Owner`s Manual and Spool Gun
Contents
1. EA and Spool Gun PRODUCTS Owner s Manual Product Prince XL Manual 091 0592 Serial 11030001 Voltage Rating 24 VDC Revision March 2011 D Gun models 317 XXX 318 XXX 319 XXX 225 Ampere Air Cooled 255 Ampere AirCooled Spool 450 Ampere Water Cooled Push Pull Welding Guns Table of Contents SAGN Consideration arv i vi farce y L Section A Technical DecIhcaHOn Sue diciones 1 Support Equipment HReoured 1 Coolant Ee ng Ee E le 1 GUN Lead ConnecUon ce GU Y A 1 SPO GUN ASSemDblyf ie ee YG Eu Gu Go aa ydy GN GG a ww wu lund 2 Set m UT Section B A e o OO O ee 4 Pe NNN 4 Controls and GtlhidS arar a 4 Drive RA amd Idler IRONS ve D ACCESS alo Y ee Section C COMOT OE EE NN Me ON ME 6 EE MC E 6 PINE T SI ge T JB RR T Oe ea AE Ma NN 8 Optional ACCES SOMO iaa 8 PT GML ONO Samaria 9 VI AINTEN ANCE E section D FEIMIN NAS AE 10 Recommended spare Parts LIS aid aa 11 KOUDIESHOOMT em E E Section E Troubleshooting GUIAS vu 13 Testing NE ON 14 NNN Section F Diagrams PET US toscanini 15 Safety Warnings Warranty Declaration of Conformity for European Community CE Products Note ll This information is provided for units with CE certification see rating label on unit Manufacturer s Name M K P rod u cts y nc 16882 Armstrong Ave Irvine CA 92606 Declares that the product P rince XL conforms to the following Directives and Standards Direct2. COMPLY WITH PRECAUTIONS 1 Protective Clothing Wear long sleeve clothing in addition to gloves hat and shoes As necessary use additional protective clothing such as leather jacket or sleeves flameproof apron and fire resistant leggings Avoid outer garments of untreated cotton Bare skin protection Wear dark substantial clothing Button collar to protect chest and neck and button pockets to prevent entry of sparks 2 Eye and Head Protection Protect eyes from exposure to arc Eyes may be damaged by radiant energy when exposed to the electric arc even when not looking in the direction of the arc Never look at an electric arc without protection Welding helmet or shield containing a filter plate shade no 12 or denser must be used when welding Place over face before striking arc Protect filter plate with a clear cover plate Cracked or broken helmet or shield should NOT be worn radiation can be passed through to cause burns Cracked broken or loose filter plates must be replaced IMMEDIATELY Replace clear cover plate when broken pitted or spattered Flash goggles with side shields MUST be worn under the helmet to give some protection to the eyes should the helmet not be lowered over the face before an arc is struck Looking at an arc momentarily with unprotected eyes particularly a high intensity gas shielded arc can cause a retinal burn that may leave a permanent dark area in the field of vision Pr
3. 9700 Z X 60 ewog ud 8070 Lat ZL OG X ZE 9 Ud uud MAINS LZ00 9 Z HL OG L X Of t Ud uud M HS 9500 9 Z OL GZ9 0 X Op Ud uud M HS 6700 9865 Z 6 LS 9 nds J YSEM opgeet c 8 LS vi MAS J USBM 000 amp y 2 OG 0 x Ob OUS MAUDS 000 8c 9 E INIA L S PX pog ssv oezz eo0 po Did SES Zuel rzereoo TXd 1961 ssy 9850 00 b c Xd J910uionuojod Assy 2990 00 L uopduoseg ON Med AID ON MENE eke e pe Prince XL Spool Gun Owner s Manual Page 16 Prince XL Head Body Exploded View 003 2290 TORQUE REQUIRES 65 5 IN LB APPLY PIPE THREAD SEALANT TO THREAD Head Body Assembly 001 0562 Gas Valve Cobra see note 002 0573 Main Body Assy Items 7 8 amp 15 can be 002 0583 Adjust Screw Idler Arm purchased as a kit 003 0568 Micro Switch Assy P N 005 0686 Note If Cobramatic Wire Feeder is equipped with a gas solenoid kit a modified gas valve stem p n 431 1080 must be installed in gun to allow gas flow from cabinet value Prince XL Spool Gun Owner s Manual Page 17 Prince XL Spool Gun Straight Barrel Assembly Air Cooled P N 003 2330 ae a p 0 260 CN KO RING GROOVE REF A APPLY HOSE LUBRICANT INSIDE INSULATOR BARREL BEFORE INSTALLING APPLY SILICONE LUBRICANT TO O RING BEFORE INSTALL ING Air Cooled Straight Barrel Assem
4. 0480 25 035 0 9 mm 044 1 1 mm 1 0 25 4 mm 621 0481 25 045 1 1mm 053 1 37 mm 1 0 25 4 mm 621 0482 25 3 64 1 2 mm 060 1 5 mm 1 0 25 4 mm 621 0483 25 Used with Flex Barrel cups 621 0465 and 621 0466 on Air Cooled models only Gas Cups Finned Copper Gas Cups 3 8 9 5mm 621 0248 112 12 7 621 0249 5 8 15 8mm 621 0260 Heavy Duty Finned Copper Gas Cups 5 8 1 8mm 621 0251 3 4 19 0mm 621 0262 Standard furnished with Air Cooled gun Prince XL Spool Gun Owner s Manual Page 6 ir Cooled Cup Water Cooled Cup Adapter Water Cooled Cup Air Cooled Cups for Prince XL Water Cooled Gun No 6 3 8 9 5mm No 8 1 2 12 7mm No 10 5 8 15 8mm A 621 0170 621 0159 621 0160 To use air cooled gas cups you must use a cup retaining nut 449 0193 and a water cooled cup adapter 621 0101 Water Cooled Cups for Prince XL Water Cooled Gun 5 8 15 9mm 621 0065 Standard furnished with gun Flex Barrel Gas Cups 1 2 12 7mm 5 8 15 8mm Works with Air Cooled models only 621 0465 621 0466 Tip Extender Tip Extenders and Gun Barrel Liners 225 Amp a A W Cooled 45 P N 003 2152 Optional on AC 450 Amp Water Cooled 45 P N 003 2316 Optional on WC Teflon liner package 5 pieces 931 0137 Steel wire only 030 045 8 1 2mm 615 0343 Tip Extender 6
5. Amps 003 2321 Prince XL Spool Gun Owner s Manual Page 7 12 Flex Air Cooled Barrel Assembly 200 Amps 003 2495 12 18 Flex Air Cooled Barrel Assembly 200 Amps 003 2495 18 24 Flex Air Cooled Barrel Assembly 200 Amps 003 2495 24 36 Flex Air Cooled Barrel Assembly 200 Amps 003 2495 36 Optional Kits Insulated drive roll kits are 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 Insulated Groove Drive Roll Kit 005 0715 For 030 0 8mm dia aluminum wire Includes insulated groove drive roll and insulated idler roll assy Insulated Groove Drive Roll Kit 005 0716 For 035 0 9mm dia aluminum wire Includes insulated groove drive roll and insulated idler roll assy Insulated Groove Drive Roll Kit 005 0717 For 040 1 0mm dia aluminum wire Includes insulated groove drive roll and insulated idler roll assy Insulated Groove Drive Roll Kit 005 0718 For 045 1 2mm dia aluminum wire In
6. Use pressure charts available from your supplier for safe and efficient recommended pressure settings on regulators Check for leaks on first pressurization and regularly thereafter Brush with soap solution Bubbles indicate leaks Clean off soapy water after test dried soap is combustible E User Responsibilities Follow all Safety Rules Remove leaky or defective equipment from service immediately for repair Read and follow user manual instructions F Leaving Equipment Unattended Close gas supply at source and drain gas G Rope Staging Support Rope staging support should not be used for welding or cutting operation rope may burn 1 3 ARC WELDING Comply with precautions in 1 1 1 2 and this section Arc Welding properly done is a safe process but a careless operator invites trouble The equipment carries high currents at significant voltages The arc is very bright and hot Sparks fly fumes rise ultraviolet and infrared energy radiates weldments are hot and compressed gases may be used The wise operator avoids unnecessary risks and protects himself and others from accidents A Burn Protection Comply with precautions in 1 2 The welding arc is intense and visibly bright Its radiation can damage eyes penetrate lightweight clothing reflect from light colored surfaces and burn the skin and eyes Skin burns resemble acute sunburn those from gas shielded arcs are more severe and painful DON T GET BURNED
7. power and remove line fuses or lock or red tag switches to prevent accidental turning ON of power Disconnect all cables from welding power source and pull all 115 volts line cord plugs Do not open power circuit or change polarity while welding If in an emergency it must be disconnected guard against shock burns or flash from switch arcing Leaving equipment unattended Always shut OFF and disconnect all power to equipment Power disconnect switch must be available near the welding power source have in bringing the product to you For selecting a quality product We want you to take CAM pride in operating this product as much pride as we Please Examine Carton and Equipment For Damage Immediately When this equipment is shipped title passes to the purchaser upon receipt by the carrier Consequently claims for material damaged in shipment must be made by the purchaser against the transportation company at the time the shipment is received Please record your equipment identification information below for future reference This information can be found on your machine nameplate Model Name amp Number Code amp Serial Number Date of Purchase Whenever you request replacements parts for or information on this equipment always supply the information you have recorded above Read this Owner s Manual completely before attempting to use this equipment Save this manual and keep it handy for quick reference Pay p
8. 21 0424 Spiral steel liner with tip extender 615 0252 Barrel Assemblies am a 450 Am 225 Amp 300 Amp Water Geen Air Cooled Water Cooled P N 003 2315 P N 003 2330 P N 003 2380 Standard on WC Standard on AC Optional on WC 200Amp Air Cooled Only P N 003 2495 12 Optional on AC Optional 6 12 and 18 Straight and Curved Barrel Assemblies 6 Curved 45 Air Cooled Barrel Assembly 003 2331 6 Straight Air Water Cooled Barrel Assembly 003 2151 6 Curved 45 Air Water Cooled Barrel Assembly 003 2152 6 Curved 45 Water Cooled Barrel Assembly 300 Amps 003 2381 6 Straight Water Cooled Barrel Assembly 300 Amps 003 2380 12 Straight Air Cooled Barrel Assembly 003 2332 12 Curved 45 Air Cooled Barrel Assembly 003 2333 12 Curved 45 Water Cooled Barrel Assembly 400 Amps 003 2319 12 Straight Water Cooled Barrel Assembly 400 Amps 003 2318 18 Straight Air Cooled Barrel Assembly 003 2334 18 Curved 45 Air Cooled Barrel Assembly 003 2335 18 Straight Water Cooled Barrel Assembly 400 Amps 003 2320 18 Curved 45 Water Cooled Barrel Assembly 400
9. 269 005 0272 Hose Retainer is re usable and can be removed and re installed as needed Power Cable includes copper wrap P N 701 0053 1 Prince XL Spool Gun Owner s Manual Page 26 Prince XL Lead Assembly Spiral Wrap Installation 033 0929 Gun End Air Cooled F Sy PRINCE XL ED Gun End A C amp W C Leads Wrap Instruction y Prince XL Spool Gun Owner s Manual Page 27 Prince XL Lead Assembly Spiral Wrap Installation 033 0929 Gun End Water Cooled s y ES od l f L x i w Pp Spiral Wrap p n 261 0094 Prince XL Spool Gun Owner s Manual Page 28 Prince XL Electrical W Clocked Amphenol Connector Viewed from front of connector 5 Pin Female Connector P N 153 0857 5 Pin Male Connector P N 153 0855 l j Female pins 7 total P N 153 0853 Male pins 7 total P N 153 0852 2 Pin Female Connector 2 Pin Male Connector P N 153 0856 P N 153 0854 Cabinet End Toren Connectors Tach menor Amphenol Connector Inside Handles Torch Lead a OS Red Pin 1 Pin 1 Red A TORCH B O Black Grey MOTOR White Grey 1 OK 3 GO vil AMW Green Grey TORCH D o S POT Bl
10. AEE CMRRBPFELEWTFSL OMATT DERES RR TD IF eco Bel Neg ZEA OFA AG Ley ails 13 Aal ida Jai YO Agile gl Al ga LEIA E COMPREENDA AS INSTRUG ES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO E SIGA AS PRATICAS DE SEGURANGA DO EMPREGADOR ESMERO home IRA ETENU TT U TL CRHORBSRECEDT FS CIT TE NS SO OG RR J BW EL RN o AZo SEN xIgixjA AME Axel FAO AIA OMM AUR EPIA vet Jarl palal GU d tags gad y Lg llar J y hardt s g ill al Glaled al y cnau L LIMITED WARRANTY Effective August 1 2010 This warranty supersedes all previous MK Products warranties and is exclusive with no other guarantees or warranties expressed or implied LIMITED WARRANTY MK Products Inc Irvine California warrants that all new and unused equipment furnished by MK Products is free from defects in workmanship and material as of the time and place of delivery by MK Products No warranty is made by MK Products with respect to trade accessories or other items manufactured by others Such trade accessories and other items are sold subject to the warran ties of their respective manufacturers if any ME Products warranty does not apply to components having normal useful life of less than one 1 year such as relay points wire conduit tungsten and welding gun parts that come in contact with the welding wire including gas cups gas cup insulators and contact tips where failure does not result from defect in workmanship
11. CH MAY CAUSE SERIOUS AND PERMANENT EYE DAMAGE AND WHICH MAY DAMAGE ANY EXPOSED SKIN AREAS Wear helmet with safety goggles or glasses with side shields underneath appropriate filter lenses or plates protected by clear cover glass This is a must for welding or cutting and chipping to protect the eyes from radiant energy and flying metal Replace cover glass when broken pitted or spattered Medical first aid and eye treatment First aid facilities and a qualified first aid person should be available for each shift unless medical facilities are close by for immediate treatment of flash burns of the eyes and skin burns Wear protective clothing leather or asbestos gauntlet gloves hat and high safety toe shoes Button shirt collar and pocket flaps and wear cuffless trousers to avoid entry of sparks and slag Avoid oily or greasy clothing A spark may ignite them Flammable hair preparations should not be used by persons intending to weld or cut Hot metal such as electrode stubs and work pieces should never be handled without gloves Ear plugs should be worn when working on overhead or in a confined space A hard hat should be worn when others work overhead B Toxic Fume Prevention WARNING The use of this product may result in exposure to chemicals known to the State of California to cause cancer and birth defects or other reproductive harm Adequate ventilation Severe discomfort illness or death can result
12. Gun Control Lincoln CV 250 CV 300 CV 400 CV 655 DC 400 DC 600 DC 655 V350 Pro factory model Ranger 250 Range 275 Ranger 305G PA M1 Spool Gun Control Miller P N 005 0261 Connects directly to Miller power supplies 24V system a PR M d that are classified with 14 Pin amphenols as type 6 or 9 and to Thermal Arc units such as MILLER SUPPLIES THERMAL ARC A Millermatic 200 Deltaweld s Thermal Arc 300GMS CC CV Shopmaster CP Series Fabricator 210 250 300 LF XMT s amp Maxtron Trailblazer 250 251 Regency s Any Gas drive that has a CV tap and contactor installed with a 14 pin amphenol PA G1 Spool Gun Control Generic P N 005 0264 This Generic Torpedo is designed to hook up to CV 0 PA G ch power supplies that supply an auxiliary 26 VAC Q 1 7 gr NN amps and uses a closing contact signal The unit is supplied with bare wires that must be connected to the SE A i power supply Some examples of power supplies that can be hooked up are Lincoln SP 250 255 amp Wirematic 250 amp 255 Beta Mig 200 amp Beta Mig LF Airco Dip Pak 200 225 amp 250 Prince XL Spool Gun Owner s Manual Page 9 Section D ESAB L TEC MigMaster 250 P N 005 0206 An amphenol adaptor cable and gas power lug are all that is needed to connect to the Migmaster Adaptor kit includes everything needed MillerMatic 250 amp Vintage Hobarts BetaMig 2510 P N 005 0205 This easy to install plug in module fits the Millermat
13. Insert new idler roll and lock washer onto screw insuring that idler groove is toward top and lock washer is beneath 3 Tighten 7 Groove Towards Top Idler Arm Lock Washer NOTE Lock washer must be under idler roll or it will not turn freely Prince XL Spool Gun Owner s Manual Page 5 Section C Accessories Contact Tips _ gt Heavy Duty Contact Tip 3 8 Diameter 030 0 8mm 041 1 0mm Spray 1 57 39 9mm 621 0390 25 Short 1 82 46 2mm 621 0396 25 035 0 9mm 044 1 1mm Spray 1 57 39 9mm 621 0391 25 621 0391 250 621 0391 500T 035 0 9mm 044 1 1mm 1 82 46 2mm 621 0397 25 045 1 1mm 053 1 35mm Short 1 82 46 2mm 621 0398 25 3 64 1 2mm 053 1 35mm Spray 1 57 39 9mm 621 0392 25 M 621 0392 250t 621 0392 500tt 3 64 1 2mm 060 1 5mm Spray 1 57 39 9mm 621 0393 25 M 621 0393 250t 621 0393 500tt 1 16 1 6mm 074 1 9mm Spray 1 57 39 9mm 621 0394 25 085 2 16mm Spray 621 0395 25 Use of tip removal tool is recommended t Also sold in quantities of 250 This size tip furnished with gun tt Also sold in quantities of 500 Spring Loaded Contact Tip 3 8 Diameter WireSize mp Arc Tip Length Qty Part Number 030 0 8 mm 035 0 9 mm 3 64 1 2 mm 3 8 Diameter Flex Barrel Tip Recommended for Flex Barrel 030 0 8 mm 041 1 mm 1 0 25 4 mm 621
14. L gun comes standard with a knurled drive roll and a grooved idler roll which will handle both steel and aluminum wire with diameters from 030 1 16 inch Optional insulated V groove drive rolls are also available for aluminum wire if desired see Optional Kits Drive roll tension is accomplished by means of a pressure adjusting allen screw located on the left hand side of the gun Proper tension is achieved when wire does not slip if a small amount of pressure is added to the wire as it exits the tip NOTE Over tightening of the drive rolls will cause excessive knurling and or deformation of the wire Drive Roll Installation Removal NOTE Neither of the handles needs to be removed to access the Drive or Idler Rolls 1 Pull the Cam Lever away from the idler roll This will relieve the pressure against the drive roll 2 Align the Drive Roll Removal Tool P N 931 0100 over the flats of the drive roll Hold the gun with one hand or on a table top with the other hand give the Removal Tool a quick snap turn in the CLOCKWISE DIRECTION 3 Once the drive roll is loose continue to spin drive roll in the clockwise direction to remove the drive roll from the gun 4 Install a new drive roll on the left hand threaded shaft The drive roll will self tighten when it is feeding wire Idler Roll Installation and Removal 1 Using a slot type screwdriver loosen idler screw taking care not to lose lock washer under idler roll 2
15. X ule At Oe JAG AL 3 11 ua e Wear eye ear and body protection e Prot jase los ojos los o dos y ei cuerpo Prot gez vos yeux vos oreilles et votre corps e Tragen Sie Augen Ohren und K r perschutz Use protec o para a vista ouvido e corpo e H ERO SG RNAEL CF a CARA HRRRUADG NA ez 19 Eo 23379 SESAR Sid y ue gDay ct pl ga 8 any READ AND UNDERSTAND THE MANUFACTURER S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER S SAFETY PRACTICES SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS CONSUMIBLES QUE VA A UTILIZAR SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER STELLERS DIE UNFALLVERH TUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN O Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone Los humos fuera de la zona de res piraci n e Mantenga la cabeza fuera de los humos Utilice ventilaci n o aspiraci n para gases e Gardez la t te l cart des fum es e Utilisez un ventilateur ou un aspira teur pour ter les fum es des zones de travail e Vermeiden Sie d
16. ammer or wrench to open a cylinder valve that cannot be opened by hand Notify your supplier Mixing gases NEVER try 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 connect hoses to fittings No copper tubing splices Use only standard brass fittings to splice hose Avoid long runs to prevent kinks and abuse Suspend hose off ground to keep it from being run over stepped on or otherwise damaged Coil excess hose to prevent kinks and tangles Protect hose from damage by sharp edges and by sparks slag and open flame Examine hose regularly for leaks wear and loose connections Immerse pressured hose in water bubbles indicate leaks Repair leaky or worn hose by cutting area out and splicing Do NOT use tape 4 Proper Connections Clean cylinder valve outlet of impurities that may clog orifices and damage seats before connecting regulator Except for hydrogen crack valve momentarily pointing outlet away from people and sources of ignition Wipe with a clean lintless cloth Match regulator to cylinder Before connecting check that the regulator label and
17. articular attention to the safety instructions we have provided for your protection Section A Installation Technical Specifications Prince XL Gun Wire Capacity e DAT 045 0 9 1 2mm solid and hard wire e 030 1 16 0 8 1 6mm aluminum and cored wire Wire Speed e 800 ipm 20 3 mpm max 900 ipm 22 9 mpm max 319 XXX Spool Size 319 XXX e 4 inches 101 6mm Duty Cycle 60 Rating is at 25V using Argon Gas 225 Amps 25 Volts Air Cooled 255 Amps 25 Volts Air Cooled 319 XXX 450 Amps 25 Volts Water Cooled Maximum pm varies depending on input voltage wire size and the control used Supper Equipment Required CV or CC power source of sufficient capacity for your needs e Regulated gas supply and hoses e Properly sized power leads from power source to wire feeder and ground e Water source and hose capable of providing a minimum of 1 quart 95 liter minute at 45 P S I when using water cooled guns Coolant Recommendations Use Cobra Coolant Aluminum Protection P N 931 0060 Cobra Coolant does not contain reactive sulphur or chlorine and does not react with copper brass or aluminum The coolant flow rate should be a minimum of 15 GPH 1 qt min between 35 and 45psi Contact the re circulator manufacturer for specifications on pressure Gun Lead Connections Power Cable Air Cooled A 2 AWG power cable is used on the Prince XL gun The gun end is threaded into the gun body The cabin
18. as Einatmen von Schweibrauch e Sorgen Sie f r gute Be und Enti ftung des Arbeitsplatzes e Mantenha seu rosto da fumaga Use ventilac o e exhaust o para remover fumo da zona respirat ria 0 c1 APEMENMSESELT F t e RAPHECTHINEBLIT R n OTM MER e TETHRIB S HALSA e daz BAR acie e 23492275 RA HASH AM 71210017114 25718 HRH Js ce an dul OD TAAL GA bo jen d Auch Jal o gd odu uat Mail ge gaal a y Turn power off before servicing Desconectar el cable de ali mentaci n de poder de fa maquina antes de iniciar cualquier servicio e D branchez le courant avant l entre tien e Strom var Wartungsarbeiten abschalten Netzstrom v llig ff nan Maschine anhalten e N o opere com as tampas removidas e Desligue a corrente antes de fazer servico e N o toque as partes el tricas nuas VFFYA F EAZKRU POMC EFRRAL we Fe BF DoT K SL e HMR esto SE HINAR Aia l SUED Jl cl yl AO adl e 9 Do not operate with panel open or guards off No operar con panel abierto o guardas quitadas AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese ATENCAO e N op rez pas avec les panneaux ouverts ou avec les dispositifs de protection enlev s O Anlage nie ohne Schutzgeh use oder Innenschutzverkleidung in Betrieb setzen e Mantenha se afastado das partes moventes e N o opere com os paineis abertos ou guardas removidas ANANPAN ERYUAL
19. bly ___PartNo Description Notavaliale separately 9 1 6210250 Assy Cup Copper Finned 10 mr Contact Tip 0 060 ID Bulk quantities 10 No 6 8 621 0393 250 available in 250 and 500 pieces 621 0393 500 Prince XL Spool Gun Owner s Manual Page 18 Prince XL Straight Barrel Assembly Water Cooled 003 2315 0 270 0 280 Apply silicone lubricant to items 5 and 6 before installing Water Cooled Straight Barrel Assembly PartNo Description Notavalable separately 25 Contact Tip 0 060 ID Bulk quantities 250 available in 250 and 500 pieces Prince XL Spool Gun Owner s Manual Page 19 12 No on KJEND 2 1 3 1 EME NEN 6 apar ESEN MEN 250 500 Prince XL Spool Gun 45 Barrel Assembly Air Cooled 003 2331 Apply hose lubricant to item 3 before installing Apply silicone lubricant to items 5 and 6 before installing Air Cooled 45 Barrel Assembly Parto Description oe Notavallable separately OT 9 1 6210250 Assy Cup copper Finned HO mr Contact Tip 0 060 ID Bulk quantities 10 Qty EN 4 8 EM 621 0393 250 available in 250 and 500 pieces 621 0393 500 Prince XL Spool Gun Owner s Manual Page 20 Curved Barrel Assembly Water Cooled 12 Prince XL Spool Gun 003 2316 RING GROOVE REF p I li FSS 7227777 Water Cooled 45 Barrel Assembly Qt
20. cludes insulated groove drive roll and insulated idler roll assy Insulated Groove Drive Roll Kit 005 0719 For 062 1 6mm dia aluminum wire Includes insulated groove drive roll and insulated idler roll assy Prince XL Handle Kil ass 005 0633 Includes left and right handle with door trigger and pin and all handle screws Spool Adanter AES 005 0632 Includes left and right handle with door trigger and pin and all handle screws Used to change a standard 319 xxx series Prince XL gun into a spool gun Heavy Duty Spool Gun Brake Spring for Hardwires 005 0682 25 7 Pin Amphenol Extension Cable 005 0660 Used to extend the spool gun Two cables may be joined together for 50 extension Power amp gas cables not included Barrel Insulator Replacement Kit 005 0696 Optional Accessories Conduits Flat Spiral Steel Conduit for steel and cored wire Standard with teflon liner NEE EE 15ft 4 5m A 2 5ft 7 6m 615 0219 einsidan ee ree 35ft 10 7m RE E EE 50ft 15 2m Snake Skin Velcro Closure Cover Leather Snake Skin protective covers are now standard on all guns You may order replacement covers to protect the lead assembly of the gun when the original factory cover becomes damaged or worn The Velcro closure makes it easy to replace in the field Snake Ski
21. compose trichloroethylene and perchloroethylene vapors to form phosgene DO NOT WELD or cut where solvent vapors can be drawn into the welding or cutting atmosphere or where the radiant energy can penetrate to atmospheres containing even minute amounts of trichloroethylene or perchloroethylene C Fire and Explosion Prevention Causes of fire and explosion are combustibles reached by the arc flame flying sparks hot slag or heated material misuse of compressed gases and cylinders and short circuits BE AWARE THAT flying sparks or falling slag can pass through cracks along pipes through windows or doors and through wall or floor openings out of sight of the goggled operator Sparks can fly many feet To prevent fires and explosion Keep equipment clean and operable free of oil grease and in electrical parts of metallic particles that can cause short circuits If combustibles are in area do NOT weld or cut Prince XL Spool Gun Owner s Manual Page i Move the work if practicable to an area free of combustibles Avoid paint spray rooms dip tanks storage areas ventilators If the work cannot be moved move combustibles at least 35 feet away out of reach of sparks and heat or protect against ignition with suitable and snug fitting fire resistant covers or shields Walls touching combustibles on opposite sides should not be welded on or cut Walls ceilings and floor near work should be protected by heat
22. cylinder marking agree and that the regulator inlet and cylinder outlet match NEVER Connect a regulator designed for a particular gas or gases to a cylinder containing any other gas Tighten connections When assembling threaded connections clean and smooth seats where necessary Tighten If connection leaks disassemble clean and retighten using properly fitting wrench Adapters Use a CGA adapter available from your supplier between cylinder and regulator if one is required Use two wrenches to tighten adapter marked RIGHT and LEFT HAND threads Regulator outlet or hose connections may be identified by right hand threads for oxygen and left hand threads with grooved hex on nut or shank for fuel gas 5 Pressurizing Steps Drain regulator of residual gas through suitable vent before opening cylinder or manifold valve by turning adjusting screw in clockwise Draining prevents excessive compression heat at high pressure seat by allowing seat to open on pressurization Leave adjusting screw engaged slightly on single stage regulators Stand to side of regulator while opening cylinder valve Open cylinder valve slowly so that regulator pressure increases slowly When gauge is pressurized gauge reaches regulator maximum leave cylinder valve in following position for oxygen and inert gases open fully to seal stem against possible leak for fuel gas open to less than one turn to permit quick emergency shut off
23. cylinders including third rails electrical wires or welding circuits They can produced short circuit arcs that may lead to a serious accident See 1 3C ICC or DOT marking must be on each cylinder It is an assurance of safety when the cylinder is properly handled Identifying gas content Use only cylinders with name of gas marked on them do not rely on color to identify gas content Notify supplier if unmarked NEVER DEFACE or alter name number or other markings on a cylinder lt is illegal and hazardous Empties Keep valves closed replace caps securely mark MT keep them separate from FULLS and return promptly Prohibited use Never use a cylinder or its contents for other than its intended use NEVER as a support or roller Locate or secure cylinders so they cannot be knocked over Passageways and work areas Keep cylinders clear of areas where they may be stuck Transporting cylinders With a crane use a secure support such as a platform or cradle Do NOT lift cylinders off the ground by their valves or caps or by chains slings or magnets Do NOT expose cylinders to excessive heat sparks slag and flame etc that may cause rupture Do not allow contents to exceed 55 degrees C 130 degrees F Cool with water spray where such exposure exists Protect cylinders particularly valves from bumps falls falling objects and weather Replace caps securely when moving cylinders Stuck valve Do NOT use a h
24. et end of the cable is equipped with a 1 2 ring lug which attaches to the top hole on the side of the power block Supplied with this gun is a 3 8 16x5 8 bolt a 3 8 spring lock washer and a 5 8 flat washer to attach the ring lug to the power block Power Cable Water Cooled Prince XL water cooled gun utilizes a power water cable with a 46 AWG cable inside a 5 16 diameter hose When water is used with this cable and the 10 water cooled gas cup P N 621 0065 the system is rated at 450 amps 60 duty cycle The power cable ends are threaded fittings which screw into the gun body These connections utilize a conductive sealant and are tightened with torque requirements of 100 5 IN LB Prince XL Spool Gun Owner s Manual Page 1 Conduit The Prince XL gun comes standard with a poly lined conduit for running aluminum wire The longer fitting with a shallow groove is used on the gun end setscrew located on top of the gun handle secures the conduit in place small spool liner P N 003 0198 is used on the spool gun and held in place by the same setscrew NE Gas Hose The gas hose is pushed over a barbed fitting on the end of the gun body and secured by twisting the hose retainer to the end of the hose shown below The hose retainer is re usable and can be removed and re installed as needed The cabinet end of the gas hose uses our standard gas fitting 1 8 27 nps Water Hose If so equipped The gas hose
25. from fumes vapors heat or oxygen enrichment or depletion that welding or cutting may produce Prevent them with adequate ventilation NEVER ventilate with oxygen Lead cadmium zinc mercury beryllium bearing and similar materials when welded or cut may produce harmful concentrations of toxic fumes Adequate local exhaust ventilation must be used or each person in the area as well as the operator must wear an air supplied respirator For beryllium both must be used Metals coated with or containing 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 oxygen concentration dangerously Do not bring gas cylinders into a confined space Leaving confined space shut OFF gas supply at source to prevent possible accumulation of gases in the space if downstream valves have been accidentally opened or left open Check to be sure that the space is safe before reentering it Vapors from chlorinated solvents can be decomposed by the heat of the arc or flame to form PHOSGENE a highly toxic gas and other lung and eye irritating products The ultraviolet radiant energy of the arc can also de
26. g wire The 24 VDC gun motor is controlled by a solid state speed control and a pot located in the gun The gun motor potentiometer and micro switch are connected to the cabinet control box via a control cable and an amphenol connector If this cable becomes damaged a variety of symptoms can occur depending on which wire s break To test check each wire for continuity and shorts With the increased torque rating in the current Prince XL motor it now draws about twice as much current on start up as the original Prince motors P N s 211 0054 amp 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 should be changed to a 3AG 4A fast blow 250V fuse This new 4A fuse is sufficient for use on all model welding guns on the wire feeders while still providing protection for the circuitry from any shorts in the motor or motor leads This fuse change includes all Cobramatic Cobramatic II and CobraMig 250 260 WC 1 Torpedo s and any other motor circuits powering Prince XL or Spool Guns Remember the micro switch in the gun activates both the 115 VAC or 42 VAC and 24 VDC circuits in the cabinet Therefore if the slave motor and brake solenoid operate but the gun does not look more toward the 24 VDC circuits speed control control cable or the gun motor If nothing operates look more toward the 115 VAC or 42 VAC inpu
27. ge 24 Prince XL Lead Assembly Water Cooled per ZJREF TIGHTEN WITH 100 5 IM LBS TORQUE 12 d SEE PROCEDURE 40230979 3 SEES 8 F _ y X is APPLY QUICK DRYING HOSE LUBRICANT NEAR NON FITTING END OF ITEMS 7 amp 8 FOR INSTALLATION OF TEM amp NW A d Al iN MERA MET SHOWN ROR CLARITY Water Cooled Lead Assembly Description 15 Part No 25 Part No 35 Part No s Assy Controller Cable 005 0268 005 0269 005 0307 005 0272 Assy Power Cable 843 0685 15 843 0685 25 843 0685 35 843 0685 50 Hose Retainer is re usable and can be removed and re installed as needed A1 1 1 4 1 1 1 Prince XL Spool Gun Owner s Manual Page 25 Prince XL Spool Gun Lead Assembly A REF 0 Ont Z lt lt TKSHTEN WITH 10025 IN LBS TORQUE SJ er 6 FN SEE PROCEDURE 003 2 Ps Bee s dy INTE d i n D e H HEAD pice EIT Ft ER at Ca z ED pr Tu ami SE aa i FN APPLY GUKCE DRYINCS HUSE LUBRICANT MEAR MOCH FI ING END OF ITEM 6 CYR INSTALLATION OE TEM 5 IN ITEM NOT SHOWN FOR CLARITY Spool Gun Lead Assembly 1 A1 Wrap Spiral Cord 5 5 LG 261 0094 2 4 Wrap Spiral Cord 13 LG 261 0094 13 Snake Skin 931 0122 931 0123 Tie Wrap 411 0202 Retainer 5 16 Hose 431 1898 Spool Gun Assy Gas Hose 552 0244 25 552 0244 50 Spool Gun Assy Power Cable 843 0484 843 0485 Ultra Power Flex Cable optional 843 0707 25 843 0707 50 Assy Controller Cable 005 0
28. ic 250 Miller Vintage machine or Hobart Betamig 2510 It and a Prince Spool Gun are all that is needed to get your customer up and running MillerMatic 250 Vintage and BetaMig 2510 Panasonic Gunslinger 260 P N 005 0617 Easy to install adapter cable using Gunslinger speed control Panasonic Gunslinger 260 ESAB MigMaster 251 P N 005 0624 A panel kit plugs directly into the front of the MigMaster 251 and includes everything that is needed to interface the spool gun MillerMatic 250X 251 P N 005 0629 Easy to install adapter cable using MillerMatic 250X speed control Reference Tech Bulletin TB 2112 found at mkproducts com for Millermatic Prince XL spool gun compatibility MillerMatic 250X amp Fabricator 250 P N 005 0689 Easy to install adapter cable using Thermal Arc G a Fabricator 250 Thermal Arc Fabricator 250 NOTE For further information on spool gun adaptability contact MK Products Maintenance Maintenance of the gun will normally consist of a general cleaning of the wire guide system including tubes drive rolls and conduit at regular intervals Remove spatter build up from inside of nozzles with a hardwood stick The only parts on the gun that are subject to normal wear are the conduit contact tips gas cups drive and idler rolls and barrel liners A supply of those parts should be maintained on hand If repairs do become necessary qualified shop maintenance personnel can ea
29. ince XL Spool Gun Owner s Manual Page ii 3 Protection of Nearby Personnel Enclose the welding area For production welding a separate room or enclosed bay is best In open areas surround the operation with low reflective noncombustible screens or panels Allow for free air circulation particularly at floor level Viewing the weld Provide face shields for all persons who will be looking directly at the weld Others working in area See that all persons are wearing flash goggles Before starting to weld make sure that screen flaps or bay doors are closed B Toxic Fume Prevention Comply with precautions in 1 2B Generator engine exhaust must be vented to the outside air Carbon monoxide can kill C Fire and Explosion Prevention Comply with precautions in 1 2C Equipment s rated capacity Do not overload arc welding equipment lt may overheat cables and cause a fire Loose cable connections may overheat or flash and cause afire Never strike an arc on a cylinder or other pressure vessel lt creates a brittle area that can cause a violent rupture or lead to such a rupture later under rough handling D Compressed Gas Equipment Comply with precautions in 1 2D E Shock Prevention Exposed electrically hot conductors or other bare metal in the welding circuit or 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
30. is pushed over a barbed fitting on the end of the gun body and secured by twisting the hose retainer to the end of the hose The hose retainer is re usable and can be removed and re installed as needed The other end is connected to the center fitting on the power block Electric Cable A seven conductor control cable is used on the Prince XL gun The gun end of the control cable is secured to the gun with a boot clamp and plugged into the pot assembly and micro switch connectors Slack is left in the electric cable as it exits the back of the gun to prevent cable breakage The cabinet end has a seven pin W clocked amphenol connector Installing Spool Assembly Kit P N 005 0632 Loosen the screw that secures the conduit through access hole located on top right rear handle with a 1 16 Allen wrench Conduit Securing Screw wm Remove conduit by pulling it out of the back of the gun Install spool liner and secure with screw E Ring Rear Wire Guide Spool Liner Remove both rear handle screws and secure spool canister with longer screws provided Spool Gun Setup Loading Electrode Wire Unscrew and remove spool cover Apply tension to drive rolls so the wire will be picked up and fed through the contact tip Straighten out the first six inches of wire and push it through the liner Jog the trigger until the wire is picked up by drive rolls and fed through the contact tip Hold the brake assembly back towards
31. ives Low Voltage Directive 2006 95 EC Electromagnetic Compatibility EMC Directive 2004 108 EC Standards Electromagnetic Compatibility EMC EN 60974 10 2007 Torches And Guns For Arc Welding EN 60974 7 2005 SAFETY CONSIDERATIONS ELECTRIC ARC WELDING EQUIPMENT CAUTION READ BEFORE ATTEMPTING INSTALLATION OPERATION OR MAINTENANCE OF THIS EQUIPMENT 1 1 INTRODUCTION This equipment is intended for ultimate application by commercial industrial users and for operation by persons trained and experienced in the use and maintenance of welding equipment Operation should not be undertaken without adequate training in the use of such equipment Training is available from many public and private schools or similar facilities Safe practices in the installation operation and maintenance of this equipment requires proper training in the art a careful study of the information provided with the equipment and the use of common sense Rules for safe use are generally provided by suppliers of welding power sources compressed gas suppliers and electrode suppliers Careful compliance with these rules will promote safe use of this equipment The following Safety Rules cover some of the more generally found situations READ THEM CAREFULLY In case of any doubt obtain qualified help before proceeding 1 2 GENERAL PRECAUTIONS A Burn Prevention ELECTRIC ARC WELDING PRODUCES HIGH INTENSITY HEAT AND ULTRAVIOLET RADIANT ENERGY WHI
32. l taper lock assembly and slide towards the cup Leave the barrel inserted in gun the body Pull the handles apart Operation General Description The 24 Volt DC gun motor is controlled by a 3 3 4 turn potentiometer recessed in the pistol grip The gun trigger is so designed that when it is partially depressed gas flow starts via the valve located in the gun body prior to ignition of the arc When the trigger is partially released after welding extinguishing the arc gas flow continues until the trigger is fully released Built in pre and post gas flow Barrels The Prince XL comes standard with a straight barrel assembly for both air and water cooled models An optional curved barrel assembly is also available In cases where these barrels need to be extended or the tip threads have been damaged a tip extender can be adapted The same tips and threads can be used however a longer Teflon liner is required Barrel Removal and Installation To remove a barrel assembly loosen the patented EZ Lock Taper lock nut assembly This will push barrel away from the body far enough so that it may be pulled out of the body To replace a barrel assembly push the barrel assembly into the gun body until it clicks to a stop To assure proper seating of the barrel open the drive idler roll door in the top of the handle The rear face of the barrel should now be flush with the gun body Take care not to damage the O rings when inserting into
33. n Cover 15 leads 931 0110 Snake Skin Cover 25 leads 931 0122 Snake Skin Cover 35 leads 931 0132 Snake Skin Cover 50 leads 931 0123 Prince XL Spool Gun Owner s Manual Page 8 Gas Valve Removal Tool Gas valve removal is performed by using P N 931 0105 Gas Valve Removal Tool This multifunctional tool has been slotted on one side to encompass and conform to the gas valve stem and seat into the slotted gas valve body as seen in Figures 1 and 2 Removal of the gas valve can be accomplished by turning the gas valve tool counter clockwise Reinstall by turning clock wise The tool doubles as a bottle opener Gas Valve Removal Tool Figure 1 Figure 2 Prince XL Spool Gun Controls WC 1 P N 001 3062 The WC 1 is desinged to hookup to any CV or CC power supply having its own contactor CC Posa Start run in speed is included as a standard feature The control operates on 115VAG 50 60hz power For machines such as gas drives that do not have contactors the MK200 Contactor Box P N 001 3066 must be used MK200 Contactor Box P N 001 3066 PA L1 Spool Gun Control Lincoln P N 005 0676 Connects directly to Lincoln Electric power supplies a PAL 42V system with 14 Pin X clocked amphenol E 6 connectors such as Spool
34. oken electrical cable iE continuity or short See specific cabinet control owners manual for speed control operation Idler roll upside down Place groove in idler roll toward top Rear wire guide missing Replace wire guide To replace a barrel assembly push the barrel assembly into the gun body until it clicks to a stop To assure Incorrect placement of proper seating of the barrel open Wire feeds erratically Idler roll stuck Wire feeds one speed only Bad speed control Wire walks out of drive rolls Poor gas water flow barrel insulator the drive idler roll door in the top of the handle the rear face of the barrel should now be flush with the gun body Prince XL Spool Gun Owner s Manual Page 13 Testing The Gun Motor Check Remove the gun connector from the cabinet Using the gun Amphenol check the resistance across pins A and B motor leads The resistance across the motor should be between 5 10 ohms If an open circuit or short exist check the motor leads and motor independently Testing the Potentiometer Using the gun Amphenol check the resistance across pin D wiper and pin C The resistance should vary from 0 5K ohms Check the resistance across pin D wiper and pin G The resistance should vary from 5K 0 ohms Testing the Micro Switch Using the gun Amphenol check for continuity across pins E and F when the trigger i
35. or containers must be vented before welding or cutting They can explode Explosive atmospheres NEVER weld or cut where the air may contain flammable dust gas or liquid vapors such as gasoline D Compressed Gas Equipment The safe handling of compressed gas equipment is detailed in numerous industry publications The following general rules cover many of the most common situations 1 Pressure Regulators Regulator relief valve is designed to protect only the regulator from overpressure it is not intended to protect any downstream equipment Provide such protection with one or more relief devices Never connect a regulator to a cylinder containing gas other than that for which the regulator was designed Remove faulty regulator from service immediately for repair first close cylinder valve The following symptoms indicate a faulty regulator Leaks if gas leaks externally Excessive Creep if delivery pressure continues to rise with downstream valve closed Faulty Gauge if gauge pointer does not move off stop pin when pressurized nor returns to stop pin after pressure release Repair Do NOT attempt repair Send faulty regulators for repairto manufacturer s designated repair center where special techniques and tools are used by trained personnel 2 Cylinders Cylinders must be handled carefully to prevent leaks and damage to their walls valves or safety devices Avoid electrical circuit contact with
36. or material MK Products shall exclusivehy remedy the limited warranty or any duties with respect to the quality of goods based upon the following options 1 repair 2 replacement 3 where authorized In writing by MK Products the reasonable cost of repair or replacement at our Irvine California plant As a matter of general policy only MK Products may honor an original user s warranty claims on warranted equipment in the event of failure resulting from a defect within the following periods from the date of delivery of equipment to the original user 1 Power Supplies and Wire Feed Cabinets 3 years 2 Weldheads Coolers Positioners and Push Pull Guns 1 year 3 Spool Guns and Spool Gun Modules 180 days 4 Repairs Exchanges Parts aeree 90 days 16882 Armstrong Ave Irvine CA 92606 Tel 949 863 1234 4 k Ef Fax 949 474 1428 PRODUCTS www mkproducts com Classification of any item into the foregoing categories shall be at the sole discretion of MK Products Motification of any failure must be made in writing within 30 days of such failure copy of the invoice showing the date of sale must accompany products returned for warranty repair or replacement All equipment returned to MK Products for service must be properly packaged to quard against damage from shipping MK Products will not be responsible for any damages resulting from shipping Normal
37. ord with a ground lead is provided with the equipment for connection to a switch box connect the ground lead to the grounded switch box If a three prong plug is added for connection to a grounded mating receptacle the ground lead must be connected to the ground prong only If the line cord comes with a three prong plug connect to a grounded mating receptacle Never remove the ground prong from a plug or use a plug with a broken ground prong 2 Connectors Fully insulated lock type connectors should be used to join welding cable lengths 3 Cables Frequently inspect cables for wear cracks and damage IMMEDIATELY REPLACE those with excessively worn or damaged insulation to avoid possibly lethal shock from bared cable Cables with damaged areas may be taped to give resistance equivalent to original cable Keep cable dry free of oil and grease and protected from hot metal and sparks 4 Terminals and Other Exposed Parts Terminals and other exposed parts of electrical units should have insulating covers secured before operation 5 Electrode Wire Electrode wire becomes electrically HOT when the power switch of gas metal arc welding equipment is ON and welding gun trigger is pressed Keep hands and body clear of wire and other HOT parts 6 Safety Devices Safety devices such as interlocks and circuit breakers should not be disconnected or shunted out Before installation inspection or service of equipment shut OFF all
38. resistant covers or shields Fire watcher must be standing by with suitable fire extinguishing equipment during and for some time after welding or cutting if 1 Appreciable combustibles including building construction are within 35 feet 2 Appreciable combustibles are further than 35 feet but can be ignited by sparks 3 Openings concealed or visible in floors or walls within 35 feet may expose combustibles to Sparks 4 Combustibles adjacent to walls ceilings roofs or metal partitions can be ignited by radiant or conducted heat Hot work permit should be obtained before operation to ensure supervisor s approval that adequate precautions have been taken After work is done check that area is free of sparks glowing embers and flames An empty container that held combustibles or that can produce flammable or toxic vapors when heated must never be welded on or cut unless container has first been cleaned in accordance with industry standards This includes a thorough steam or caustic cleaning or a solvent of liquid washing depending on the combustible s solubility followed by purging and inerting with nitrogen or carbon dioxide and using protective equipment Water filling just below working level may substitute for inerting A container with unknown contents should be cleaned see paragraph above Do NOT depend on sense of smell or sight to determine if it is safe to weld or cut Hollow castings
39. s pressed W Clocked Amphenol Connector Viewed from front of connector Prince XL Spool Gun Owner s Manual Page 14 Section F Diagrams Parts List Prince XL Exploded View 16 Head Body Exploded View 17 Straight Barrel Assembly 18 Straight Barrel Assembly Water Cooled 19 45 Barrel Assembly 20 Curved Barrel Assembly Water Cooled 21 Cup Insulator and O Ring Maintenance 22 Spool Assembly Exploded View 23 Lead Assembly Air Cooled 24 Lead Assembly Water Cooled 25 Lead ASSEMBLY SPOR 26 Spiral Wrap Installation 27 Fe i l MEE 29 Prince XL Spool Gun Owner s Manual Page 15 Prince XL Exploded View PIOS NOM SANG LOLO LIS 6L BL pue 2L OL EL LL OL 6 eegnen 8b g Z Sue aul sepnjou ry lpueH PH TX eouud ejpued Jaoeds J c0 V OL TX e uug 100q Buds pzLe sep SL OlScLX 60 lewog Uld 6070 Lat L
40. sily replace any parts Your Cobramatic System is designed to provide years of reliable service Normal wear and component failure may require occasional service The number of units in operation and the importance of minimal down time will determine to what extent spare parts should be stocked on hand See the Recommended Spart Parts List for the most commonly replaced parts Prince XL Spool Gun Owner s Manual Page 10 Maintenance Tools Gas Valve Removal Tool 931 0105 Contact Tip Removal Tool 931 0044 Drive Roll Removal Tool 931 0100 Recommended Spart Parts List PartNumber Description 005 0661 Potentiometer Kit Cover Assy Spool Gun Idler Roll 005 0686 It Drive Roll 511 0101 s Gao vAC L 18 k Micro Switch Assy switch with leads 003 0568 Prince XL Spool Gun Owner s Manual Page 11 Section E Troubleshooting All MK Products push pull guns operate on the same principle The 115 VAC or 42VAC slave motor in the feeder runs at a fast constant speed but has very low torque it is always trying to feed more wire than the gun motor wants and when the gun motor gets all it wants it slows the slave motor preventing a bird s nest Because of the low torque produced by the slave motor a brake system is used to prevent wire overrun rather than tension The drag adjustment in the spindle is used simply to keep the wire slightly taut so it will not unspool while feedin
41. 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 Sweat sea water or moisture between body and an electrically HOT part or grounded metal reduces the body surface electrical resistance enabling dangerous and possibly lethal currents to flow through the body 1 Grounding the Equipment When installing connect the frames of each unit such as welding power source control work table and water circulator to the building ground Conductors must be adequate to carry ground currents safely Equipment made electrically HOT by stray currents may shock possibly fatally Do NOT GROUND to electrical conduit or to a pipe carrying ANY gas or a flammable liquid such as oil or fuel Three phase connection Check phase requirement of equipment before installing If only three phase power is available connect single phase equipment to only two wires of the three phase line Do NOT connect the equipment ground lead to the third live wire or the equipment will become electrically HOT a dangerous condition that can shock possibly fatally Before welding check ground for continuity Prince XL Spool Gun Owner s Manual Page iii Be sure conductors are touching bare metal of equipment frames at connections If a line c
42. surface transportation charges one way for products returned for warranty repair or replacement will be borne by MK Products except for products sold to foreign markets 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 LAW CUSTOM OF TRADE OR COURSE OF DEALING INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR OF FITNESS FOR PARTICULAR PURPOSE WITH RESPECT TO AN Y AND ALL EQUIPMENT FURNISHED BY MK PRODUCTS IS EXCLUDED AND DISCLAIMED BY MK PRODUCTS EXCEPT AS EXPRESSLY PROVIDED BY MK PRODUCTS IN WRITING MK s PRODUCTS ARE INTENDED FOR ULTIMATE PURCHASE BY COM MERCIAL INDUSTRIAL USERS AMD FOR OPERATIOM BY PERSONS TRAINED AND EXPERIENCED IN THE USE AND MAINTENANCE OF WELDING EQUIPMENT AND NOT FOR CONSUMERS OR CONSUMER USE MK PRODUCTS WARRANTIES DO NOT EXTEND TO AND NO RE SELLER I5 AUTHORIZED TO EXTEND MK PRODUCTS WARRANTIES TO ANY CONSUMER USE OF OTHER THAN GENUINE MK PRODUCTS CONSUMABLES PARTS AND ACCESSORIES MAY INVALIDATE YOUR PRODUCT WARRANTY August 1 2010 THIS PAGE INTENTIONALLY BLANK MIL PRODUCTS www mkproducts com 16882 Armstrong Ave Irvine California 92606 Tel 949 863 1234 Fax 949 474 1428
43. t micro switch leads or micro switch Prince XL Spool Gun Owner s Manual Page 12 Troubleshooting Guide 115 42 VAC control fuse in feeder Replace fuse No wire feed at gun feeder not operating Micro switch defective not i e no slave motor or being activated brake solenoid Replace switch Check switch for operation Check micro switch wires for continuity 4 amp fuse in feeder Check motor leads for shorts then Control box blown replace fuse Bad potentiometer Check potentiometer with meter Check motor and potentiometer wires for continuity Broken electrical cable No wire feed at gun feeder operating Broken electrical cable properly See specific cabinet control box Bad speed control PCB owners manual for speed control operation Loose or no cable Check all power connections connections Wire feeds but welding wire is not energized Check power supply owners manual Contactor control cable for location and type of contactor loose or in wrong position signal required i e closing or 115 VAC Welding power source Check power source manual Dirty or worn conduit Blow out or replace conduit Incorrect pressure on Adjust pressure at both feeder and drive rolls gun Check for lock washer under idler roll or replace if damaged Wrong size contact tip See contact tip table Bad potentiometer Check with meter Check potentiometer wires for Br
44. the body Tighten taper lock nut assembly firmly so that barrel cannot rotate Barrel Rotation To rotate a barrel assembly loosen the patented EZ Lock Taper lock nut assembly no more than 1 turn Rotate barrel to the position of your choice and retighten taper lock nut assembly firmly so that the barrel cannot rotate WARNING Do not attempt to weld without the barrel being tightly secured in the gun body or damage to the barrel or body may result Failure to take such precaution will void your warranty Controls and Settings Potentiometer The potentiometer is located in the bottom of the pistol grip and provides 3 3 4 turns of adjustment for up to 800 ipm The potentiometer is mounted to one side of a PC board and is held in place by a support plate Both the potentiometer and the support plate have slots that locate and secure the potentiometer in the handle The other side of the PC board houses the motor connectors and ribbon cable Locking disks behind the potentiometer knob provides a stop at the minimum and maximum potentiometer settings Prince XL Spool Gun Owner s Manual Page 4 Micro Switch The micro switch assembly consists of the micro switch leads and connector The assembly is secured to the gun block with two 2 screws An insulator between the gun block and micro switch prevents accidental shorting of the switch leads The leads are laid in the channel under the motor Drive and Idler Rolls The Prince X
45. the top of the gun load the spool Prince XL Spool Gun Owner s Manual Page 2 PRINCE XL SPOOL GUN TO WC 1 WELD CONTROL BOX CONSTANT VOLTAGE OR CONSTANT CURRENT POWER SUPPLY CC OR CC POWER SUPPLY 115 VAC PLUG CONTACTOR LEADS ELECTRICAL CABLE WC 1 CONSTANT CURRENT POSA START SENSING LEADS NOT NEEDED WITH CONSTANT VOLTAGE SUPPLIES NOTE The Posa Start feature permits the TO CUSTOMER GAS SUPPLY WC 1 to be used in combination with any Constant Current DC power source with an open circuit voltage in excess of 55 volts PRINCE XL SPOOL GUN TO COMMON POWER SUPPLIES PA L 1 Spool Gun Adapter 14 Pin C D Trigger og V350 PRO 120VAC Output Power Cable and Gas Hose must also be connected PAM e ao PA M 1 Spool Gun Adapter 14 Pin A B Trigger XMT 304 For more power supply options see Spool Gun Controls in Section C 120VAC Output Prince XL Spool Gun Owner s Manual Page 3 Section B onto shaft with the wire coming off the bottom of the spool Release the brake assembly to rest on the wire surface Replace the spool cover making sure that the opening is over liner Note The brake assembly is designed to automatically control spool drag and keep the wire from jumping off the spool Disassembly of Prince XL Spool Gun Remove the trigger pin with punch and remove the trigger Remove the six 6 handle screws and the spool adapter if installed Remove the barrel from the gun loosen the barre
46. this will help it slide onto the barrel Push the Insulator onto the barrel until it bottoms out screw onto barrel threads The Insulator MUST be all the way onto the barrel to avoid assure proper coolant passage and from blocking the gas outlet orifices 6 Push Water Cooled Gas Cup or Chrome Nut Cup Adapter and Gas Cup Assembly onto Cup Insulator Slide Retaining Nut forward and tighten Insulator Barrel Correct Installation Incorrect Installation Prince XL Spool Gun Owner s Manual Page 22 Prince XL 1 Ib Spool Assembly 003 2021 Spool Gun Assembly Qty PartNo Description HD Brake Spring for Hard Wires optional 6 1 0030198 Wire Guide Prince XL Spool Gun Owner s Manual Page 23 Prince XL Lead Assembly Air Cooled AU IOC E gt TIGHTEN WITH 10025 MARS TORQUE As EE PROCEDURE BOLS FEN AA APPLY QUICK DRYING HOSE LUBRICANT NEAR NON ATTING END OF MEM FOR INSTALLATION OF ITEM 3 FI TEM HOT SHOAH FOR CLARITY Air Cooled Lead Assembly EE SHINE MN DEPTO A EA A ees 6 1 Assy cas Lee 5522024225 5520242335 520200 Lm L i S gt a tra Power iexCablo optona 5435070745 849070725 842070735 640 0707 50_ Tao assycontolercae 006 0266 0050269 005037 0080272 Hose Retainer is re usable and can be removed and re installed as needed Power Cable includes copper wrap P N 701 0053 1 Prince XL Spool Gun Owner s Manual Pa
47. ue Grey CO Brown Pin 1 Pin 1 Red EO H I TORCH N F Gr Yellow Orange Red TRIGGER Prince XL Spool Gun Owner s Manual Page 29 Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese ATENCAO Do not touch electrically live parts or electrode with skin or wet clothing e Insulate yourself from work and ground e No toque las partes o los electrodos bajo carga con la piel o ropa moja da e Aislese del trabajo y de la tierra O Ne laissez ni la peau ni des v te ments mouill s entrer en contact avec des pi ces sous tension e Isolez vous du travail et de la terre e Ber hren Sie keine stromf hrenden Teile oder Elektroden mit Ihrem K rper oder feuchter Kleidung e isolieren Sie sich von den Elektroden und dem Erdboden e N o toque partes el tricas e eiec trodos com a pele ou roupa molha da Isole se da pega e terra e S hOR ES NU 3HI E 7PENLEKTMNEULIE Ke k 2 BYR ATUIMELIT FAL JEGER EE JEF TEEN Se e ff g Bl GMT PF43648 SAM SYSE Xe Sd mue xu Sex ng e EA HAT HX MAR AA gym ui left oe VO AU ly deli P da le VIE Gig Keep flammable materials away Mantenga el material combustible fuera del rea de trabajo e Gardez l cart de tout mat riel inflammable Entfernen Sie brennbarres Material Mantenha inflamaveis bem guarda dos RAPT CGOOATORKER RBH LTREHEHA e 89 9 218 HEIER e l k mau Sc AI
48. y PartNo Description SEENEN BC Taper took Bae assy aros maoa asas ATT a wow Jones Contact Tip 0 060 ID Bulk quantities 5 0 1 1 1 0393 621 0393 250 available in 250 and 500 pieces 621 0393 500 Prince XL Spool Gun Owner s Manual Page 21 2 5 CUP INSULATOR AND O RING MAINTENANCE CAUTION Power off the coolant pump before disassembling water cooled barrels 1 Unscrew Retaining Nut and slide back on barrel 2 Using a firm pull and twist action the Water Cooled Gas Cup or Air Cooled Gas Cup Assembly can be removed from the Cup Insulator 3 Inspect the Cup Insulator and o rings included with Insulator for wear and proper lubrication It is considered good practice to replace all o rings at the same time 4 To remove the Cup Insulator it must be unscrewed and pulled from the barrel Use a rag or towel due to o ring lubrication and wrap it around the Cup Insulator Unscrew and pull when completed unthreaded from barrel Be sure the Insulator is fully unscrewed from the threads Pulling the Insulator over barrel threads will damage the threads on the Insulator Inspect o rings on barrel for wear and lubrication It is considered good practice to replace all O rings at the same time 5 To install the Cup Insulator it must be pushed all the way onto the barrel then screwed onto the threads If necessary place small amount of o ring lubricant on the inside diameter of the Cup Insulator
Download Pdf Manuals
Related Search