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®
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MAGNUM PRO THRU THE
IM10071-A
April 2013
ARM ROBOTIC TORCH
Models
K2917-100iC K3353-100iC K3353-100iCW K3359-100iC K3359-100iCA K3359-100iCW
K2917-100iC/6L K3353-100iC/6L K3353-100iC/6LW K3359-100iC/6L K3359-100iC/6LA K3359-100iC/6LW
K2917-120iC K3353-120iC K3353-120iCW K3359-120iC K3359-120iCA K3359-120iCW
K2917-120iC/10L K3353-120iC/10L K3353-120iC/10LW K3359-120iC/10L K3359-120iC/10LA K3359-120iC/10LW
Safety Depends on You
Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However,
your overall safety can be
increased by proper installation
... and thoughtful operation on
your part. DO NOT INSTALL,
OPERATE OR REPAIR THIS
EQUIPMENT WITHOUT READING THIS MANUAL AND THE
SAFETY PRECAUTIONS CONTAINED THROUGHOUT. And,
most importantly, think before
you act and be careful.
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
OPERATORʼS MANUAL
Copyright © Lincoln Global Inc.
• World's Leader in Welding and Cutting Products •
• Sales and Service through Subsidiaries and Distributors Worldwide •
Page 2
i
SAFETY
i
WARNING
CALIFORNIA PROPOSITION 65 WARNINGS
Diesel engine exhaust and some of its constituents
are known to the State of California to cause cancer, birth defects, and other reproductive harm.
The Above For Diesel Engines
ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.
KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.
Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you
purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box
351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available
from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.
BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
The engine exhaust from this product contains
chemicals known to the State of California to cause
cancer, birth defects, or other reproductive harm.
The Above For Gasoline Engines
FOR ENGINE
powered equipment.
1.a. Turn the engine off before troubleshooting and maintenance
work unless the maintenance work requires it to be running.
____________________________________________________
1.b. Operate engines in open, well-ventilated
areas or vent the engine exhaust fumes
outdoors.
____________________________________________________
1.c. Do not add the fuel near an open flame
welding arc or when the engine is running.
Stop the engine and allow it to cool before
refueling to prevent spilled fuel from vaporizing on contact with hot engine parts and
igniting. Do not spill fuel when filling tank. If
fuel is spilled, wipe it up and do not start
engine until fumes have been eliminated.
____________________________________________________
1.d. Keep all equipment safety guards, covers and devices in
position and in good repair.Keep hands, hair, clothing and
tools away from V-belts, gears, fans and all other moving
parts when starting, operating or repairing equipment.
____________________________________________________
1.e. In some cases it may be necessary to remove safety
guards to perform required maintenance. Remove
guards only when necessary and replace them when the
maintenance requiring their removal is complete.
Always use the greatest care when working near moving
parts.
___________________________________________________
1.f. Do not put your hands near the engine fan.
Do not attempt to override the governor or
idler by pushing on the throttle control rods
while the engine is running.
1.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
hot.
ELECTRIC AND
MAGNETIC FIELDS
may be dangerous
2.a. Electric current flowing through any conductor causes
localized Electric and Magnetic Fields (EMF). Welding
current creates EMF fields around welding cables and
welding machines
2.b. EMF fields may interfere with some pacemakers, and
welders having a pacemaker should consult their physician
before welding.
2.c. Exposure to EMF fields in welding may have other health
effects which are now not known.
2.d. All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:
2.d.1.
Route the electrode and work cables together - Secure
them with tape when possible.
2.d.2. Never coil the electrode lead around your body.
2.d.3. Do not place your body between the electrode and
work cables. If the electrode cable is on your right
side, the work cable should also be on your right side.
___________________________________________________
1.g. To prevent accidentally starting gasoline engines while
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate.
2.d.4. Connect the work cable to the workpiece as close as
possible to the area being welded.
2.d.5. Do not work next to welding power source.
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ii
SAFETY
ii
ELECTRIC SHOCK can
kill.
3.a. The electrode and work (or ground) circuits
are electrically “hot” when the welder is on.
Do not touch these “hot” parts with your bare
gloves to insulate hands.
3.b. Insulate yourself from work and ground using dry insulation.
Make certain the insulation is large enough to cover your full
area of physical contact with work and ground.
In addition to the normal safety precautions, if welding
must be performed under electrically hazardous
conditions (in damp locations or while wearing wet
clothing; on metal structures such as floors, gratings or
scaffolds; when in cramped positions such as sitting,
kneeling or lying, if there is a high risk of unavoidable or
accidental contact with the workpiece or ground) use
the following equipment:
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
• AC Welder with Reduced Voltage Control.
3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically “hot”.
3.d. Always be sure the work cable makes a good electrical
connection with the metal being welded. The connection
should be as close as possible to the area being welded.
3.e. Ground the work or metal to be welded to a good electrical
(earth) ground.
3.f.
Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace
damaged insulation.
3.g. Never dip the electrode in water for cooling.
3.h. Never simultaneously touch electrically “hot” parts of
electrode holders connected to two welders because voltage
between the two can be the total of the open circuit voltage
of both welders.
3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.
3.j. Also see Items 6.c. and 8.
skin or wet clothing. Wear dry, hole-free
ARC RAYS can burn.
4.a. Use a shield with the proper filter and cover
plates to protect your eyes from sparks and
the rays of the arc when welding or observing
open arc welding. Headshield and filter lens
should conform to ANSI Z87. I standards.
4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
the arc rays.
4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
themselves to the arc rays or to hot spatter or metal.
FUMES AND GASES
can be dangerous.
5.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing these
fumes and gases. When welding, keep
your head out of the fume. Use enough
fumes and gases away from the breathing zone. When
welding with electrodes which require special
ventilation such as stainless or hard facing (see
instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
which produce highly toxic fumes, keep exposure as
low as possible and within applicable OSHA PEL and
ACGIH TLV limits using local exhaust or mechanical
ventilation. In confined spaces or in some circumstances, outdoors, a respirator may be required.
Additional precautions are also required when welding
on galvanized steel.
5. b. The operation of welding fume control equipment is affected
by various factors including proper use and positioning of
the equipment, maintenance of the equipment and the specific welding procedure and application involved. Worker
exposure level should be checked upon installation and
periodically thereafter to be certain it is within applicable
OSHA PEL and ACGIH TLV limits.
5.c.
Do not weld in locations near chlorinated hydrocarbon
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors
form phosgene, a highly toxic gas, and other irritating products.
5.d. Shielding gases used for arc welding can displace air and
cause injury or death. Always use enough ventilation,
especially in confined areas, to insure breathing air is safe.
ventilation and/or exhaust at the arc to keep
vapors
to
5.e. Read and understand the manufacturer’s instructions for this
equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employer’s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
5.f. Also see item 1.b.
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iii
SAFETY
iii
WELDING and CUTTING
SPARKS can
cause fire or explosion.
6.a.
Remove fire hazards from the welding area.
If this is not possible, cover them to prevent
Remember that welding sparks and hot
materials from welding can easily go through small cracks
and openings to adjacent areas. Avoid welding near
hydraulic lines. Have a fire extinguisher readily available.
6.b. Where compressed gases are to be used at the job site,
special precautions should be used to prevent hazardous
situations. Refer to “Safety in Welding and Cutting” (ANSI
Standard Z49.1) and the operating information for the
equipment being used.
6.c. When not welding, make certain no part of the electrode
circuit is touching the work or ground. Accidental contact
can cause overheating and create a fire hazard.
6.d. Do not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances
inside. They can cause an explosion even
been “cleaned”. For information, purchase “Recommended
Safe Practices for the
Containers and Piping That Have Held Hazardous
Substances”, AWS F4.1 from the American Welding Society
(see address above).
6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.
Sparks and spatter are thrown from the welding arc. Wear oil
6.f.
free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes and a cap over your hair. Wear
ear plugs when welding out of position or in confined places.
Always wear safety glasses with side shields when in a
welding area.
6.g. Connect the work cable to the work as close to the welding
area as practical. Work cables connected to the building
framework or other locations away from the welding area
increase the possibility of the welding current passing
through lifting chains, crane cables or other alternate circuits. This can create fire hazards or overheat lifting chains
or cables until they fail.
6.h. Also see item 1.c.
the welding sparks from starting a fire.
though
they have
Preparation
for Welding and Cutting of
CYLINDER may explode
if damaged.
7.a. Use only compressed gas cylinders
containing the correct shielding gas for the
process used and properly operating
regulators designed for the gas and
pressure used. All hoses, fittings, etc. should be suitable for
the application and maintained in good condition.
7.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.
7.c. Cylinders should be located:
• Away from areas where they may be struck or subjected to
physical damage.
• A safe distance from arc welding or cutting operations and
any other source of heat, sparks, or flame.
7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.
7.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.
7.f. Valve protection caps should always be in place and hand
tight except when the cylinder is in use or connected for
use.
7.g. Read and follow the instructions on compressed gas
cylinders, associated equipment, and CGA publication P-l,
“Precautions for Safe Handling of Compressed Gases in
Cylinders,” available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202.
FOR ELECTRICALLY
powered equipment.
8.a. Turn off input power using the disconnect
switch at the fuse box before working on
the equipment.
8.b. Install equipment in accordance with the U.S. National
Electrical Code, all local codes and the manufacturer’s
recommendations.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
6.I. Read and follow NFPA 51B “ Standard for Fire Prevention
During Welding, Cutting and Other Hot Work”, available
from NFPA, 1 Batterymarch Park, PO box 9101, Quincy, Ma
022690-9101.
6.j. Do not use a welding power source for pipe thawing.
Refer to http://www.lincolnelectric.com/safety for additional safety information.
Page 5
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SAFETY
iv
PRÉCAUTIONS DE SÛRETÉ
Pour votre propre protection lire et observer toutes les instructions
et les précautions de sûreté specifiques qui parraissent dans ce
manuel aussi bien que les précautions de sûreté générales suivantes:
Sûreté Pour Soudage A LʼArc
1. Protegez-vous contre la secousse électrique:
a. Les circuits à lʼélectrode et à la piéce sont sous tension
quand la machine à souder est en marche. Eviter toujours
tout contact entre les parties sous tension et la peau nue
ou les vétements mouillés. Porter des gants secs et sans
trous pour isoler les mains.
b. Faire trés attention de bien sʼisoler de la masse quand on
soude dans des endroits humides, ou sur un plancher
metallique ou des grilles metalliques, principalement dans
les positions assis ou couché pour lesquelles une grande
partie du corps peut être en contact avec la masse.
c. Maintenir le porte-électrode, la pince de masse, le câble
de soudage et la machine à souder en bon et sûr état
defonctionnement.
d.Ne jamais plonger le porte-électrode dans lʼeau pour le
refroidir.
e. Ne jamais toucher simultanément les parties sous tension
des porte-électrodes connectés à deux machines à souder
parce que la tension entre les deux pinces peut être le
total de la tension à vide des deux machines.
f. Si on utilise la machine à souder comme une source de
courant pour soudage semi-automatique, ces precautions
pour le porte-électrode sʼapplicuent aussi au pistolet de
soudage.
6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque dʼincendie dû aux étincelles.
7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque dʼincendie.
8. Sʼassurer que la masse est connectée le plus prés possible
de la zone de travail quʼil est pratique de le faire. Si on place
la masse sur la charpente de la construction ou dʼautres
endroits éloignés de la zone de travail, on augmente le risque
de voir passer le courant de soudage par les chaines de levage, câbles de grue, ou autres circuits. Cela peut provoquer
des risques dʼincendie ou dʼechauffement des chaines et des
câbles jusquʼà ce quʼils se rompent.
9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles
galvanisées plombées, ou cadmiées ou tout autre métal qui
produit des fumeés toxiques.
10. Ne pas souder en présence de vapeurs de chlore provenant
dʼopérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de lʼarc peuvent réagir avec les vapeurs
du solvant pour produire du phosgéne (gas fortement toxique)
ou autres produits irritants.
11. Pour obtenir de plus amples renseignements sur la sûreté,
voir le code “Code for safety in welding and cutting” CSA
Standard W 117.2-1974.
2. Dans le cas de travail au dessus du niveau du sol, se protéger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le câble-électrode autour de nʼimporte quelle partie
du corps.
3. Un coup dʼarc peut être plus sévère quʼun coup de soliel,
donc:
a. Utiliser un bon masque avec un verre filtrant approprié
ainsi quʼun verre blanc afin de se protéger les yeux du rayonnement de lʼarc et des projections quand on soude ou
quand on regarde lʼarc.
b. Porter des vêtements convenables afin de protéger la
peau de soudeur et des aides contre le rayonnement de
lʻarc.
c. Protéger lʼautre personnel travaillant à proximité au
soudage à lʼaide dʼécrans appropriés et non-inflammables.
4. Des gouttes de laitier en fusion sont émises de lʼ arc de
soudage. Se protéger avec des vêtements de protection libres
de lʼhuile, tels que les gants en cuir, chemise épaisse, pantalons sans revers, et chaussures montantes.
5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
zones où lʼon pique le laitier.
PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR
1. Relier à la terre le chassis du poste conformement au code de
lʼélectricité et aux recommendations du fabricant. Le dispositif
de montage ou la piece à souder doit être branché à une
bonne mise à la terre.
2. Autant que possible, Iʼinstallation et lʼentretien du poste seront
effectués par un électricien qualifié.
3. Avant de faires des travaux à lʼinterieur de poste, la debrancher à lʼinterrupteur à la boite de fusibles.
4. Garder tous les couvercles et dispositifs de sûreté à leur
place.
Page 6
Thank You
vv
for selecting a QUALITY product by Lincoln Electric. We want you
to take pride in operating this Lincoln Electric Company product
••• as much pride as we have in bringing this product to you!
The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equipment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask Lincoln
Electric for advice or information about their use of our products. We respond to our customers based on the best information in our possession at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such information or advice. We expressly disclaim any warranty of any kind, including any warranty of fitness for any customerʼs particular purpose,
with respect to such information or advice. As a matter of practical consideration, we also cannot assume any responsibility for updating or
correcting any such information or advice once it has been given, nor does the provision of information or advice create, expand or alter any
warranty with respect to the sale of our products.
Lincoln Electric is a responsive manufacturer, but the selection and use of specific products sold by Lincoln Electric is solely within the control
of, and remains the sole responsibility of the customer. Many variables beyond the control of Lincoln Electric affect the results obtained in
applying these types of fabrication methods and service requirements.
Subject to Change – This information is accurate to the best of our knowledge at the time of printing. Please refer to www.lincolnelectric.com
for any updated information.
CUSTOMER ASSISTANCE POLICY
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 equipment nameplate or product carton label.
Model Name and Sales Spec Number (K-xxx) _____________________________________
Date of Purchase __________________________________
Whenever you request replacement parts for or information on this equipment always supply the information
you have recorded above.
On-Line Product Registration
- Register your machine with Lincoln Electric either via fax or over the Internet.
• For faxing: Complete the form on the back of the warranty statement included in the literature packet
accompanying this machine and fax the form per the instructions printed on it.
• For On-Line Registration: Go to our
Your Product”. Please complete the form and submit your registration.
Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it
handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.
The level of seriousness to be applied to each is explained below:
WEB SITE at www.lincolnelectric.com. Choose “Support” and then “Register
WARNING
This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life.
CAUTION
This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment.
Page 7
vivi
Page
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section A
General DescriptIon, Recommended Processes and Equipment. . . . . . . . . . . . . . . . . . . . . . A-1
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2
Magnum® Pro Thru the Arm For
Magnum® Pro Thru the Arm For
Magnum® Pro Thru the Arm For
__________________________________________________________________________________________
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section B
(Standard Robot Assembly)
Connecting Torch to Robot Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
Connecting Cable to Robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1,B-2
Connecting Gooseneck and Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2
Electrodes and Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3
Making a Weld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3
Avoiding Wire Feeding Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3
(Wire Brake Information)
Connecting Torch to Robot Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-4
Connecting Cable to Robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-4, B-5
Installation of Nose Cone Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-5
Connecting Gooseneck and Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-6
__________________________________________________________________________________________
100iC, 100iC/6L
120iC
Robots
120iC/10L
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4
Robots
Robots . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4
Accessories. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section C
(Optional Air Blast)
Connecting Torch to Robot Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1
Connecting Cable to Robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1,C-2
Installation of Nose Cone Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-3
Connecting Gooseneck and Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-3
Electrodes and Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-4
Making a Weld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-4
Avoiding Wire Feeding Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-4
__________________________________________________________________________________________
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section D
Removal, Installation and Trimming Instructions for All Magnum® Liners . . . . . . . . . . . . D-1
Gun Tubes and Nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1
Cable Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1
To Replace Wire Brake Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-2
__________________________________________________________________________________________
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section E
__________________________________________________________________________________________
Parts Lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-202-AG
__________________________________________________________________________________________
Page 8
A-1
GENERAL DESCRIPTION
A-1
GENERAL DESCRIPTION
The Magnum® Pro product line is designed for heavy
duty applications and possesses market leading ratings and simplicity in maintenance.
The Magnum® Pro Thru the Arm Robotic Torch has
been designed to meet specifications for welding with
steel electrode using the GMAW (gas metal arc welding) and gas-shielded FCAW (flux-cored arc welding)
processes.
The Magnum® Pro Thru the Arm Robotic Torch is
rated for 550 amps at 100% duty cycle with 100%
CO2 shielding gas. It is rated at 375 amps at 100%
duty cycle with mixed gas.
The Thru-arm Torch is designed for use with the
Fanuc
® ARC Mate® 100iC, 100iC/6L, 120iC and
120iC/10L. Models are factory equipped with a feeder
connector for most Lincoln robot-mounted feeders (i.e.
4R90, 4R100 4R220).
WARNING
• Wirefeeders:
• K2917, K3353 and K3359 Series are not compatible with the Power Feed 10R. They are designed
only to work with “nested” wire feeders such as
the 4R90, 4R100 and 4R220.
• It is not recommended that the K2917, K3353 or
K3359 Series be used with any non robot-mounted wirefeeder.
COMMON EQUIPMENT PACKAGES
The available replacement parts for the Thru-arm are
shown in Table A.1.
• KP2918/KP2919 series gooseneck are used in
K2917 torches.
• KP3354/KP3355 series goosneck are used in
K3353 and K3359 torches.
TABLE A.1
MAGNUM®PRO THRU THE ARM
REPLACEMENT EQUIPMENT
Product Number
Description
• Do not touch electrically live parts
such as output terminals or internal wiring.
------------------------------------------------------------------------
RECOMMENDED PROCESSES AND
EQUIPMENT
RECOMMENDED PROCESSES
• GMAW, GMAW-P, GMAW-STT, FCAW, FCAW-SS
PROCESS LIMITATIONS
• This product is not recommended for submerged
arc welding.
EQUIPMENT LIMITATIONS
• Robots:
• K2917-100iC, K2917-100iC/6L, K2917-120iC and K2917-
120iC/10L, K3353-100iC, K3353-100iC/6L, K3353-120iC,
K3353-120iC/10L, K3353-100iCW, K3353-100iC/6LW, K3353120iCW, K3353-120iC/10LW, K3359-100iC, K3359-100iC/6L,
K3359-120iC, K3359-120iC/10L, K3359-100iCA, K3359100iC/6LA, K3359-120iCA, K3359-120iC/10LA, K3359100iCW, K3359-100iC/6LW, K3359-120iCW, K3359120iC/10LW
the Fanuc
and 120iC/10L respectively. Because the cables
are routed through the robot and have a precise
length, these welding torches cannot be used on
any other model robot.
are specifically designed to be used with
® ARC Mate® 100iC, 100iC/6L, 120iC
®
KP2918-22 Tregaskiss
KP2918-45 Tregaskiss
KP2919-22 Binzel
KP2919-45 Binzel
KP2919-180 Binzel
KP3354-22 Tregaskiss
KP3354-45 Tregaskiss
KP3355-22 Binzel
KP3355-45 Binzel
KP3355-180 Binzel
22° TCP Gooseneck
®
45° TCP Gooseneck
®
22° TCP Gooseneck
®
45° TCP Gooseneck
®
180° TCP Gooseneck
®
22° TCP Gooseneck
®
45° TCP Gooseneck
®
22° TCP Gooseneck
®
45° TCP Gooseneck
®
180° TCP Gooseneck
KP2920-1 Breakaway Disc
KP3066-100iC Cable Assembly, Fanuc
KP3066-100iC/6L
Cable Assembly, Fanuc® 100iC/6L
KP3066-120iC Cable Assembly, Fanuc
KP3066-120iC/10L
Cable Assembly, Fanuc® 120iC/10L
®
100iC
®
120iC
• Activation limits are as follows: J6 Axis [+/-270º]
MAGNUM® PRO THRU THE ARM ROBOTIC TORCH
Page 9
A-2
GENERAL DESCRIPTION
SPECIFICATIONS: K2917-100iC, K2917-100iC/6L, K2917-120iC, K2917-120iC/10L,
K3353-100iC, K3353-100iC/6L, K3353-120iC, K3353-120iC/10L,
K3353-100iCW, K3353-100iC/6LW, K3353-120iCW, K3353-120iC/10LW,
K3359-100iC, K3359-100iC/6L, K3359-120iC, K3359-120iC/10L,
K3359-100iCA, K3359-100iCW, K3359-100iC/6LA, K3359-100iC/6LW,
K3359-120iCA, K3359-120iCW, K3359-120iC/10LA, K3359-120iC/10LW
Magnum® Pro Thru the Arm Series - Rated Output
Duty Cycle Amperes – Mixed Gas Amperes – CO
40% 575 845
60% 460 700
80% 400 610
100% 375 550
2
Welding Processes
Process
GMAW-Pulsed
GMAW-STT
Electrode Diameter
Range
.035” – 5/64"
(0.9 – 2.0 mm)
Output Range
(Amperes)
375A @ 100%
460A @ 60%
Wire Feed Speed Range
See wire feeder literature.
A-2
FCAW- Gas Shielded
Model
K2917-100iC
K3353-100iC
K3353-100iCW
K3359-100iCA
K3359-100iCW
K2917-100iC/6L
K2917-120iC
K3353-100iC/6L
K3353-100iC/6LW
K3359-100iC/6LA
K3359-100iC/6LW
K3353-120iC
K3353-120iCW
K3359-120iCA
K3359-120iCW
K2917-120iC/10L
K3353-120iC/10L
K3353-120iC/10LW
K3359-120iC/10LA
K3359-120iC/10LW
Physical Dimensions and Temperature Ranges
Cable Length
3ft (.9m)
3.5ft (1.1m)
4ft (1.2m)
5.50 lbs (2.5 kg)
5.75 lbs (2.6 kg)
6.00 lbs (2.7 kg)
Weight
OPERATING TEMPERATURE RANGE
-4°F to 104°F (-20°C to 40°C)
MAGNUM® PRO THRU THE ARM ROBOTIC TORCH
STORAGE TEMPERATURE RANGE
-40°F to 185°F (-40°C to 85°C)
Page 10
A-3
Description
Product
Number
Gun Cable
Length (m)
GENERAL DESCRIPTION
MAGNUM® PRO THRU THE ARM FOR 100iC ROBOT
550 AMPS AT 100% DUTY CYCLE WITH CO
375 AMPS AT 100% DUTY CYCLE WITH MIXED GAS
Wire Size
Range
in. (mm)
Contact Tips
Standard
Duty
Gas Diffuser
Assembly
Gas
Nozzle
Insulator
GAS
2
Cable Liner
Gun Tube 45
°
Jump Liner
A-3
K2917-100iC
K3353-100iC
K3353-100iCW
K3010-100iC
(Ready Pak)
K3359-100iC
K3359-100iCA
K3359-100iCW
(Ready Pak)
Description
Product
Number
K2917-100iC/6L
K3353-100iC/6L
K3353-100iC/6LW
K3010-100iC/6L
(Ready Pak)
3 ft.
(.9)
3 ft.
(.9)
3 ft.
(.9)
.035 (0.9)
5/64 (2.0)
.035 (0.9)
5/64 (2.0)
.035 (0.9)
5/64 (2.0)
KP2745-035R
KP2745-045R
KP2745-040
KP2747-1
KP2747-2
KP2743-1-62R
KP2743-1-62R
KP2773-1
KP2773-1
MAGNUM® PRO THRU THE ARM FOR 100iC/6L ROBOT
550 AMPS AT 100% DUTY CYCLE WITH CO
375 AMPS AT 100% DUTY CYCLE WITH MIXED GAS
Gun Cable
Length (m)
3.5 ft.
(1.1)
3.5 ft.
(1.1)
Wire Size
Range
in. (mm)
.035 (0.9)
5/64 (2.0)
.035 (0.9)
5/64 (2.0)
Contact Tips
Standard
Duty
KP2745-035R
KP2745-045R
Gas Diffuser
Assembly
KP2747-1
Gas
Nozzle
KP2743-1-62R
Insulator
KP2773-1
KP45-3545-15
KP45-3545-6
GAS
2
Cable Liner
KP45-3545-15
KP2919-45
KP3355-45
Gun Tube 45
KP2919-45
KP3364-1
“W” ONLY
°
Jump Liner
K3359-100iC/6L
K3359-100iC/6LA
K3359-100iC/6LW
(Ready Pak)
Description
Product
Number
K2917-120iC
K3353-120iC
K3353-120iCW
K3011-120iC
(Ready Pak)
K3359-120iC
K3359-120iCA
K3359-120iCW
(Ready Pak)
3.5 ft.
(1.1)
Gun Cable
Length (m)
3.5 ft.
(1.1)
3.5 ft.
(1.1)
3.5 ft.
(1.1)
.035 (0.9)
5/64 (2.0)
KP2745-040
KP2747-1
KP2743-1-62R
KP2773-1
KP45-3545-6
MAGNUM® PRO THRU THE ARM FOR 120iC ROBOT
550 AMPS AT 100% DUTY CYCLE WITH CO
GAS
2
375 AMPS AT 100% DUTY CYCLE WITH MIXED GAS
Wire Size
Range
in. (mm)
.035 (0.9)
5/64 (2.0)
.035 (0.9)
5/64 (2.0)
.035 (0.9)
5/64 (2.0)
Contact Tips
Standard
Duty
KP2745-035R
KP2745-045R
KP2745-040
Gas Diffuser
Assembly
KP2747-1
KP2747-1
Gas
Nozzle
KP2743-1-62R
KP2743-1-62R
Insulator
KP2773-1
KP2773-1
Cable Liner
KP45-3545-15
KP45-3545-6
KP3355-45
Gun Tube 45
KP2919-45
KP3355-45
KP3364-1
“W” ONLY
°
Jump Liner
KP3364-1
“W” ONLY
MAGNUM® PRO THRU THE ARM ROBOTIC TORCH
Page 11
A-4
GENERAL DESCRIPTION
MAGNUM® PRO THRU THE ARM FOR 120iC/10L ROBOT
550 AMPS AT 100% DUTY CYCLE WITH CO
375 AMPS AT 100% DUTY CYCLE WITH MIXED GAS
GAS
2
A-4
Description
Product
Number
K2917-120iC/6L
K3353-120iC/10L
K3353-120iC/10LW
K3011-120iC/6L
(Ready Pak)
K3359-120iC/10L
K3359-120iC/10LA
K3359-120iC/10LW
(Ready Pak)
Gun Cable
Length (m)
4 ft.
(1.2)
4 ft.
(1.2)
4 ft.
(1.2)
Wire Size
Range
in. (mm)
.035 (0.9)
5/64 (2.0)
.035 (0.9)
5/64 (2.0)
.035 (0.9)
5/64 (2.0)
Contact Tips
Standard
Duty
KP2745-035R
KP2745-045R
KP2745-040
Gas Diffuser
Assembly
KP2747-1
KP2747-1
Gas
Nozzle
KP2743-1-62R
KP2743-1-62R
ROBOT ACTIVATION LIMITS
ROBOT ARM
Insulator
KP2773-1
KP2773-1
Cable Liner
KP45-3545-15
KP45-3545-6
Gun Tube 45
KP2919-45
KP3355-45
°
Jump Liner
KP3364-1
“W” ONLY
J6 AXIS: +/- 270º
MAGNUM® PRO THRU THE ARM ROBOTIC TORCH
Page 12
B-1
1
2
3
Cable Cover
Hex and Crimp
Robot Axis J5 rotated down 90°
1
Read this entire installation section before you
start installation.
INSTALLATION
SAFETY PRECAUTIONS
WARNING
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts
such as output terminals or internal wiring.
B-1
CONNECTING CABLE ASSEMBLY TO
ROBOT
(See Figure B.2)
1. Remove Magnum Liner Item 1 and Cable Assembly
Item 2 from packaging. Lay both Items on a flat sur-
face to be assembled.
2. Trim Magnum Liner to approximately 5.5ft.(1.7m).
Insert liner into Feeder Connector Assembly and
secure with Set Screw Item 3.
• Insulate yourself from the work and
ground.
• Always wear dry insulating gloves.
------------------------------------------------------------------------
STANDARD ROBOT ASSEMBLY
(
)
CONNECTING TORCH TO ROBOT ARM,
FANUC MODEL 100iC, 100iC/6L, 120iC OR
120iC/10L
(See Figure B.1)
1. Removing Torch Assembly from packaging
Disassemble the Torch Assembly:
• Remove the 2 sets of 4 Socket Head Cap Screws
Item 1, holding the Nose Cone Item 2, to the Housing
Item 3 and the Housing to the Breakaway Disc Item
4.
2. Assemble the Breakaway Disc to the J6 axis Item 5 of
the robot, making sure the Scribe Mark is facing up.
Secure with the (4) M4 Screws Item 6 provided.
Torque to 6-8 in-lbs (.9-1.1Nm).
3. Assemble the Housing to the Breakaway Disc. Align
Scribe Marks and secure with Long Socket Head
Caps Screws. Torque to 8-10 in-lbs (.9-1.1Nm).
FIGURE B.2
3. Pull back cable cover and grip cable behind front hex
and crimp. With the robot axis J5 rotated down 90°,
insert hex thru housing until it passes thru and
secure with attached Socket Head Cap Screw Item
1. Push cable cover forward until it snaps into
breakaway disc.
(See Figure B.3)
FIGURE B.3
4. Assemble the Nose Cone assembly to the Housing.
Align Scribe Marks and secure with remaining
Socket Head Caps Screws. Torque to 8-10 in-lbs.
(.9-1.1Nm).
5
FIGURE B.1
4
6
3
Scribe Marks
MAGNUM® PRO THRU THE ARM ROBOTIC TORCH
1
2
Page 13
B-2
SET SCREW
PLUG COVER
SPOT FACE
ON GOOSENECK
GUN TUBE (GOOSENECK)
GAS DIFFUSER
TIP
GAS NOZZLE
INSULATOR
LINER TRIM
LENGTH
5/8" (16.0 mm)
INSTALLATION
4. Insert Feeder Connector thru Robot Arm cavity and
into wire feeder and secure. Make sure that the
cable is not twisted when installed. Connect gas
hose to gas fitting on feeder connector.
(See Figure
B.4) Adjust feeder location until approximately 1-
1/2 inch cable rise as shown in robot front view
below.
FIGURE B.4
GAS FITTING
FEEDER CONNECTOR END
ROBOT ARM
B-2
CONNECTING GOOSENECK AND CONSUMABLES
(See Figure B.5)
Remove plug cover from nose cone. Loosen set
screw. Insert gooseneck into nose cone (spot-face
facing up) and secure with set screw. Replace plug
cover. Trim Magnum liner to 5/8”(16.0mm) stick out
from end of gooseneck. Attach desired Magnum Pro
consumables to gooseneck.
INSERT FEEDER
CONNECTOR END HERE.
MAKE SURE THE CABLE
IS NOT TWISTED.
PROVIDE CABLE RISE (ROBOT FRONT VIEW)
1-1/2 IN.
PLUG COVER
SET SCREW
FIGURE B.5
SPOT FACE
ON GOOSENECK
GUN TUBE (GOOSENECK)
LINER TRIM
LENGTH
5/8" (16.0 mm)
GAS DIFFUSER
INSULATOR
TIP
GAS NOZZLE
MAGNUM® PRO THRU THE ARM ROBOTIC TORCH
Page 14
B-3
INSTALLATION
B-3
ELECTRODES AND EQUIPMENT
The (Thru the Arm Robotic Torch) has been designed
for use with Lincoln GMAW wire electrodes. Refer to
the appropriate Lincoln Process and Procedure
Guidelines for the electrode used for information on
recommended electrical and visible stickouts.
MAKING A WELD
WARNING
When using an open arc process, it is necessary
to use eye, head, and body protection.
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts
such as output terminals or internal wiring.
• Insulate yourself from the work and
ground.
AVOIDING WIRE FEEDING
PROBLEMS
Wire feeding problems can be avoided by observing the
following gun handling procedures:
1. Keep the electrode cable as straight as possible when
welding or loading electrode through cable.
2. Keep cable clean by following maintenance instructions.
3. Use only clean, rust-free electrode. The Lincoln electrodes have proper surface lubrication.
4. Replace contact tip when the arc starts to become
unstable or the contact tip end is fused or deformed.
• Always wear dry insulating gloves.
------------------------------------------------------------------------
FUMES AND GASES can be dangerous.
• Keep your head out of fumes.
• Use ventilation or exhaust to
remove fumes from breathing zone.
------------------------------------------------------------------------
WELDING SPARKS can cause fire or
explosion.
• Keep flammable material away.
------------------------------------------------------------------------
RAYS can burn.
ARC
• Wear eye, ear and body protection.
------------------------------------------------------------------------
Only qualified personnel should operate this
equipment.
MAGNUM® PRO THRU THE ARM ROBOTIC TORCH
Page 15
B-4
Read this entire installation section before you
start installation.
INSTALLATION
WARNING
SAFETY PRECAUTIONS
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts
such as output terminals or internal wiring.
• Insulate yourself from the work and
ground.
• Always wear dry insulating gloves.
------------------------------------------------------------------------
(WIRE BRAKE UNIT)
CONNECTING TORCH TO ROBOT ARM,
FANUC MODEL 100ic, 100ic/6L, 120iC, OR
120iC/10L
(See Figure B.6)
1. Removing Torch Assembly from packaging
Disassemble the Torch Assembly:
• Remove the set of 4 Socket Head Cap Screws Item
1, the Housing Item 2 and the Housing to the
Breakaway Disc Item 3.
2. Assemble the Breakaway Disc to the J6 axis Item 4 of
the robot, making sure the Scribe Mark is facing up.
Secure with the (4) M4 Screws Item 5 provided.
Torque to 6-8 in-lbs (.9-1.1Nm).
B-4
CONNECTING CABLE ASSEMBLY TO
ROBOT
(See Figure B.7)
1. Remove Magnum liner ITEM 1, Cable Assembly
ITEM 2 and Air hose ITEM 6 from packaging. Lay
items on a flat surface to be assembled.
2. Push Air Hose ITEM 6 thru access hole on Cable
Handle ITEM 4 until approximately 4 inches protrudes
from front. If hose does not feed freely, proceed to
step 3. Otherwise, proceed to step 6.
3. Remove Feeder Connecter Assembly ITEM 5 from
Cable Handle ITEM 4. Remove cable handle from
cable assembly. Feed air hose thru cable handle
access hole until approximately 4 inches protrudes
from front of cable cover.
4. Slide cable handle onto cable asembly; align flats and
install. If at any time hose is not free to move, remove
and rotate cable handle 180 degrees clockwise and
reinstall.
5. Install Feeder Connector ITEM 5 and torque to 12 ft-
16.27
lbs (
6. Insert liner into feeder connector assembly and secure
with set screw ITEM 3. Trim liner flush to 1/16 inch
protrusion from front connector.
N-M).
FIGURE B.7
3. Assemble the Housing to the Breakaway Disc. Align
Scribe Marks and secure with Long Socket Head
Caps Screws. Torque to 8-10 in-lbs (.9-1.1Nm).
FIGURE B.6
4
3
2
1
5
Scribe Marks
MAGNUM® PRO THRU THE ARM ROBOTIC TORCH
6
5
PUSH AIR HOSE THRU
ACCESS HOLE HERE
3
1
4
2
FLUSH TO 1/16”
AIR HOSE
4 IN.
Page 16
B-5
INSTALLATION
7. Remove plug cover ITEM 4. Pull back cable cover
and grip cable cable behind front hex / crimp. With
robot axis J5 rotated down 90 degrees, insert hex
thru housing until it passes thru. Push cable cover
forward until it snaps into Breakaway Disk.
8. Connect Air Hose ITEM 1 to Wire Brake ITEM 2.
9. Slide Nose Cone ITEM 3 into Torch Cable ITEM 5
until it bottoms. Secure with attached Socket Head
Cap screw ITEM 7. Reinstall plug cover ITEM 4.
Ensure that air hose is not kinked during this
process. Align scribe marks and secure nose cone
with remaining Socket Head Cap Screws ITEM 6.
Torque to 8-10 in-lbs. (0.9 - 1.1 N-m) (See Figure
B.8)
FIGURE B.8
B-5
10. Push approximately 2 inches of air hose into torch
cable on feeder connector end to ensure that air
hose is slack at all times.
11. Insert Feeder Connector and air hose thru Robot
Arm cavity; secure feeder connection. Make sure
that the cable is not twisted when installed.
Connect gas hose to gas fitting on feeder connector. (See Figure B.9) Adjust feeder location until
approximately 1-1/2 inch cable rise as shown in
robot front view below.
FIGURE B.9
GAS FITTING
FEEDER CONNECTOR END
AIR HOSE
ROBOT ARM
Cable Cover
4
INSERT FEEDER
CONNECTOR END HERE.
MAKE SURE THE CABLE
Robot Axis J5
IS NOT TWISTED.
rotated down 90°
PROVIDE CABLE RISE (ROBOT FRONT VIEW)
1-1/2 IN.
7
Hex and Crimp
5
1
2
3
6
MAGNUM® PRO THRU THE ARM ROBOTIC TORCH
Page 17
B-6
SET SCREW
PLUG COVER
JUMP LINER
SPOT FACE
ON GOOSENECK
GUN TUBE (GOOSENECK)
GAS DIFFUSER
TIP
GAS NOZZLE
INSULATOR
LINER TRIM
LENGTH
5/8" (16.0 mm)
INSTALLATION
CONNECTING GOOSENECK AND CONSUMABLES
Slide Jump Liner into desired gooseneck assembly
from gooseneck rear. Remove plug cover from nose
cone. Loosen set screw. Insert gooseneck into nose
cone (spot-face facing up) and secure with set screw.
Replace plug cover. Trim jump liner to 5/8" (16.0 mm)
stickout from end of gooseneck. Attach desired
Magnum Pro comsumables to gooseneck.
(See Figure B.10)
FIGURE B.10
B-6
SET SCREW
PLUG COVER
JUMP LINER
SPOT FACE
ON GOOSENECK
GAS DIFFUSER
GUN TUBE (GOOSENECK)
LINER TRIM
LENGTH
5/8" (16.0 mm)
INSULATOR
TIP
GAS NOZZLE
MAGNUM® PRO THRU THE ARM ROBOTIC TORCH
Page 18
C-1
5 IN.
1
2
3
4
PUSH AIR HOSE
THRU ACCESS HOLE HERE
AIR HOSE
5
6
Read this entire installation section before you
start installation.
ACCESSORIES
SAFETY PRECAUTIONS
C-1
CONNECTING CABLE ASSEMBLY TO
ROBOT
(See Figure C.2)
WARNING
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts
such as output terminals or internal wiring.
• Insulate yourself from the work and
ground.
• Always wear dry insulating gloves.
------------------------------------------------------------------------
OPTIONAL AIR BLAST UNIT
(
NON WIRE BRAKE ONLY
CONNECTING TORCH TO ROBOT ARM,
FANUC MODEL 100iC, 100iC/6L, 120iC OR
120iC/10L
(See Figure C.1)
1. Removing Torch Assembly from packaging
Disassemble the Torch Assembly:
• Remove the set of 4 Socket Head Cap Screws Item
1, the Housing Item 2 and the Housing to the
Breakaway Disc Item 3.
)
1. Remove Magnum liner ITEM 1, Cable Assembly
ITEM 2 and Air Hose ITEM 6 from packaging. Lay
items on a flat surface to be assembled.
2. Push Air Hose ITEM 6 thru access hole on Cable
Handle ITEM 4 until approximately 5 inches protrudes from front. If hose does not feed freely, proceed to step 3. Otherwise, proceed to step 6.
3. Remove Feeder Connecter Assembly ITEM 5 from
Cable Handle ITEM 4. Feed air hose thru cable handle access hole until approximately 5 inches protrudes from front of cable cover.
4. Slide cable handle onto cable asembly; align flats
and install. If at any time hose is not free to move,
remove and rotate cable handle 180 degrees clockwise and reinstall.
5. Install Feeder Connector ITEM 5 and torque to 12 ftlbs. (16.27 N-M).
6. Trim Magnum Liner to approximately 5.5ft.(1.7m).
Insert liner into Feeder Connector Assembly and
secure with Set Screw Item 3.
2. Assemble the Breakaway Disc to the J6 axis Item 4 of
the robot, making sure the Scribe Mark is facing up.
Secure with the (4) M4 Screws Item 5 provided.
Torque to 6-8 in-lbs (.9-1.1Nm).
3. Assemble the Housing to the Breakaway Disc. Align
Scribe Marks and secure with Long Socket Head
Caps Screws. Torque to 8-10 in-lbs (.9-1.1Nm).
FIGURE C.1
4
3
2
1
5
Scribe Marks
FIGURE C.2
MAGNUM® PRO THRU THE ARM ROBOTIC TORCH
Page 19
C-2
1
2
3
4
5
6
7
8
Cable Cover
Hex and Crimp
Robot Axis J5
rotated down 90°
9
10
ACCESSORIES
C-2
7. Remove Plug Cover ITEM 9. Pull back cable cover
and grip cable behind front hex and crimp. With the
robot axis J5 rotated down 90°, insert hex thru housing until it passes thru. Push cable cover forward
until it snaps into breakaway disc.
8. Remove 5mm set screw from nose cone air blast
port ITEM 1 and dicard. Install air blast fitting ITEM
2, tighten until snug using 2.5mm allen key
.
9. Press Air hose ITEM 6 into air blast fitting ITEM 2 on
nose cone ITEM 7 to seat fully.
10. Assemble the Nose Cone ITEM 7 assembly to the
Housing ITEM 3.
Secure with attached Socket
Head Cap screw ITEM 10. Reinstall plug cover
ITEM 9.
Align Scribe Marks and secure with remain-
ing Socket Head Caps Screws ITEM 8. Torque to 810 in-lbs. (.9-1.1Nm).
(See Figure C.3)
FIGURE C.3
11. Push approximatently 2 inches of air hose into torch
cable on feeder connector end to ensure that air blast
hose is slack at all times.
12. Insert Feeder Connector and air blast hose thru
Robot Arm cavity; secure feeder connection.
Make sure that the cable is not twisted when
installed. Connect gas hose to gas fitting on feeder connector. (See Figure C.4)
Adjust feeder
location until approximately 1-1/2 inch cable rise
as shown in robot front view below.
FIGURE C.4
GAS FITTING
FEEDER CONNECTOR END
AIR BLAST HOSE
ROBOT ARM
INSERT FEEDER
CONNECTOR END HERE.
MAKE SURE THE CABLE
IS NOT TWISTED.
PROVIDE CABLE RISE (ROBOT FRONT VIEW)
1-1/2 IN.
MAGNUM® PRO THRU THE ARM ROBOTIC TORCH
Page 20
C-3
SPOT FACE
ON GOOSENECK
GUN TUBE (GOOSENECK)
GAS DIFFUSER
TIP
GAS NOZZLE
INSULATOR
LINER TRIM
LENGTH
5/8" (16.0 mm)
SET SCREW
PLUG COVER
ACCESSORIES
CONNECTING GOOSENECK AND CONSUMABLES
(See Figure C.5)
Remove plug cover from nose cone. Loosen set
screw. Insert gooseneck into the nose cone (spot-face
facing up) and secure with set screw. Replace plug
cover. Trim Magnum liner to 5/8”(16.0mm) stick out
from end of gooseneck. Attach desired Magnum Pro
consumables to gooseneck.
C-3
PLUG COVER
SET SCREW
FIGURE C.5
SPOT FACE
ON GOOSENECK
GUN TUBE (GOOSENECK)
LINER TRIM
LENGTH
5/8" (16.0 mm)
GAS DIFFUSER
GAS NOZZLE
INSULATOR
TIP
MAGNUM® PRO THRU THE ARM ROBOTIC TORCH
Page 21
C-4
ACCESSORIES
C-4
ELECTRODES AND EQUIPMENT
The (Thru the Arm Robotic Torch) has been designed
for use with Lincoln GMAW wire electrodes. Refer to
the appropriate Lincoln Process and Procedure
Guidelines for the electrode used for information on
recommended electrical and visible stickouts.
MAKING A WELD
WARNING
When using an open arc process, it is necessary
to use eye, head, and body protection.
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts
such as output terminals or internal wiring.
• Insulate yourself from the work and
ground.
AVOIDING WIRE FEEDING
PROBLEMS
Wire feeding problems can be avoided by observing the
following gun handling procedures:
1. Keep the electrode cable as straight as possible when
welding or loading electrode through cable.
2. Keep cable clean by following maintenance instructions.
3. Use only clean, rust-free electrode. The Lincoln electrodes have proper surface lubrication.
4. Replace contact tip when the arc starts to become
unstable or the contact tip end is fused or deformed.
• Always wear dry insulating gloves.
------------------------------------------------------------------------
FUMES AND GASES can be dangerous.
• Keep your head out of fumes.
• Use ventilation or exhaust to
remove fumes from breathing zone.
------------------------------------------------------------------------
WELDING SPARKS can cause fire or
explosion.
• Keep flammable material away.
------------------------------------------------------------------------
RAYS can burn.
ARC
• Wear eye, ear and body protection.
------------------------------------------------------------------------
Only qualified personnel should operate this
equipment.
MAGNUM® PRO THRU THE ARM ROBOTIC TORCH
Page 22
D-1
MAINTENANCE
REMOVAL, INSTALLATION AND
TRIMMING INSTRUCTIONS FOR
MAGNUM® LINERS
NOTE: The variation in cable lengths prevents the
(See Figure D-1 for instructions 1-5)
1. Robot Axis J5 rotated down 90° to help remove
2. Before sliding Cable Assembly out of Robot Arm
3. Loosen the fasteners holding the hex connection
4. Back out Cable Cover.
5. Back out Hex Connection.
interchangeability of liners. Once a liner has
been cut for a particular gun, it should not be
installed in another gun, unless it can meet the
liner cut off length requirement. Liners are
shipped with the jacket of the liner extended
the proper amount.
Cable Assembly.
unfasten Gas Hose from Fitting and Untighten
Fastener from Autodrive Wire Drive which is holding brass connector end.
and feeder connection. Remove Cable Assembly
from robot.
FIGURE D.1
2. Before sliding Cable Assembly
out of Robot Arm unfasten
Gas Hose from Fitting and
Untighten Fastener from Autodrive
Wire Drive which is holding
brass connector end.
4. Back out Cable Cover
5. Back out Hex Connection
D-1
(See Figure D-2 for instructions 6,7)
6. Lay Cable Assembly out straight on a flat surface.
7. Loosen set screw located in the brass feeder connector using 5/64 (2.0 mm) Allen wrench. Pull liner
out of cable.
FIGURE D.2
Replace Cable Liner
7. Loosen set screw located in the brass feeder connector
using 5/64 (2.0 mm) Allen wrench. Pull liner out of cable.
6. Lay Cable Assembly out straight on a flat surface.
For installation and trimming instructions for Magnum
liners and wire brake jump/liners see Installation
Section.
GUN TUBES AND NOZZLES
(See Figure D-3)
1. Replace worn contact tips as required.
2. Remove spatter from from contact tip, gas dif-
fuser, insulator and gun tube after each 10 minutes of arc time or as required.
3. To remove gun tube from gun, loosen set screw
in nose cone assembly with 3/16" (4.8 mm) Allen
wrench.
4. Pull gun tube out from nose cone assembly. To
reinstall, insert the gun tube, push in as far as
possible, and line up spot face of gun tube
retighten Set Screw.
CABLE CLEANING
Clean cable liner after using approximately 150 (68
kg) pounds of electrode. Remove the cable from the
wire feeder. Remove the contact tip from the gun.
Using an air hose and only partial pressure, gently
blow out the cable liner from the diffuser end.
1. Robot Axis J5 rotated down 90°
To help remove Cable Assembly
CAUTION
• Excessive pressure at the start may cause the
3. LOOSEN HEX HEAD FASTENER
THEN SLIDE CABLE ASSEMBLY
OUT.
Figure D.3
3/16” SET SCREW
NOSE CONE ASSEMBLY
MAGNUM® PRO THRU THE ARM ROBOTIC TORCH
dirt to form a plug.
------------------------------------------------------------------------
Flex the cable over its entire length and again blow
out the cable. Repeat this procedure until no further
dirt comes out.
SPOT FACE
ON GUN TUBE
GUN TUBE
LINER TRIM
LENGTH
5/8" (16.0 mm)
INSULATOR
GAS DIFFUSER
GAS NOZZLE
TIP
Page 23
D-2
MAINTENANCE
TO REPLACE THE WIRE BRAKE COMPONENTS, FOLLOW THESE STEPS:
(See Section B-4 thru B-6 to help follow these steps
also see Figure D.4)
1. Remove plug cover on nose cone. Loosen set
screw and remove gooseneck.
2. Remove plug cover from Housing. Loosen socket
head cap screw. Remove 4 socket head cap
screws from front of Nose Cone Assembly
Disconnect air hose and remove nose cone assembly from torch assembly.
3. Loosen 2 socket head cap screws ITEM 6 and
remove wire brake cap ITEM 5 from nose cone
assembly. Remove spring ITEM 3 from piston
guide ITEM 2 and reserve. Remove piston guide
ITEM 2. Remove wire guide ITEM 1 from within
nose cone assembly.
4. Install new wire guide ITEM 1 by inserting thru front
of nose cone. Align wire access hole with wire
brake access port in nose cone.
FIGURE D.4
1
WIRE ACCESS HOLE
NOSE CONE ASSEMBLY
5
6
3
24
D-2
5. Apply a small amount of thread sealant to threads
on piston guide ITEM 2. Install and tighten piston
guide ITEM 2 thru nose cone access port until
threads are no longer visible and piston guide ITEM
2 is firmly seated. Carefully torque piston guide
ITEM 2 to 14-17 in.-lbs.(1.6-1.9Nm). Do not damage edges of piston guide, as this may cause edge
burrs on the piston guide ITEM 2 and damage Item
5 brake cap cylinder bore. The shaft on piston ITEM
4 can help align the piston guide when threading
into wire guide ITEM 1.
6. Install the air fitting ITEM 7 in the air brake cap
ITEM 5 with 2.5mm hex key to 3.5-4.0 in.-lbs.(.40.46Nm).
7. Apply a liberal amount of silicone lubricant to the oring ITEM 8 on the wire brake piston ITEM 4.
Reinstall the wire brake spring ITEM 3 into the
pocket on the piston guide ITEM 2. Install the air
brake piston ITEM 4 thru the spring ITEM 3.
8. Push the air brake cap ITEM 5 over the piston
ITEM 4 and secure with the 2 socket head cap
screws ITEM 6. Torque screws to 2.5 to 3.5inlbs.(.28-.40Nm)
7
PISTON SHAFT
THREAD SEALANT
HERE
8
WIRE BRAKE
ACCESS HOLE
Reinstall air hose, nose cone assembly in the
reverse order from above.
MAGNUM® PRO THRU THE ARM ROBOTIC TORCH
Page 24
E-1
TROUBLESHOOTING
HOW TO USE TROUBLESHOOTING GUIDE
WARNING
Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician and
machine operator and will invalidate your factory warranty. For your safety and to avoid
Electrical Shock, please observe all safety notes and precautions detailed throughout this
manual.
__________________________________________________________________________
This Troubleshooting Guide is provided to
help you locate and repair possible machine
malfunctions. Simply follow the three-step
procedure listed below.
E-1
Step 1. LOCATE PROBLEM (SYMPTOM).
Look under the column labeled “PROBLEM
(SYMPTOMS)”. This column describes
possible symptoms that the machine may
exhibit. Find the listing that best describes
the symptom that the machine is exhibiting.
Step 2. POSSIBLE CAUSE.
The second column labeled “POSSIBLE
CAUSE” lists the obvious external possibilities that may contribute to the machine
symptom.
Step 3. RECOMMENDED COURSE OF
ACTION
This column provides a course of action for
the Possible Cause, generally it states to
contact you local Lincoln Authorized Field
Service Facility.
If you do not understand or are unable to
perform the Recommended Course of
Action safely, contact you local Lincoln
Authorized Field Service Facility.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
MAGNUM® PRO THRU THE ARM ROBOTIC TORCH
Page 25
E-2
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
TROUBLESHOOTING
POSSIBLE
CAUSE
E-2
RECOMMENDED
COURSE OF ACTION
No wire feed occurs.
Sluggish wire feed.
1. Out of wire.
2. Contact tip burn back.
3. Fully or partially blocked gun liner.
4. Bird nest.
5. No motor voltage or current from
machine
6. Contact tip size too small for wire
diameter used.
1. Drive roll is worn or galled
2. Machineʼs wire feed speed setting is too low.
3. Wire is obstructed somewhere
along the wire feed path in the
gun.
4. Low motor voltage.
5. Gun cable is twisted.
6. Mechanical resistance to wire
feeding is too large
1. Install full spool of specified wire.
2. Replace contact tip.
3. Remove and clean or replace gun
liner.
4. Cut out bird nest, reload wire, and
check for proper wire alignment.
5. See Troubleshooting section in
welding machineʼs or wire feederʼs instruction manual.
6.Replace contact tip with one that
is the correct size.
1. Clean drive roll or replace drive
roll.
2. Increase wire feed speed.
3. Check for obstructions: remove
any wire shavings; remove kinked
wire; remove and clean or
replace gun liner.
4. See Troubleshooting section in
welding machineʼs instruction
manual.
5. Remove cable and reinstall per
installation instructions.
6. Reposition robot so that cable is
less twisted or bent.
Intermittent wire feed.
Frequent birdnesting or kinking of
wire in the gun cable.
Wire Brake not functioning.
1. Drive roll has become galled.
2. Wire has become kinked along its
feed path.
1 Wire shavings/lubricant is building
up in the cable.
2 Cable liner is too large for wire
size.
1. Air not being supplied.
2. Wire brake stuck closed.
1. Remove and then clean or
replace drive roll
2. Manually pull wire slowly thru gun
until unkinked wire emerges
1. Clean cable or replace cable
liner.
2 Install the smallest possible liner
which is specified for the wire
being used (i.e. use a .052-1/16
liner instead of a 1/16-5/64 liner
when welding with 1/16” diameter
wire.
1. Ensure proper air supply.
2. Repair / Replace as needed
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
MAGNUM® PRO THRU THE ARM ROBOTIC TORCH
Page 26
E-3
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
TROUBLESHOOTING
POSSIBLE
CAUSE
E-3
RECOMMENDED
COURSE OF ACTION
Frequent occurrence of contact tip
burnback.
Poor weld bead appearance.
1. Improper welding parameters or
technique (example: ESO “electrical stick out” is too short).
2. Wire may be feeding intermittently.
1. Improper electrode polarity.
2. Improper welding parameters or
technique.
1. See welding wire literature for
proper settings.
2. See symptoms on intermittent or
sluggish wire feed.
1. Reconnect machineʼs welding output to proper electrode polarity.
2. See welding wire literature for
proper settings.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
MAGNUM® PRO THRU THE ARM ROBOTIC TORCH
Page 27
WARNING
Spanish
AVISO DE
PRECAUCION
Do not touch electrically live parts or
electrode with skin or wet clothing.
Insulate yourself from work and
ground.
No toque las partes o los electrodos
bajo carga con la piel o ropa mojada.
Aislese del trabajo y de la tierra.
Keep flammable materials away.
Mantenga el material combustible
fuera del área de trabajo.
Wear eye, ear and body protection.
Protéjase los ojos, los oídos y el
cuerpo.
French
ATTENTION
German
WARNUNG
Portuguese
ATENÇÃO
Japanese
Chinese
Korean
Arabic
Ne laissez ni la peau ni des vête-
ments mouillés entrer en contact
avec des pièces sous tension.
Isolez-vous du travail et de la terre.
Berühren Sie keine stromführenden
Teile oder Elektroden mit Ihrem
Körper oder feuchter Kleidung!
Isolieren Sie sich von den
Elektroden und dem Erdboden!
Não toque partes elétricas e elec-
trodos com a pele ou roupa molhada.
Isole-se da peça e terra.
Gardez à l’écart de tout matériel
inflammable.
Entfernen Sie brennbarres Material!
Mantenha inflamáveis bem guarda-
dos.
Protégez vos yeux, vos oreilles et
votre corps.
Tragen Sie Augen-, Ohren- und Kör-
perschutz!
Use proteção para a vista, ouvido e
corpo.
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 HERSTELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.
Page 28
Keep your head out of fumes.
Use ventilation or exhaust to
remove fumes from breathing zone.
Turn power off before servicing.
Do not operate with panel open or
guards off.
WARNING
Los humos fuera de la zona de res-
piración.
Mantenga la cabeza fuera de los
humos. Utilice ventilación o
aspiración para gases.
Gardez la tête à l’écart des fumées.
Utilisez un ventilateur ou un aspira-
teur pour ôter les fumées des zones
de travail.
Vermeiden Sie das Einatmen von
Schweibrauch!
Sorgen Sie für gute Be- und
Entlüftung des Arbeitsplatzes!
Mantenha seu rosto da fumaça.
Use ventilação e exhaustão para
remover fumo da zona respiratória.
Desconectar el cable de ali-
mentación de poder de la máquina
antes de iniciar cualquier servicio.
Débranchez le courant avant l’entre-
tien.
Strom vor Wartungsarbeiten
abschalten! (Netzstrom völlig öffnen; Maschine anhalten!)
Não opere com as tampas removidas.
Desligue a corrente antes de fazer
serviço.
Não toque as partes elétricas nuas.
No operar con panel abierto o
guardas quitadas.
N’opérez pas avec les panneaux
ouverts ou avec les dispositifs de
protection enlevés.
Anlage nie ohne Schutzgehäuse
oder Innenschutzverkleidung in
Betrieb setzen!
Mantenha-se afastado das partes
moventes.
Não opere com os paineis abertos
ou guardas removidas.
Spanish
AVISO DE
PRECAUCION
French
ATTENTION
German
WARNUNG
Portuguese
ATENÇÃO
Japanese
Chinese
Korean
Arabic
LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS
PRÁTICAS DE SEGURANÇA DO EMPREGADOR.
Page 29
• World's Leader in Welding and Cutting Products •
• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
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