: ... CUSTOMER SUPPLIED Ground Lead WC 1 CONSTANT CURRENT POSA START SENSING LEADS NOT NEEDED WITH CONSTANT VOLTAGE SUPPLIES red green COUPLER AW 430 RH M K P N 753 3377 CONSTANT VOLTAGE OR CONSTANT CURRENT POWER SUPPLY _ CONTACTOR LEADS PRINCE XL SPOOL GUN TO WC 1 WELD CONTROL BOX 115VAC PLUG WATER POWER CABLE PRINCE XL TORCH TO COBRAMATIC I CABINET 150 003 150 203 Weld Control Box ELECTRICAL CABLE EL...

Page 16: ...r cooled barrels have an adapter P N 003 2593 that is easily replaced if the cup threads become damaged The adapter is threaded onto the barrel The barrel assembly locks to the Prince XL body using the patented EZ Lock sys tem 16 2 2 Water Cooled The Prince XL water cooled systems 212 xxx come standard with a straight water cooled barrel assembly An optional curved water cooled barrel assembly P N...

Page 17: ...able Water Cooled Prince XL water cooled torch utilizes a power water cable with a 4AWG cable inside a 5 8 16MM diameter hose When water is used with this cable and the 10 water cooled gas cup is used P N 621 0065 the system is rated at 400 amps 100 duty cycle If water is not used with this cable the system is rated at 100 amps 50 duty cycle 16 5 3 Conduit The Prince XL Torch comes standard with a...

Page 18: ...lls will cause excessive knurling and or deformation of the wire 16 6 2 DRIVE ROLL INSTALLATION REMOVAL Rotate drive roll by jogging drive motor with trigger switch or with finger tips until slots line up with door Hold the drive roll with 3 8 open end wrench Insert a slot type screwdriver into the slot on motor shaft and turn screwdriver CCW left hand thread Install new drive roll on motor shaft ...

Page 19: ...onduit through access hole located on top right rear handle with a 1 16 Allen wrench Remove conduit by pulling it out of the back of the gun Install spool liner and secure with screw Remove both rear handle screws and secure spool canister with longer screws provided 2 SCREWS CONDUIT SECURING SCREW SPOOL LINER REAR WIRE GUIDE E RING ...

Page 20: ...from gun loosen barrel taper lock assembly and slide towards cup Leave barrel inserted in gun body Pull handles apart Section 19 MAINTENANCE Maintenance of the torch will normally consist of a general cleaning of the wire guide system including tubes drive rolls and conduit at regular inter vals The only parts on the gun that are subject to normal wear are the conduit contact tips gas cups drive r...

Page 21: ...up as the original Prince motors P N s 211 0054 211 0056 Even though the duration of start up is very short about 15msec it is too much for the standard 2A fuse to handle For this reason all 2A fuses in the motor circuitry F1 should be changed to a 3AG 4A fast blow 250V fuse P N 151 0043 This new 4A fuse is sufficient for use on all model welding guns on the wire feeders while still providing prot...

Page 22: ... wrong position Welding power source Check all power connections Check power supply owners manual for location and type of contactor signal required i e closing or 115 VAC Check power source manual Wire feeds erratically Excessive spool drag pressure Dirty or worn conduit Incorrect pressure on drive rolls Idler roll stuck Wrong size contact tip Decrease spool drag pressure Blow out or replace cond...

Page 23: ...in D wiper and pin G The resistance should vary from 5K 0 ohms 21 3 Testing the Micro Switch Using the torch Amphenol check for continuity across pins E and F when the trigger is pressed E C A B D G F TORCH MOTOR TORCH POT TORCH TRIGGER 5K Red Black Blue Yellow Orange Brown White Green Red Grey Grey 1 3 2 Grey Grey Red Red Pin 1 Pin 1 Pin 1 Pin 1 Cabinet End Amphenol Connector Torch Connectors Ins...

Page 24: ...onduit 25 1 005 0661 Potentiometer Kit 1 003 0568 Micro Switch 1 005 0633 Handle Kit 1 511 0101 Drive Roll 1 511 0001 Idler Roll 1 325 0206 Idler Roll Screw 1 333 0082 Idler Roll Washer 1 003 0585 Trigger Assy 1 431 3117 Door 1 003 0198 Wire Guide Spool Gun 1 003 2072 Brake Assy Spool Gun 1 003 2071 Cover Assy Spool Gun pxl spares tbl ...

Page 25: ...re guide 2 1 333 0082 Washer split 10 3 1 419 0020 Spring compress 0 29 od x 0 047 4 1 321 1074 Set scr mod 6 32unc x 5 8 5 1 325 0206 Screw pan head 10 24 3 8 6 7 8 1 431 1427 Pivot pin 9 1 421 0129 Pin spring 0 063 x 0 437 10 1 003 0568 Micro switch assy 11 1 511 0001 Idler wire feed assy 12 1 431 1424 Idler arm 13 1 001 0562 Gas valve cobra 14 2 431 3034 Fitting 3 16 hose to 1 16 27npt 15 1 313...

Page 26: ...er Split 4 ST 5 3 328 0003 Screw Shc 4 40 x 0 50 6 2 336 0056 Screw Pnh Phil 4 40 x 1 50 7 2 336 0003 Screw Pnh Phil 4 40 x 0 50 8 2 336 0070 Screw Pnh Phil 6 32 x 1 50 9 1 003 1972 Head Body Prince XL 10 1 003 0567 Potentiometer 11 1 421 0408 Pin Dowel 0 093 x 2 00 LG 12 1 421 0409 Pin Dowel 0 093 x 1 25 LG 13 1 211 0071 Motor 14 1 436 0136 Handle Right 15 1 436 0137 Handle Left 16 1 511 0101 Dri...

Page 27: ...on 23 for parts breakdown No Qty Part No Description 1 1 003 1259 Assy Head 2 1 153 0857 Conn Molex 5 Pos 3 1 153 0856 Conn Molex 2 Pos 4 1 001 1317 Lead 25 Ft Spool 5 1 003 1980 Barrel Straight 7 00 6 7 153 0852 Pin 7 1 411 0045 Tie Wrap 8 13 ft 739 0006 Tube H S 1 4 9 1 003 2021 Assy Spool MK Tb 1390c tbl ...

Page 28: ... Ref No Qty P N Description 1 1 003 2572 Taper lock assy 2 2 303 0094 O Ring 0 301 I D x 0 070 3 4 303 0010 O Ring 0 489 I D x 0 629 O D 4 1 303 0093 O Ring 0 364 I D x 0 07 w 5 1 615 0537 Liner teflon 6 1 001 0138 Gas cup 8 7 1 003 2593 Cup assy Prince 8 1 621 0003 Contact tip MK 0 060 9 1 002 0575 Brazed barrel air cooled tb 1980b tbl ...

Page 29: ...N Description 1 2 303 0094 O Ring 0 301 I D x 0 070 2 2 303 0010 O Ring 0 489 I D x 0 629 O D 3 1 621 0003 Contact tip MK 0 060 4 1 615 0539 Liner teflon 0 175od 5 1 303 0093 O Ring 0 364 I D x 0 07 w 6 1 003 2593 Cup air barrel Prince XL 7 1 003 2572 Taper lock assy Prince XL 8 1 002 0591 Barrel curved 45 a c 9 1 001 0138 Gas cup 8 tb 1986b tbl ...

Page 30: ... 431 0977 retaining Nut 3 2 303 0094 O Ring 0 301 I C x 0 070 4 8 303 0010 O Ring 0 489 I D x 0 629 O D 5 1 615 0323 Liner teflon Prince XL 6 1 261 0381 Insulator cup King includes 4 ea O ring P N 003 0012 7 1 621 0159 Cup 8 assy 8 1 621 0162 Contact tip 0 060 9 1 002 0574 Brazed barrel straight 7 00 10 1 621 0101 Cup adaptor with insulator 11 1 449 0193 Gas cup nut 12 1 751 0011 Round vinyl cap t...

Page 31: ...9 O D 2 2 303 0094 O Ring 0 301 I D x 0 070 3 1 621 0162 Contact tip 0 060 4 1 621 0159 Cup 8 assy 5 1 615 0539 Liner teflon 0 175od x 8 06 6 1 431 0977 Retaining nut 7 1 261 0381 Insulator cup includes 4 ea O ring P N003 0012 8 1 003 2572 Taper lock assy 9 1 002 0592 Barrel curve 45 w c 10 1 621 0101 Cup adapter with insulator 11 1 449 0193 Gas cup nut 12 1 751 0011 Round vinyl cap tb 1987a tbl ...

Page 32: ...age 32 Section 29 Taper Lock Nut Assembly Exploded View P N 003 2572 Ref No Qty MK P N Description 1 1 431 1416 Taper lock nut 2 1 431 1423 Taper lock collar 3 1 437 0227 Taper lock insulator 4 1 313 0027 Snap ring 0 750 shaft tb 2572 tbl ...

Page 33: ...lb Spool Assembly Exploded View P N 003 2021 No Qty Part No Description 1 1 437 0235 Spindle 2 1 003 2072 Assembly Brake 3 1 003 2071 Assembly Cover 4 2 336 0073 SCR Pan HD Phil 6 32 x 2 00 ST 5 2 333 0005 Washer Split 6 6 1 003 0198 Wire Guide Tb 2021b tbl ...

Page 34: ...Cable Gas Hose Snake Skin 15 4 5m 615 0007 001 2527 005 0268 001 0537 931 0110 25 7 6m 615 0008 001 2528 005 0269 001 0538 931 0122 50 15 2m 615 0068 001 1042 005 0272 001 0665 931 0123 Cable Fittings for Air Cooled Torches Power Cable Torch End Fitting Cabinet End Lug Assy Part No 431 1128 003 1328 Gas Hose Nut Insert Ferrule Part No 753 0464 469 0161 ...

Page 35: ...005 0268 001 0537 001 0529 931 0110 25 7 6m 615 0008 001 2524 005 0269 001 0538 001 0530 931 0122 50 15 2m 615 0068 843 0338 005 0272 001 0665 001 0667 931 0123 Cable Fittings for Water Cooled Torches Water Power Cable Torch End Fitting Cabinet End Lug Assy Ferrule 650 1ea Part No 003 0590 003 1327 469 0002 Gas Hose Nut Insert Ferrule Part No 753 0464 469 0161 Water Hose Nipple Nut Ferrule Part No...

Page 36: ...able Electrical Cable Gas Hose Snake Skin 25 7 6m 843 0484 005 0269 552 0202 931 0122 50 15 2m 843 0485 005 0272 552 0203 931 0123 Power Cable and Gas Hose Fittings Power Cable Torch End Fitting Lug End Fitting Part No 431 1128 185 0410 Gas Hose Ferrule Nut Nipple Ferrule Part No 449 0161 753 0159 753 0656 449 0161 ...

Page 37: ...as power lug are all that is needed to connect to the Migmaster 250 Adaptor kit includes everything needed A panel kit plugs directly into the front of the Migmaster 251 and includes everything that is needed to interface the spool gun Note In order to achieve proper operation with the Prince and Prince XL Spool Guns please install the 800 ipm spool gun motor P N 211 0071 if not already in use For...

Page 38: ... 3062 WC 1 001 3066 Contactor Box 216 725 25 Spool Gun 005 0261 Miller Torpedo 216 750 50 Spool Gun 005 0206 L Tec Migmaster 250 005 0264 Generic Torpedo 005 0205 Millermatic 250 Vintage 005 0624 ESAB Migmaster 251 005 0629 Millermatic 250X 005 0617 Panasonic Gunslinger 005 0264 005 0261 005 0206 005 0205 005 0624 ...

Page 39: ...Prince XL Spool Gun Owner s Manual Page 39 THIS PAGE INTENTIONALLY BLANK ...

Page 40: ...inal user 1 Torches and Weldheads 1 year 2 All Other Equipment 3 years 3 Repairs 90 days Classification of any item into the foregoing categories shall be at the sole discretion of MK Products Notification of any failure must be made in writing within 30 days of such failure A copy of the invoice showing the date of sale must accompany products returned for warranty repair or replacement All equip...

Page 41: ... the U S A MK Products Inc 16882 Armstrong Ave Irvine CA 92606 TEL 949 863 1234 TEL 949 863 1234 TEL 949 863 1234 TEL 949 863 1234 TEL 949 863 1234 F F F F FAX 949 474 1428 AX 949 474 1428 AX 949 474 1428 AX 949 474 1428 AX 949 474 1428 ...

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