EQUIPMENT DESCRIPTION
The ArcMaster 1450 Spray Gun
The ArcMaster 1450 is a twin wire electric arc spray gun. It is a lightweight, high output, heavy-duty unit designed for
automatic and manual operation. It is equipped with a powerful DC motor with a planetary gear head and a maintenancefree gearbox with wire drive rollers.
Spray Head
Positioner
Nozzle
Tip
Retaining Nut
Contact
Tube
Air In
Power Lead
Power
Lug
Diagram of Air and Power Supply
A compressed air hose is attached to the fitting at the bottom of the front plate. The air then passes through the holes in
the front plate and into the spray head. From the spray head the air exhausts through the positioner and the nozzle,
which forms an atomizing jet. This air jet atomizes the molten metal, produced by an electric arc between the twin
spray wires, and applies melted particles onto a substrate forming a coating. The current from the power supply comes to
the wire through two leads, power connection lugs, and contact tubes with tips. The maximum operating current is 300 A.
WARNING:
DO NOT EXCEED MAXIMUM OPERATING CURRENT INDICATED IN THIS
SPECIFICATION! DOING SO CAN RESULT IN SERIOUS PERSONAL INJURY OR DEATH
ArcMaster 1450 Arc Spray Gun
This Gun consists of the following basic parts:
• DC Motor Unit
• Wire Drive Unit with side protective covers
• Counter Wheel Assembly
• Wire Drive Rollers Tension Unit
• Spray Head Assembly with retaining nut
• Handle
The DC Motor Unit includes a high torque 90 W DC motor integrated with a planetary gearbox, motor shell with cover, and
control buttons. The DC Motor Unit is attached to the Wire Drive Unit by three M4X16 and one M4X25 screws.
The Wire Drive Unit conveys power from the DC Motor Unit to the Wire Drive Rollers. It includes a gearbox with two Wire
Drive Rollers and two Rear Wire Guides (Figure 5-4). The right Wire Drive Roller and the right Roller Gear have left hand
threads and a black finish. The left Wire Drive Roller and the left Roller Gear have right hand threads and a metallic finish.
The gearbox is sealed and does not require lubrication.
The Counter-Wheel Assembly consists of two Counter Wheels with Wire Drive Rollers sitting on a common shaft
(Figure 5-5). The left Gear Assembly and the left Wire Drive Roller have left hand threads and a black finish. The right
Gear Assembly and the right Wire Drive Roller have right hand threads and a metallic finish. A setscrew adjusts the gap
between the Wire Drive Unit Drive Roller and the Counter-Wheel Drive Roller. The Gear Assemblies are sealed at the
factory and should not be taken apart in the field. The whole assembly should be replaced if needed.
The Wire Drive Rollers Tension Unit serves to apply pressure to the Counter Wheel Wire Drive Rollers in order to create
the necessary gripping force between the top and the bottom Driving Rollers.
The Tension Unit Housing is comprised of two Wire Roller Release Levers with camshafts, two tension springs with
setscrews and two L-shaped arms (Figure 5-6). The spring strength can be adjusted by a setscrew to work with wires of
different hardness.
Figure 5-7 ArcMaster 1450 Electronic Control Console
5.2 Control Console
The Control Unit of the ArcMaster 1450 gun consists of control cabinets: Electronic Control Unit (Figure 5-7) and
Air Control Unit (Figure 5-8), connected by control cable and mounted on Miller power supply (refer to Miller
power supply Manual for detailed instructions on use and maintenance).
PLC-based Electronic Control Unit provides the complete control of the system. It comprises 48 VDC power
supply, DC motor drive and PLC (Figure 5-9).
The Air Control Unit comprises a solenoid valve, a pressure sensor, and a pressure regulator (Figure 5-10).
Figure 5-8 Air Control Unit
5.4 Wire Box
The Wire Box is an enclosure for two wire spools (Figure 5-12). It protects the operator from accidental
contact with electrically live wires and prevents short circuits between the wires.
The Wire Box consists of:
• Wire spool spindle with brake assembly
• Wire guides and connectors for wire conduits
• Enclosure
• Wire conduits