Thermion BRIDGEMASTER, Owner'S Manual

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5 Operation (General)
5.1 Power Supply
Refer to the owner's manual for the welding power supply for operation and maintenance.
5.2 Wire Loading and Drive Adjustment
IMPORTANT Lubrication, threading, and adjusting the feed roll pressures are important
for smooth thermal spray operation. Proceed as follows:
1.
Completely lubricate the inside of each liner prior to threading each spool of wire by
disconnecting the leads from the wire feeder. Then spray a metalizing wire lubricant
(WD-40) into the feeder end of the liner, using air to blow the lubricant through the
liner. This lubricates the entire liner and clears excess lubricant. Lubricate each liner
in this manner when loading additional spools of metalizing wire. It has been learned
in practice, that lubricating is not necessary, when operating with 3/16" zinc or 85-15
(zinc/aluminum) wire.
2. Round off the free end of the metalizing wire with a file prior to feeding into the liner.
Sharp edges left on the wire will cut and damage liner.
3. Hand feed the wire through the inlet guide, over the feed rolls, through the centering
guide, and into the liner. Lower the clapper assembly, making sure the gears are
meshed.
4. With the wire completely through the liner and contact tips, adjust the pressure spring.
First, relax spring to minimum pressure, and then tighten spring pressure until the
wire feeds without slipping. The spring pressure applied should be the minimum
required to provide positive, non-slip wire feed. Too little pressure will result in wire
slippage, while excessive pressure will scar and deform the wire.