Thermion BRIDGEMASTER, Owner'S Manual

Page: 28 / 59

15
6.1 Operating Parameters
Operation:
Most materials will operate at a wide range of voltage and amperage settings,
excessive amperage may burn out chemical elements critical for the device
intended and provide poor deposit efficiency.
Wire Size:
The Bridgemaster can spray up to 3/16" diameter wire. 1/8" (3.2 mm) and 3/16"
(4.8 mm) diameter aluminum and zinc are the optimum size for the Thermion
equipment. 1/16" (1.6 mm) and 3/32" (2.4 mm) diameters are the most common
used sizes of the hard wire types.
Voltage:
Voltage controls arc gap. Normal range for low melting, soft materials is between
24 and 32 volts. Normal range for higher temperature hard wires is between 28
and 35 volts.
Amperage:
Amperage can be varied considerably for all materials. Non-alloyed materials, i.e.
aluminum, zinc, tin, etc. can be operated without fear of dealloying. However,
this equipment runs 3/32" (2.4 mm) material best at 200-250 amps and 1/8" (3.2
mm) and 3/16" (4.8 mm) between 250 and 500 amps. Alloyed material of 1/16”
(1.6 mm) and 3/32" (2.4 mm) size operates and maintains reasonable chemistry at
180-250 AMPS.
Adjusting Parameters:
Set the wire feeder volt dial on 80% & amp dial on 40%, start spraying at this
setting and while machine is running, adjust amperage to desired setting, then
lower voltage to minimum given in spray tables or until erratic arc is noticed.
Then, raise voltage until arc smoothes out.
Material Size Volts Amps Air Pressure
Aluminum 3 mm - 4.8 mm (1/8" - 3/16") 28-32 350-500 90-110 PSI
Zinc 3 mm - 4.8 mm (1/8" - 3/16") 28-32 325-500 90-110 PSI
Zinc-
Aluminum
3 mm - 4.8 mm (1/8" - 3/16") 28-32 300-500 90-110 PSI
Steels 1.6 mm - 2.4 mm (1/16” - 3/32") 28-35 200-250 90-110 PSI
Bronzes 1.6 mm - 2.4 mm (1/16” - 3/32") 28-35 200-250 90-110 PSI
400 Stainless 1.6 mm - 2.4 mm (1/16” - 3/32") 28-35 200-250 90-110 PSI
300 Stainless 1.6 mm - 2.4 mm (1/16” - 3/32") 28-35 200-250 90-110 PSI