Spoolmatic 1

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My Spoolmatic 1 gun does nothing when the trigger is pulled.  The 4 pin connector is connected to my MM200 and the arc lead is plugged into the machine.  The machine makes no sound, nor does the gun when the trigger is pulled.  Is there a place I should start to test the gun, or am I overlooking something simple?TA Arcmaster 300CM3XMT 304S22P12 suitcase feederX-Treme 12VSOptima pulserTA161SMaxstar 150STLHypertherm PM45OP setupStihl 020AVP, 039, 066 Magnum
Reply:Check for a failed control relay CR2 or a failed bridge rectifier SR2 that spoolgun power is supplied thru.Also make sure there is continuity between pins B and D of the spoolgun control cable plug when the trigger is pulled all the way.MM200 w/Spoolmatic 1Syncrowave 180SDBobcat 225G Plus - LP/NGMUTT Suitcase WirefeederWC-1S/Spoolmatic 1HF-251D-1PakMaster 100XL '68 Red Face Code #6633 projectStar Jet 21-110Save Second Base!
Reply:Originally Posted by duaneb55Check for a failed control relay CR2 or a failed bridge rectifier SR2 that spoolgun power is supplied thru.Also make sure there is continuity between pins B and D of the spoolgun control cable plug when the trigger is pulled all the way.
Reply:I found the schematics on the Miller website. Thanks.TA Arcmaster 300CM3XMT 304S22P12 suitcase feederX-Treme 12VSOptima pulserTA161SMaxstar 150STLHypertherm PM45OP setupStihl 020AVP, 039, 066 Magnum
Reply:Make sure you plug in the unit SNs to get the correct revision manuals for each.MM200 w/Spoolmatic 1Syncrowave 180SDBobcat 225G Plus - LP/NGMUTT Suitcase WirefeederWC-1S/Spoolmatic 1HF-251D-1PakMaster 100XL '68 Red Face Code #6633 projectStar Jet 21-110Save Second Base!
Reply:No continuity between B and D with or without trigger pull.  I got 55 volts at the plug from the welder across 2 leads, though I cant be sure which ones at the moment.  Can report that back.TA Arcmaster 300CM3XMT 304S22P12 suitcase feederX-Treme 12VSOptima pulserTA161SMaxstar 150STLHypertherm PM45OP setupStihl 020AVP, 039, 066 Magnum
Reply:55 volts?  DC?  Should be more like 32VDC+/- seeing as that transformer output is 36V and you'd be measuring thru the coil windings of CR2.  Voltage testing probe points should be 4-pin receptacle pins B and D - same as the ones on the Spoolmatic 1 control cable plug you checked for continuity with the SM-1 trigger pulled.I'd say no continuity on the SM-1 plug means either a bad switch, bad connection or broken wire in the control cable.If you're truely getting 55VDC, I would check to make sure the main transformer isn't configured for 200VAC power source rather than 230VAC as it should be.Another check you may want to make is checking the OCV (open circuit voltage) at the various Hi and Lo settings.  To do so, disengage the wire feed roll and check voltage between the gun tip and work clamp with the gun trigger pulled.  Compare your test result with the manual / chart figures just to see.  Don't worry about a volt or two one way or the other as every machine is a little different from the next and your specific service voltage is also a factor.  My machine OCVs tend to run high as the transformer is right outside the shop and service voltage runs 244-45V all the time.Last edited by duaneb55; 09-04-2011 at 11:48 PM.MM200 w/Spoolmatic 1Syncrowave 180SDBobcat 225G Plus - LP/NGMUTT Suitcase WirefeederWC-1S/Spoolmatic 1HF-251D-1PakMaster 100XL '68 Red Face Code #6633 projectStar Jet 21-110Save Second Base!
Reply:Originally Posted by duaneb55I'd say no continuity on the SM-1 plug means either a bad switch, bad connection or broken wire.
Reply:Where does the gas hookup?  Is there a gas solenoid in the gun?  Does it hookup directly to the argon gas gauge and have continual flow, or is there a connection for gas in the machine?TA Arcmaster 300CM3XMT 304S22P12 suitcase feederX-Treme 12VSOptima pulserTA161SMaxstar 150STLHypertherm PM45OP setupStihl 020AVP, 039, 066 Magnum
Reply:Ok, got it.   The trigger has a gas valve in it from what I researched.  Now that it's up and working, what would be the nitch for this spool gun?  I already have a great TIG for aluminum, and the spool gun looks like it's only good for really thick Aluminum work.  The welds I've seen posted don't look nearly as clean, strong or controllable as TIG welds do.  I guess it's a helluva lot faster though.   Would you part with it?TA Arcmaster 300CM3XMT 304S22P12 suitcase feederX-Treme 12VSOptima pulserTA161SMaxstar 150STLHypertherm PM45OP setupStihl 020AVP, 039, 066 Magnum
Reply:It's a speed thing and although I'm not the most talented with aluminum TIG or MIG, very attractive welds have and can be made on aluminum with MIG.The ends of these boxes were TIGed (mostly for practice) . . .. . . but the boxes were MIGed into the aluminum treadplate steps for speed and the fact the 180 SD doesn't have enough umph to do the 3/16" smooth to 1/4" TP with any speed or efficiency.I'd be keeping it.  It's just another tool in the toolbox and it can be used for MIGing other materials in addition to aluminum.MM200 w/Spoolmatic 1Syncrowave 180SDBobcat 225G Plus - LP/NGMUTT Suitcase WirefeederWC-1S/Spoolmatic 1HF-251D-1PakMaster 100XL '68 Red Face Code #6633 projectStar Jet 21-110Save Second Base!
Reply:I got significant burnback with the gun on the factory recommended settings.  Although much faster than TIG WHEN it actually worked, I spent more time refeeding wire and cleaning the tip than actually laying down beads.  Is 5356 an easier alloy to use in a spoolgun?TA Arcmaster 300CM3XMT 304S22P12 suitcase feederX-Treme 12VSOptima pulserTA161SMaxstar 150STLHypertherm PM45OP setupStihl 020AVP, 039, 066 Magnum
Reply:The beads from the spoolTA Arcmaster 300CM3XMT 304S22P12 suitcase feederX-Treme 12VSOptima pulserTA161SMaxstar 150STLHypertherm PM45OP setupStihl 020AVP, 039, 066 Magnum
Reply:Too cold.  Burning back to the tip is usually too slow on the wire feed and/or tip too close to the work.I use both 4043 and 5056.  4043 tends to flow a little smoother and can make a little better looking bead.What gas?MM200 w/Spoolmatic 1Syncrowave 180SDBobcat 225G Plus - LP/NGMUTT Suitcase WirefeederWC-1S/Spoolmatic 1HF-251D-1PakMaster 100XL '68 Red Face Code #6633 projectStar Jet 21-110Save Second Base!
Reply:100% Argon.  Machine on Low 4. Spool gun speed at 5.5.  The roll of wire looks to be pretty old with some oxidation on it.  Also, these beads were run outside on a night with little wind.  I had no idea what kind of spatter to expect.  Aluminum plate was 3/16 with no preheat.   It certainly ran smoother as the plate heated up.  The top bead was the first.  I got a TON of black soot on the welds, so I'm sure the shielding gas coverage wasn't great.  I brushed between and before welds with a SS brush.  The wire was really tight in the tip.  I think I need a replacement one.TA Arcmaster 300CM3XMT 304S22P12 suitcase feederX-Treme 12VSOptima pulserTA161SMaxstar 150STLHypertherm PM45OP setupStihl 020AVP, 039, 066 Magnum
Reply:Gotta crank the heat up.  Shouldn't get any spatter.  Aluminum MIG should be spray transfer (hissing sound not short circuit frying bacon).  IIRC those 3/16" smooth to 1/4" TP welds I posted were at HI-5 with wfs on the gun just under 50% (5).Make sure you use the "push" method and not "drag" with aluminum MIG to minimize the soot and hold the gas on for a second or two after letting up on the trigger to stop the wire feed at the end of a run to minimize oxidation as the puddle solidifies.MM200 w/Spoolmatic 1Syncrowave 180SDBobcat 225G Plus - LP/NGMUTT Suitcase WirefeederWC-1S/Spoolmatic 1HF-251D-1PakMaster 100XL '68 Red Face Code #6633 projectStar Jet 21-110Save Second Base!