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IM10101
RETURN TO MAIN MENU
MAGNUM®PRO ROBOTIC TORCH
Models
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.
K2646-[ ], K2647-[ ]
K2647-[ ]
K2646-[ ]
October, 2011
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
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
i
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.
Page 3
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
skin or wet clothing. Wear dry, hole-free
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.
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
ventilation and/or exhaust at the arc to keep
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.
vapors
to
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.
5.e. Read and understand the manufacturerʼs instructions for this
equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employerʼs safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
5.f. Also see item 1.b.
Page 4
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 manufacturerʼs
recommendations.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturerʼs 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
iv
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.
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.
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.
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.
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.
4. Des gouttes de laitier en fusion sont émises de lʼarc 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.
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 the 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
TABLE OF CONTENTS
Page
General Description ..................................................................................................... Section A
_______________________________________________________________________________________
Installation .................................................................................................................... Section B
Connecting Mounting Arm to Robot ............................................................................ B-1
Assembly of Cable Liner to Gun ................................................................................. B-1
Connecting Gun to Mounting Arm .............................................................................. B-1
Connecting Cable Assembly to Wire Feeder .............................................................. B-1
Electrodes and Equipment .......................................................................................... B-1
Avoiding Wire Feeding Problems ............................................................................... B-4
_______________________________________________________________________________________
Accessories ................................................................................................................... Section C
Gun Consumable Parts ......................................................................................................... C-1
Air Cooled Consumables ................................................................................................... C-1
Water Cooled Consumables .............................................................................................. C-1
_______________________________________________________________________________________
Maintenance .................................................................................................................. Section D
Removal, Installation and Trimming Instructions for MAGNUM® Liners ........................... D-1
Air Cooled Goose Neck and Nozzles ................................................................................ D-1
Water Cooled Goosenecks ................................................................................................ D-1
Cable Cleaning ........................................................................................................... D-1
_______________________________________________________________________________________
vivi
Troubleshooting ........................................................................................................... Section E
_______________________________________________________________________________________
Parts Lists ............................................................................................................. P-202-AD, -AE
_______________________________________________________________________________________
Page 8
GENERAL DESCRIPTION
A-1A-1
GENERAL DESCRIPTION
PRODUCT SUMMARY
The Magnum Pro Robotic GMA gun and cable assemblies have been designed to meet IEC 60974-7 specification for welding with steel electrode using the
GMAW (gas metal arc welding) and the gas-shielded
FCAW (flux-cored arc welding) processes. The
Magnum Pro product line is designed for heavy duty
applications possessing market leading ratings and
simplicity in maintenance.
The Robomag is rated for 550 amps at 100% duty
cycle with 100% CO2shielding gas. It is rated at 375
amps at 100% duty cycle with mixed gas.
RECOMMENDED PROCESSES AND
EQUIPMENT
RECOMMENDED PROCESSES
• GMAW, GMAW-P, GMAW-STT, FCAW, FCAW-SS
TABLE A.1
Magnum Pro Robotic Torch Mounting Kits
Product Number
KP2769-22
KP2769-45
KP2769-180
KP3054-22
KP3055-22
S22645-301
Air-Cooled Replacement Equipment
Product Number
KP3056-22
KP3056-45
KP3056-180
KP3057-22
Description
22° Mounting Kit (Lincoln TCP)
45° Mounting Kit (Lincoln TCP)
180° Mounting Kit (Lincoln TCP)
22° Mounting Kit (Tregaskiss TCP,
Fanuc Solid Mount)
22° Mounting Kit (Tregaskiss TCP,
Tregaskiss Clutch Mount
Mounting Adapter
TABLE A.2
Description
22° AC Gooseneck (Lincoln TCP)
45° AC Gooseneck (Lincoln TCP)
180° AC Gooseneck (Lincoln TCP)
22° AC Gooseneck (Tregaskiss TCP)
TABLE A.3
PROCESS LIMITATIONS
• This product is not recommended for submerged arc
welding.
EQUIPMENT LIMITATIONS
• Wire Size:
• Water -cooled robotic torches are designed for up to
1/16” wire
• Air-cooled robotic torches are designed for up to
5/64” wire
• Wire Feeders:
• The water-cooled robotic torch is designed for a
Lincoln or Tweco #5 power pin only.
• The air-cooled robotic torch can use any of the standard power pins.
COMMON EQUIPMENT PACKAGES
The external dress robotic torch is currently available
in two models. K2646 (water-cooled) and K2647 (aircooled). Both series are designed to be used for external dress robotic applications. They can also be
applied to hard automation systems with the end user
being responsible for mounting.
Water-Cooled Replacement Equipment
Product Number
KP2766-22
KP2766-180
KP2767-4
KP2767-4L
KP2767-5L
KP2767-8
KP2767-11
KP2768-116
KP3058-1
Description
22° W/C Gooseneck (Lincoln TCP)
180° W/C Gooseneck (Lincoln TCP)
Power Cable & Liner Assemblies,
Robotic W/C, 4ʼ
Power Cable & Liner Assemblies,
Robotic W/C, 4.5ʼ
Power Cable & Liner Assemblies,
Robotic W/C, 5.5ʼ
Power Cable & Liner Assemblies,
Robotic W/C, 8ʼ
Power Cable & Liner Assemblies,
Robotic W/C, 11ʼ
Robotic W/C Cable Liner, Up to
1/16”
Nozzle Clamp
The available replacement parts for the Magnum Pro
robotic torches are shown in Table A.1, A.2 and A.3.
MAGNUM® PRO ROBOTIC TORCH
Page 9
Description
Product
Number
GENERAL DESCRIPTION
MAGNUM PRO AIR-COOLED ROBOTIC TORCH
550 amperes AT 100% DUTY CYCLE WITH CO2 GAS
375 amperes AT 100% DUTY CYCLE WITH MIXED GAS
Gun
Cable
Length
(m)
Wire
Size
in. (mm)
Robotic
Contact
Tips
Gas
Diffuser
Assembly
Gas
Nozzle
Insulator
Cable
Liner
A-2A-2
Gun Tube
22
K2647-4
K2647-5L
K2647-8
K2647-11
Description
Product
Number
K2646-4
4 ft.
(1.3)
5.5 ft.
(1.7)
8 ft.
(2.6)
11 f t.
(3.4)
.035 (0.9)
.045 (1.2)
.052 (1.3)
1/16 (1.6)
5/64 (2.0)
KP2745-035R
KP2745-045R
KP2745-052R
KP2745-116R
KP2745-564R
KP2747-1
KP2743-1-62R
KP2773-1
MAGNUM PRO WATER-COOLED ROBOTIC TORCH
550 amperes AT 100% DUTY CYCLE WITH CO2 GAS
375 amperes AT 100% DUTY CYCLE WITH MIXED GAS
Gun
Cable
Length
(m)
4 ft.
(1.3)
Wire
Size
in. (mm)
Robotic
Contact
Tips
Tip Holder
Diffuser
Cap
Gas Nozzle
KP44-564-15
Nozzle Clamp
KP1950-1
KP1950-1
KP1950-3
KP1950-3
Cable
Liner
KP3056-22
Gun Tube
Assembly
K2646-4L
K2646-5L
K2646-8
K2646-11
4.5 ft.
(1.4)
5.5 ft.
(1.7)
8 ft.
(2.6)
11 f t.
(3.4)
.035 (0.9)
.045 (1.2)
.052 (1.3)
1/16 (1.6)
KP2764-035
KP2764-045
KP2764-052
KP2764-116
KP2765-1
KP3049-1
KP3050-2-62R
MAGNUM® PRO ROBOTIC TORCH
KP3058-1
KP2768-116
KP2766-22
Page 10
A-3
GENERAL DESCRIPTION
SPECIFICATIONS: K2646-[ ], K2647-[ ]
A/C Magnum Pro Robotic Torch - Rated Output IEC 60974-7
Duty Cycle
Amperes – Mixed Gas
Amperes – CO
A-3
2
40%
60%
80%
100%
W/C Magnum Pro Robotic Torch - Rated Output IEC 60974-7
Duty Cycle
40%
60%
80%
100%
Process
GMAW-Pulsed
GMAW-STT
FCAW- Gas
Shielded
Model
575
460
400
375
Amperes – Mixed Gas
575
460
400
375
Welding Processes
Electrode Diameter Range
.035” – 1/16"
(0.8 – 1.6 mm)
.035” – 1/16"
(0.8 – 1.6 mm)
.035” – 1/16"
(0.8 – 1.6 mm)
Physical Dimensions – Air-Cooled
Output Range (Amperes)
375A @ 100%
460A @ 60%
375A @ 100%
460A @ 60%
375A @ 100%
460A @ 60%
Cable Length
845
700
610
550
Amperes – CO
845
700
610
550
Wire Feed Speed Range
(See wire feeder
Instruction Manual)
2
Weight
K2647-4
K2647-5L
K2647-8
K2647-11
Model
K2646-4
K2646-4L
K2646-5L
K2646-8
K2646-11
Operating Temperature
Storage Temperature
4 ft (1.3m)
5.5 ft (1.7m)
8 ft (2.6m)
11 ft (3.4m)
Physical Dimensions – Water-Cooled
Cable Length
4 ft (1.3m)
4.5 ft (1.4m)
5.5 ft (1.7m)
8 ft (2.6m)
11 ft (3.4m)
Temperature Ranges
-4°F to 104°F (-20°C to 40°C)
-40°F to 185°F (-40°C to 85°C)
MAGNUM® PRO ROBOTIC TORCH
7 lbs (3.2 kg)
7.75 lbs (3.5 kg)
9 lbs (4.1 kg)
10.5 lbs (4.8 kg)
Weight
6 lbs (2.7 kg)
6.25 lbs (2.8 kg)
6.75 lbs (3.1 kg)
8 lbs (3.6 kg)
9.5 lbs (4.3 kg)
Page 11
INSTALLATION
Y
B-1B-1
Read this entire installation section before you
start installation.
SAFETY PRECAUTIONS
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.
------------------------------------------------------------------------
Only qualified personnel should install, use or
service this equipment
CONNECTING MOUNTING ARM TO
ROBOT
Make sure that the robot is in its Zero position.
Assemble mounting arm adapter to J6 of robot arm
using 4 M4x0.7 SHCS. Assemble mounting arm
assembly to adapter using 4 M6x1.0 SHCS. Make sure
the hex bracket on the mounting arm is oriented down.
(See Figure D.1)
FIGURE D.1
J6 ROBOT ARM
Gas Tube Kit is available to provide tool-less gas tube
connection to Lincoln wire feeders. Install per the
instructions sent with the kit.
(4) M4x0.7 SHCS
MOUNTING ARM ASSEMBL
(4) M6x1.0 SHCS
MOUNTING ARM ADAPTER
CONNECTING GUN TO MOUNTING ARM
Insert front of gun thru rear of mounting arm hex,
ensuring that gun is oriented with gooseneck down.
Push gun forward until gun handle bottoms out on hex.
Thru holes for set screw should be aligned. Secure
with 2 attached SHCS. (See Figure D.2)
FIGURE D.2
Gun handle bottoms
out on hex bracket of
arm adapter in this area.
CONNECTING CABLE ASSEMBLY TO
WIRE FEEDER
Ensure that the appropriate bushing is installed on the
wire feeder to match the connector on the gun. Insert
feeder connector into wire feeder bushing and secure.
Ensure that cable is not twisted when installed.
Connect gas hose to gas fitting. (If Applicable)
ELECTRODES AND EQUIPMENT
The Magnum Pro 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.
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.
ASSEMBLY OF CABLE LINER TO GUN
(FOR GUNS WITHOUT PREINSTALLED
LINERS)
Lay gun flat and insert liner into back end of gun. Feed
liner forward until liner bushing bottoms out and secure
with set screw. For air-cooled torches, trim liner 5/8”
from end of gooseneck. For water-cooled torches, trim
liner flush to gooseneck, then remove liner and trim an
additional 1” off of the liner. Insert back into gun and
secure. Attach desired consumables to gooseneck.
MAGNUM® PRO ROBOTIC TORCH
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.
Page 12
C-1
ACCESSORIES
C-1
GUN CONSUMABLE PARTS
Air-Cooled Consumables
1. Liner Assembly
Wire Diameter
0.035
0.045
0.052
1/16
2. Gun Tubes
KP Number
KP3056-22
KP3056-45
KP3056-180
KP3057-22
Bend Angle
22.5°
45°
180°
22.5°
Liner KP No.
KP45-3545-15
KP45-3545-15
KP45-116-15
KP45-116-15
Notes
Lincoln® TCP
Lincoln® TCP
Lincoln® TCP
Tregaskiss®-style TCP
3. Contact Tips
Wire
Diameter
KP3056-22
KP3056-45
KP3056-180
KP3057-22
4. Diffusers
Style
Slip-on
Thread-on
5. Insulator
10-piece pack
KP2745-035R
KP2745-045R
KP2745-052R
KP2745-116R
1-piece pack
KP2747-1
KP2747-2
KP Numbers
1-piece pack
KP2747-1
KP Numbers
100-piece pack
KP2745-035R-B100
KP2745-045R-B100
KP2745-052R-B100
KP2745-116R-B100
KP Numbers
25-piece pack
KP2747-1-B25
KP2747-2-B25
25-piece pack
KP2773-1-B25
Style
Thread-On
Thread-On
Thread-On
Thread-On
Thread-On
Thread-On
Thread-On
Thread-On
Thread-On
Slip-On
Slip-On
Slip-On
Slip-On
Slip-On
Slip-On
Slip-On
Slip-On
Slip-On
Stickout
1/8” Recessed
1/8” Recessed
1/8” Recessed
Flush
Flush
Flush
1/8” Stickout
1/8” Stickout
1/8” Stickout
1/8” Recessed
1/8” Recessed
1/8” Recessed
Flush
Flush
Flush
1/8” Stickout
1/8” Stickout
1/8” Stickout
6. Nozzles
ID
1/2”
3/4”
5/8”
1/2”
3/4”
5/8”
1/2”
3/4”
5/8”
1/2”
3/4”
5/8”
1/2”
3/4”
5/8”
1/2”
3/4”
5/8”
KP Numbers
1-piece pack
KP2743-1-50R
KP2743-1-75R
KP2743-1-62R
KP2743-1-50F
KP2743-1-75F
KP2743-1-62F
KP2743-1-50S
KP2743-1-75S
KP2743-1-62S
KP2743-2-50R
KP2743-2-75R
KP2743-2-62R
KP2743-2-50F
KP2743-2-75F
KP2743-2-62F
KP2743-2-50S
KP2743-2-75S
KP2743-2-62S
25-piece pack
KP2743-1-50R-B25
KP2743-1-75R-B25
KP2743-1-62R-B25
KP2743-1-50F-B25
KP2743-1-75F-B25
KP2743-1-62F-B25
KP2743-1-50S-B25
KP2743-1-75S-B25
KP2743-1-62S-B25
KP2743-2-50R-B25
KP2743-2-75R-B25
KP2743-2-62R-B25
KP2743-2-50F-B25
KP2743-2-75F-B25
KP2743-2-62F-B25
KP2743-2-50S-B25
KP2743-2-75S-B25
KP2743-2-62S-B25
MAGNUM® PRO ROBOTIC TORCH
Page 13
C-2
Water-Cooled Consumables
1. Liner Assembly
ACCESSORIES
C-2
Wire Diameter
Up to 1/16”
2. Gun Tubes
KP Number
KP2766-22
3. Contact Tips
Wire
Diameter
0.035
0.045
0.052
1/16
4. Tip Holder
Wire
Diameter
Up to 1/16
Bend Angle
22.5°
10-piece pack
KP2764-035
KP2764-045
KP2764-052
KP2764-116
5-piece pack
KP2765-1
Liner KP No.
KP2768-116
Notes
Lincoln® TCP
KP Numbers
100-piece pack
KP2764-035-B100
KP2764-045-B100
KP2764-052-B100
KP2764-116-B100
KP Numbers
25-piece pack
KP2765-1-B25
5. Diffuser Cap
Style
Standard
6. Nozzles
Slip-On
Slip-On
Slip-On
7. Nozzle Clamp
KP Number
KP3058-1
5-piece pack
Style
KP3049-1
KP Numbers
25-piece pack
KP3049-1-B25
Stickout
1/8” Recessed
1/8” Recessed
1/8” Recessed
MAGNUM® PRO ROBOTIC TORCH
ID
5/8”
18mm
3/4”
KP Numbers
1-piece pack
KP3050-2-62R
KP3050-2-72R
KP3050-2-75R
25-piece pack
KP3050-2-62R-B25
KP3050-2-72R-B25
KP3050-2-75R-B25
Page 14
MAINTENANCE
D-1D-1
REMOVAL, INSTALLATION AND TRIMMING
®
INSTRUCTIONS FOR MAGNUM
NOTE: The variation in cable lengths prevents the
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 with the proper amount.
1. Loosen the hex bracket fasteners and the feeder
connection. Remove cable from robot.
2. Lay gun and cable out straight on a flat surface.
3. Loosen set screw located in the brass feeder connector using 5/64 (2.0 mm) Allen wrench. Pull liner
out of cable.
4 For installation and trimming instructions for
Magnum liners see INSTALLATION section.
LINERS
AIR COOLED Goosenecks and Nozzles
1. Replace worn contact tips as required.
2. Remove spatter from contact tip, diffuser, nozzle,
insulator and gun tube after each 10 minutes of arc
time or as required.
5. Remove SHCS holding gooseneck assembly to
power cable clamp and unplug power cable and
liner assemblies from gooseneck.
6. Install new gooseneck assembly, reattach cable
assemblies and clamp with SHCS. Assemble handle halves, snap handle end cap onto handle, and
tighten hose clamp. Attach gun to robot and
secure. Attach expendables.
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.
CAUTION
Excessive pressure at the start may cause the 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.
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 handle assembly. To reinstall, insert the gun tube, push in as far as possible,
and retighten set screw.
WATER COOLED Goosenecks and
Nozzles
1. Replace worn contact tips as required.
2. Remove spatter from contact tip, tip holder, insula-
tor, nozzle and gun tube after each 10 minutes of arc
time or as required.
3. Loosen the hex bracket fasteners and the feeder
connection. Remove cable from robot and lay gun
and cable out straight on a flat surface.
4. Remove nozzle, contact tip, and tip holder.
Remove hose clamp and handle end cap and open
handle halves.
MAGNUM® PRO ROBOTIC TORCH
Page 15
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.
__________________________________________________________________________
E-1E-1
This Troubleshooting Guide is provided to help you
locate and repair possible machine malfunctions.
Simply follow the three-step procedure listed below.
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 your
local Lincoln Authorized Field Service Facility.
If you do not understand or are unable to perform the
Recommended Course of Action safely, contact your
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 ROBOTIC TORCH
Page 16
E-2
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
E-2
PROBLEMS
(SYMPTOMS)
No wire feed occurs.
Sluggish wire feed.
POSSIBLE CAUSE REMEDY
PROBLEMS
1. Out of wire.
2. Contact tip burnback.
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.
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.
Intermittent wire feed.
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. Drive roll has become galled.
2. Wire has become kinked along its
feed path.Wire shavings/lubricant
is building up in the cable.
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.
1. Remove and then clean or replace
drive roll.
2. Manually pull wire slowly thru gun
until unkinked wire emerges.Clean
cable or replace cable liner.
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 ROBOTIC TORCH
Page 17
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
E-3E-3
PROBLEMS
(SYMPTOMS)
Frequent birdnesting or kinking of
wire in the gun cable.
Frequent occurrence of contact tip
burnback.
POSSIBLE CAUSE REMEDY
PROBLEMS
1. Wire shavings/lubricant is building
up in the cable.
2. Cable liner is too large for wire
size.
3. Mechanical resistance to wire
feeding is too large.
1. Improper welding parameters or
technique (example: ESO
[Electrode Stick Out] is too short).
2. Wire may be feeding intermittently.
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.
3. Reposition robot so that cable is
less twisted or bent.
1. See welding wire literature for
proper settings.
2. See symptoms on intermittent or
sluggish wire feed.
Poor weld bead appearance.
Gun Overheating.
1. Improper electrode polarity.
2. Improper welding parameters or
technique.
1. Gun maybe beyond recommended amperage.
2. Water may not be flowing properly.
1. Reconnect machineʼs welding output to proper electrode polarity.
2. See welding wire literature for
proper settings.
1. See duty cycle chart for recommended amperage.
2. Check that water cooler is turned
on, check water lines for leaks.
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 ROBOTIC TORCH
Page 18
NOTES
MAGNUM® PRO ROBOTIC TORCH
Page 19
NOTES
MAGNUM® PRO ROBOTIC TORCH
Page 20
WARNING
Spanish
AVISO DE
PRECAUCION
G Do not touch electrically live parts or
electrode with skin or wet clothing.
G Insulate yourself from work and
ground.
G No toque las partes o los electrodos
bajo carga con la piel o ropa mojada.
G Aislese del trabajo y de la tierra.
G Keep flammable materials away.
G Mantenga el material combustible
fuera del área de trabajo.
G Wear eye, ear and body protection.
G Protéjase los ojos, los oídos y el
cuerpo.
French
ATTENTION
German
WARNUNG
Portuguese
ATENÇÃO
Japanese
Chinese
Korean
Arabic
G Ne laissez ni la peau ni des vête-
ments mouillés entrer en contact
avec des pièces sous tension.
G Isolez-vous du travail et de la terre.
G Berühren Sie keine stromführenden
Teile oder Elektroden mit Ihrem
Körper oder feuchter Kleidung!
G Isolieren Sie sich von den
Elektroden und dem Erdboden!
G Não toque partes elétricas e elec-
trodos com a pele ou roupa molhada.
G Isole-se da peça e terra.
G Gardez à l’écart de tout matériel
inflammable.
G Entfernen Sie brennbarres Material!
G Mantenha inflamáveis bem guarda-
dos.
G Protégez vos yeux, vos oreilles et
votre corps.
G Tragen Sie Augen-, Ohren- und Kör-
perschutz!
G 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 21
G Keep your head out of fumes.
G Use ventilation or exhaust to
remove fumes from breathing zone.
G Turn power off before servicing.
G Do not operate with panel open or
guards off.
WARNING
G Los humos fuera de la zona de res-
piración.
G Mantenga la cabeza fuera de los
humos. Utilice ventilación o
aspiración para gases.
G Gardez la tête à l’écart des fumées.
G Utilisez un ventilateur ou un aspira-
teur pour ôter les fumées des zones
de travail.
G Vermeiden Sie das Einatmen von
Schweibrauch!
G Sorgen Sie für gute Be- und
Entlüftung des Arbeitsplatzes!
G Mantenha seu rosto da fumaça.
G Use ventilação e exhaustão para
remover fumo da zona respiratória.
G Desconectar el cable de ali-
mentación de poder de la máquina
antes de iniciar cualquier servicio.
G Débranchez le courant avant l’entre-
tien.
G Strom vor Wartungsarbeiten
abschalten! (Netzstrom völlig öffnen; Maschine anhalten!)
G Não opere com as tampas removidas.
G Desligue a corrente antes de fazer
serviço.
G Não toque as partes elétricas nuas.
G No operar con panel abierto o
guardas quitadas.
G N’opérez pas avec les panneaux
ouverts ou avec les dispositifs de
protection enlevés.
G Anlage nie ohne Schutzgehäuse
oder Innenschutzverkleidung in
Betrieb setzen!
G Mantenha-se afastado das partes
moventes.
G 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 22
• 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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