Thermion, Inc.

• Wire Types/SizeAll Soft Conductive Wires; 1/16" dia.
• Air80-100 Psi @ 20- 40 Cfm, inlet line- no less than 3/8" dia.
• Power Source300 Amp, Single Phase - 60 Hz *Optional power supplies available
• Feeder55 Lbs. / 25 Kgs.

The AVD 250 is the newest spray system in our AVD series. It has was designed specifically as an economical solution for applications that call for lighter production needs. Intended for shops that metalize as a sideline business as well as startup operations this AVD system comes complete and ready to spray. Utilizing our most up to date Arc Voltage Driven (AVD) technology this unit uses pure DC power from the Arc Energy to drive the wire feed motor. This patented feature automatically controls the wire rate to maintain a set arc gap for perfect atomization. All Thermion AVD spray systems are fitted with the most advanced long-life friction free wire feeders with sealed roller bearings for all moving parts. This quick and simple wire clamping system allows the wire to automatically be straightened as it is feed through the feeder. Coupling this technology with our light weight leads we can now offer a light weight portable machine the not only uses far less air than other spray systems but is also capable of easily maneuvering in small tight areas. Additionally, the patented wire drive has virtually eliminated welding of wire to the tips and extended spare parts life, with the replacement being simple and quick when required.

• Small Wire Change Over Kits1/16" (1.6 mm), 2 mm, 3/32" (2.3 mm)
• Jet Force Headfor low-density coatings applied at high velocities

The PRECISION ARC 3.2 Metalizing Spray (Model 58000-3.2) uses Thermion®'s patented design, originally introduced as the Thermion®'s 500. This Metalizer allows for trouble-free spraying minimizing wire clipping. In looking at the successes of this Twin Wire Arc metallizing system, it has proven itself to be the most reliable and productive machine using 18" diameter zinc, aluminum, and zincaluminum alloy materials on the market. A main stake amongst contractors performing corrosion control coatings in both the field and shop worldwide Thermion®'s Precision Arc 3.2 is built robust and modular making it very portable and easy to use in even the harshest of metalizing environments. Its modular design coupled with Thermion®'s proprietary technology has improved “up time" on nearly every metalizing job it has been used on. Metalizing contractors around the world have found that this twin wire arc spray system is a must have when metal spraying any job with time constraints. This Thermion® Metalizing unit uses our Fan Spray Gun that can be hand held or machine mounted for fully automatic spraying. It is designed to use standard thermal spray wire spools and can be setup to use our Precision Drum Dispenser which allows the use of large payoff drums, thus providing up to a day of continuous spraying, thus saving daily labor, increasing up time and savings on material cost. This standard metalizing spray equipment comes complete with all the basic components to perform metal spraying in either the shop or on the job site. The PRECISION ARC series has a full function remote control at the feeder allowing wire speed and voltage to be adjusted by the operator. There are also meters for the amperage and voltage on the feeder for this piece of metallizing equipment. Wear life of consumable parts is exceptionally long, with the replacement being simple and quick due to its modular design. Features of Precision Arc 3.2 Anti Corrosion Spray: Remote Amperage And Voltage Meters With Control At The Feeder Arc Shorting Control Technology Thermion® Exclusive Modular Construction Deposit Efficiency; Aluminum 75%, Zinc 70-%, 8515, Zinc Aluminum 70% Emergency Shut Off HD Hi Temp Machine Components Thermion®'s Exclusive Ergonomic Handle All components are factory built to be "plug and play": no tools are needed when connecting components. Additionally, connection errors have been eliminated because each fitting is unique to itself.

• Wire Capabilities:All Conductive Wires; ? " (3.2mm), 3/32;" (2.3mm), 2mm or 1/16;" (1.6mm)
• Air Requirements:80-100 PSI at 70 CFM. Air inlet no less than ½ " dia.
• Power SupplyN/S) Conventional 450 Amp. Incoming power; 3 phase multi Voltage at 60 Hz

Read about our new High-Density Coating System technology that goes into the Jet Force AVD 456HD Arc Spray System. Preset Spring Pressure allows a continuous and precise pressure on the wires at all times and does not change when new wires are loaded. More importantly, the spring pressure adjustment is set to the correct amount not relying on operator experience. Roller Bearing Inlet Guides is a Thermion exclusive feature that minimizes friction and drag on the wires as they enter the feeder. This is such an important performance upgrade that all Thermion's arc spray systems include this feature. Wire Straighteners are also one of the important performance features that are included in all Thermion's arc spray systems. Most spray wires are packaged on spools and during the packaging process the wire develops a helix, spiral or kinks; these features can cause spraying malfunctions. Thermion removes the malfunction potential by using wire straighteners which are built to straighten solid or cored wires using the same unit so operators can switch wires without changing straightener parts. Six Roll Wire Drive is another Thermion exclusive feature available on the High-Density spray system. The six roll system adds performance value in providing an absolute non-slip wire feed at all times during operation while overcoming friction on the wires caused by dryness, dust or wire defects. Center Wire Supports is a feature of the six roll drive and worth mentioning as a separate performance improvement item. On the last set of feed rolls, just before the wire enters the liners a smooth set of feed rolls iron the sires to knock down the knurls put on the wires by the four other feed rolls. Knurled feed rolls are necessary to provide a positive feed, however, they add friction and wear to liners and tips. The wire ironing feature knocks down these knurls reducing friction and extending the life of liners and tips, therefore, enhancing spray performance. Minimizing Power Connections improves current flow and reduces voltage loss. Thermion has minimized the number of electrical connections while maintaining a portable quick set up spray system. History has shown that poor lead connections can cause the equipment to malfunction in many different ways that are often hard to diagnose; thus minimizing connections reduces problem potential.

• PowerSingle or Three Phase – 50/60 Hz
• Air:80-100 Psi @ 65 cfm, inlet line- no less than ½" diameter

Thermion®'s AVD series utilizes our latest technology. The patented "AVD" or Arc Voltage Drive automatically controls the motor speed to maintain a perfect arc gap which creates consistent high-density coatings. Coupled with our recently developed Jet Force Head, which is a closed nozzle design, we are achieving unprecedented coating quality for the twin wire arc process. This new method of controlling wire feed along with reversing the wire at the end of the spray cycle thus eliminating wire fusing and allowing for smooth starts every time the trigger is pulled. All Thermion® AVD metallizing systems are using the most advanced, long-life, friction-free wire drive assemblies that include sealed roller bearings for the feed rolls and the v-grooved bearings used for wire straightening. The wire straighteners are designed into the wire drive assembly and can be easily adjusted to the wire size being sprayed. The clamping pressure for each feed roll is automatically adjusted according to wire size and type. This quick and simple wire clamping system allows consistent, trouble-free feeding of all spray wires. AVD 350 Our light weight Front End Assembly consists of two combination leads which carry the power, air and wire along with a small supplemental air line and the trigger cord. This creates a very flexible and durable 13' gun. For the AVD 350, we have attached the Jet Force gun to create low porosity coatings. The AVD 350 is most commonly used for machine element coatings, or dimensional restoration for shafts, pump casings, paper rolls etc. All wire types from 116" to 332" can be sprayed with this system. Increasing wire size is very productive when applying wear coatings, coatings for chemical corrosion atmospheres as well as galvanic protection coatings. A new area metalizing is being used in what is know as Architectural coating using materials such as copper, bronze etc. There has also been a drastic increase in Architectural coatings using materials from the copper and bronze family. Features:

• Feeder55 Lbs. / 31.8 Kgs. ¼ HP Motor, Positive Feed, Low Maintenance
• Power Source350 Amp, Single/Three Phase, 220-475 Volts, 50 or 60 Cycle
• Air90-110 Psi @ 50 Cfm, ½” IPS connection
• Control ConsoleSealed, Flexible, Reliable and robust modular components

Shown above with optional power supply This custom pray welding system package includes all hardware, cables, and controls to perform spraying on tubing seam welds. The control console can be positioned at the tube manufacturing control station so spray rate can be readily changed to suit tube production. This twin wire arc spray system connects to just about any primary voltage source, including single or three-phase power 50 or 60 cycles, voltages from 2 20 to 575. For a fully automated custom spray system, all functions of the spray system can be PLC controlled andor the start and stop function can be limit switch actuated. Custom Spray Welding Systems The spray rate can be controlled through a very wide range to allow adjustment for spray thickness, spray width, and tube speed. The dependability of this spray system allows numerous units to be added in series to coat very high production pipe systems. This spray system in many ways is over designed for this application, however, this robustness translates into a spray system with a very long life. All components of the system are modularly constructed with quick disconnects on all components, which allows very quick field maintenance minimizing downtime.

• Air:80-100 Psi @ 65 cfm, inlet line- no less than ½" diameter
• PowerThree Phase – 50/60 Hz, 230/460/575 V.

• Same set feeds1/16” (1.6mm), 5/64” (2mm)
• One set feeds3/16” (4.8mm) diameter

The SWESCO SA 40 patented wire feed system, introduced some three decades ago for the welding industry, has confronted and satisfied every requirement of wire feeding in extremely demanding environments. This robust wire feed system takes the wire from the spools or drums and delivers it to the spray head, straightening the wire as it is fed through the feed rollers. The feed rollers are self-adjusting to the wire diameter and are forgiving to imperfections in the wire, such as kinks and diameter variances. Its uniquely designed drive and straightener system delivers features not available on any competitive models and offers the optimum in positive wire feeding performance. HIGH PRODUCTION WELDING WIRE FEED SYSTEM The SWESCO SA 40 feed rollers are self-adjusting to the wire diameter and are forgiving to imperfections in the wire, such as kinks and diameter variances. Its uniquely designed drive and straightener system delivers features not available on any competitive models and offers the optimum in positive wire feeding performance. For example, core wires have been impossible to straighten with standard back-setting techniques, due to their non-uniform helics. The six feed rollers of the SWESCO feed system shapes the wire and straightens it, the results have practically eliminated mismatch of the spray wires at the spray head which contributes to the arc spray systems dependability.Wire Drive Features: Six gear driven feed rolls No tools required for normal attendance Wire threading is simple; wire feeds through the rollers without relaxing spring tension Self-adjusting spring tension: this eliminates operator attendance and chance for error Feed rollers spin on sealed roller bearing: roller bearings eliminates friction, bearing maintenance and extends motor life Extra hardening of feed roller gears extends their service life Feeds core wires and solid wires with same rollers

Thermion®'s AVD series utilizes our latest technology. The patented "AVD" or Arc Voltage Drive automatically controls the motor speed to maintain a perfect arc gap which creates consistent high-density coatings. Coupled with our recently developed Jet Force Head, which is a closed nozzle design, we are achieving unprecedented coating quality for the twin wire arc process. This new method of controlling wire feed along with reversing the wire at the end of the spray cycle thus eliminating wire fusing and allowing for smooth starts every time the trigger is pulled. All Thermion® AVD metallizing systems are using the most advanced, long-life, friction-free wire drive assemblies that include sealed roller bearings for the feed rolls and the v-grooved bearings used for wire straightening. The wire straighteners are designed into the wire drive assembly and can be easily adjusted to the wire size being sprayed. The clamping pressure for each feed roll is automatically adjusted according to wire size and type. This quick and simple wire clamping system allows consistent, trouble-free feeding of all spray wires. AVD 350 Our light weight Front End Assembly consists of two combination leads which carry the power, air and wire along with a small supplemental air line and the trigger cord. This creates a very flexible and durable 13' gun. For the AVD 350, we have attached the Jet Force gun to create low porosity coatings. The AVD 350 is most commonly used for machine element coatings, or dimensional restoration for shafts, pump casings, paper rolls etc. All wire types from 116" to 332" can be sprayed with this system. Increasing wire size is very productive when applying wear coatings, coatings for chemical corrosion atmospheres as well as galvanic protection coatings. A new area metalizing is being used in what is know as Architectural coating using materials such as copper, bronze etc. There has also been a drastic increase in Architectural coatings using materials from the copper and bronze family. Features:

Spray Systems for Engineered Coatings Thermion®'s AVD series utilizes our latest technology. The patented Arc Voltage Drive automatically controls the motor speed to maintain a perfect arc gap which creates consistent high-density coatings. This new method of controlling wire feed along with reversing the wire at the end of the spray cycle eliminates wire fusing and allows for smooth starts every time the trigger is pulled. All Thermion® AVD metallizing systems are using the most advanced, long-life, friction-free wire drive assemblies that include sealed roller bearings for the feed rolls and the v-grooved bearings used for wire straightening. The wire straighteners are designed into the wire drive assembly and can be easily adjusted to the wire size being sprayed. The clamping pressure for each feed roll is automatically adjusted according to wire size and type. This quick and simple wire clamping system allows consistent, trouble-free feeding of all spray wires. Our light weight Front End Assembly consists of two combination leads which carry the power, air and wire along with a small supplemental air line and the trigger cord. This creates a very flexible and durable 13' gun. For the AVD 450, we have attached the Fan Spray gun to create uniform, wide spray patterns. The AVD 450 is commonly used to spray engineered coatings or machine element wires in diameters of 116�, 2mm and 332� but it can also spray corrosion control wires like aluminum, zincaluminum and zinc in 18� diameters. In the corrosion industry, all wire types from 116� to 18� can be sprayed with this system. Increasing wire size is very productive when applying wear coatings, coatings for chemical corrosion atmospheres as well as galvanic protection coatings using Zinc, Aluminum and ZincAluminum that don�t demand the high production of 316� size materials