Tweco Lightweight Quick Robotic Torch User Manual

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QUICK ROBOTICS

TORCH

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Installation Guide and

Replacement Parts Manual

Version No: AA:01 Issue Date: June 30, 2006 Manual No: SM-QRLTORCH (06/06)

WE APPRECIATE YOUR BUSINESS!

Congratulations on your new Tweco® Robotics product. We are proud
to have you as our customer and will strive to provide you with the
best service and reliability in the industry. This product is backed by
our extensive warranty and world-wide service network. To locate your
nearest distributor or service agency call 800-426-1888, or visit us on
the web at www.tweco.com.

This Operating Manual has been designed to instruct you on the
correct use and operation of your Tweco® Robotics product. Your
satisfaction with this product and its safe operation is our ultimate
concern. Therefore, please take the time to read the entire manual,
especially the Safety Precautions. They will help you to avoid
potential hazards that may exist when working with this product.

YOU ARE IN GOOD COMPANY!

The Brand of Choice for Contractors and Fabricators Worldwide.

Tweco® Robotics is a Global Brand of Arc Welding Products for
Thermadyne Industries Inc. We manufacture and supply to major
welding industry sectors worldwide including; Manufacturing,
Construction, Mining, Automotive, Aerospace, Engineering, Rural and
DIY/Hobbyist.

We distinguish ourselves from our competition through market-leading,
dependable products that have stood the test of time. We pride ourselves
on technical innovation, competitive prices, excellent delivery, superior
customer service and technical support, together with excellence in
sales and marketing expertise.

Above all, we are committed to develop technologically advanced
products to achieve a safer working environment within the welding
industry.

!

WARNING

Read and understand this entire Manual and your employer’s safety practices before installing, operating, or
servicing the equipment.

While the information contained in this Manual represents the Manufacturer’s best judgment, the Manufacturer
assumes no liability for its use.

Light Weight Quick Robotics Torch
Installation Guide and Replacement Parts Manual
Instruction Manual Number SM-QRLTORCH

Published by:
Tweco® Products Inc.
2800 Airport Road
Denton, TX 76208
[phone]

www.tweco.com

Copyright © 2006 by
Thermadyne Industries Inc.

® All rights reserved.

Reproduction of this work, in whole or in part, without written permission of the publisher is prohibited.

The publisher does not assume and hereby disclaims any liability to any party for any loss or damage caused by any error or
omission in this Manual, whether such error results from negligence, accident, or any other cause.

Publication Date: June 30, 2006

Record the following information for Warranty purposes:

Where Purchased: ________________________

Purchase Date: ________________________

Equipment Serial #: ________________________

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Quick ROBOtics light weight tORch

Table of Contents

SECTION 1:

SAFETY INSTRUCTIONS AND WARNINGS .................................................. 1-1

1.01 Welding Hazards .......................................................................................

1.02 Principal Safety Standards ........................................................................

1.03 Safety and Health ......................................................................................

SECTION 2:

INTRODUCTION AND DESCRIPTION ......................................................... 2-4

2.01 How to Use this Manual ............................................................................2-4

2.02 Receipt of Equipment ................................................................................2-4

2.03 Introduction ..............................................................................................

2.04 Standard Features .....................................................................................

SECTION 3:

Installation and Disassembly ................................................................. 3-6

3.01 Installation ...............................................................................................3-6

3.02 Disassembly .............................................................................................3-8

SECTION 4:

WIRING ........................................................................................... 4-9

SECTION 5:

MAINTENANCE .................................................................................5-10

1-1
1-3
1-3

2-4
2-4

SECTION 6:

TROUBLESHOOTING ..........................................................................6-11

SECTION 7:

QRL REPLACEMENT PARTS .................................................................. 7-12

SECTION 8:

CONDUIT LINERS .............................................................................. 8-14

SECTION 9:

FACTORY REPAIR CENTER ...................................................................9-15

LIMITED WARRANTY ................................................................................9-16

GLOBAL CUSTOMER SERVICE CONTACT INFORMATION ....................................... 9-17

SM-QRLTORCH

ii

Quick ROBOtics light weight tORch

!

SECTION 1:

SAFETY INSTRUCTIONS AND WARNINGS

WARNING

SERIOUS INJURY OR DEATH may result if welding and cutting equipment is not properly installed, used and maintained.
Misuse of this equipment and other unsafe practices can be hazardous. The operator, supervisor and helper must
read and understand the following safety warnings and instructions before installing or using any welding or cutting
equipment.

The welding and cutting process is used in many potentially dangerous environments such as elevated heights, areas
of limited ventilation, close quarters, around water, in hostile environments, etc., and it is important that the operator(s)
are aware of the dangers associated with working in these types of conditions. Be certain that the operator(s) are
trained in safe practices for environments in which they are expected to work and under competent supervision.

It is essential that the operator, supervisor and all other personnel in the work area are aware of the dangers of the
welding or cutting process. Training and proper supervision are important for a safe work place. Keep these instructions
for future use. Additional recommended safety and operating information is referenced in each section.

1.01 Welding Hazards

WARNING

EL ECTRIC SHOCK CAN CAUSE INJURY OR
DEATH.

INSTALL AND MAINTAIN EQUIPMENT IN ACCORDANCE
WITH THE NATIONAL ELECTRICAL CODE (NFPA 70)
AND LOCAL CODES. DO NOT SERVICE OR REPAIR
EQUIPMENT WITH POWER ON. DO NOT OPERATE
EQUIPMENT WITH PROTECTIVE INSULATORS
OR COVERS REMOVED. SERVICE OR REPAIR TO
EQUIPMENT MUST BE DONE BY A QUALIFIED REPAIR
TECHNICIAN, OR TRAINED PERSONNEL ONLY.

1. Do not touch live electrical parts.

2. Do not touch an electrode with bare skin and electrical
ground at the same time.

3. Always keep welding gloves dry and in good condition.

NOTE

5. All ground connections must be checked periodically
to determine that they are mechanically strong and
electrically adequate for the required current.

6. When engaged in alternating current, welding, or cutting
under wet conditions or warm surroundings where
perspiration is a factor, the use of reliable automatic
controls for reducing the no-load voltage is recommended
to reduce shock hazard.

7. When the welding or cutting process requires values of
open circuit voltages in alternating current machines
higher than 80 volts, and direct current machines higher
than 100 volts, means must be provided to prevent the
operator from making accidental contact with the high
voltage by adequate insulation or other means.

8. When welding is to be suspended for any substantial
length of time, such as during lunch or overnight, all
electrodes should be removed from the electrode
holder and the electrode holder carefully located so that
accidental contact cannot occur.

9. The holder must be disconnected from the power source
when not in use.

10. Never immerse Mig-Guns, electrode holders, tig torches,
plasma torches, or electrodes in water.

WARNING

Aluminized protective clothing can become part
of the electrical path.

4. Keep oxygen cylinders, chains, wire ropes, cranes, hoists,
and elevators away from any part of the electrical path.

SM-QRLTORCH

1-1

SMOKE, FUMES AND GASES CAN BE DANGEROUS
TO YOUR HEALTH.

SAFETY INSTRUCTIONS AND WARNINGS

Quick ROBOtics light weight tORch

11. Keep smoke, fumes, and gases from the breathing area.

12. Fumes from the welding or cutting process are of various
types and strengths, depending on the kind of base metal
being worked on. To ensure your safety, do not breathe these
fumes.

13. Ventilation must be adequate to remove smoke, fumes, and
gases during the operation to protect operators and other
personnel in the area.

14. Vapors of chlorinated solvents can form the toxic gas
“Phosgene” when exposed to ultraviolet radiation from an
electric arc. All solvents, degreasers, and potential sources
of these vapors must be removed from the work area.

15. Fumes produced by welding or cutting, particularly in confined
places, can cause discomfort and physical harm if inhaled over
an extended period of time.

16. Provide adequate ventilation in the welding or cutting area.
Use air-supplied respirators if ventilation is not adequate to
remove all fumes and gases. Never ventilate with oxygen.
Oxygen supports and vigorously accelerates fire.

WARNING

ARC RAYS, HOT SLAG AND SPARKS CAN INJURE
EYES AND BURN SKIN .

17. The welding and cutting processes produce extreme localized
heat, and strong ultraviolet rays.

18. Never attempt to weld or cut without a welding helmet with
the proper lens. Ensure that the lens complies with federal
guidelines. A number 12 to 14 shade filter lens provides the
best protection against arc radiation. When in a confined
area, prevent the reflected arc rays from entering around the
helmet.

19. Ensure all personnel in the work area are protected from arc
rays and sparks. Approved shielding curtains and appropriate
goggles should be used to provide protection to staff in the
surrounding area and operators of nearby equipment.

20. Unprotected skin should also be covered from arc rays, heat
and molten metal. Always wear protective gloves and clothing
that does not allow skin to become exposed. All pockets
should be closed and cuffs sewn shut. Leather aprons, sleeves,
leggings, etc., should be worn for out-of-position welding and
cutting or for heavy operations using large electrodes. High top
work shoes provide adequate protection from foot burns.
For added protection use leather spats.

21. Flammable hair preparations should not be used when
welding or cutting. Wear ear plugs to protect ears from
sparks.

22. Where the work area permits, the operator should be
enclosed in an individual booth painted with a finish of
low reflectivity such as zinc oxide. This is an important
factor for absorbing ultraviolet radiations, and lamp black.
The operator should be enclosed with non-combustible
screens similarly painted.

WARNING

WELDING SPARKS CAN CAUSE FIRES AND
EXPLOSIONS.

23. Causes of fire and explosion are: combustibles reached by
the arc, flame, flying sparks, hot slag, or heated material.
Remove combustibles from the work area and/or provide
a fire watch.

24

. Avoid oily or greasy clothing as sparks may ignite them. Have

a fire extinguisher nearby, and know how to use it.

25.

Be alert to the danger of conduction or radiation. For
example, if welding or cutting is to be done on a metal
wall, partition, ceiling, or roof, precautions must be taken
to prevent ignition of combustibles on the other side.

26. Do not w
All hollow spaces, cavities and containers should be
vented prior to welding or cutting to permit the escape
of air or gases. Purging with inert gas is recommended.

Never use oxygen in a welding torch. Use only inert

27.
gases or inert gas mixes as required by the process. Use
of combustible compressed gases can cause explosions
resulting in personal injury or death. Arcing against any
compressed gas cylinder can cause cylinder damage or
explosion.

28. Noise from the air carbon-arc process can damage your
hearing. Wear protective hearing devices to ensure protection
when noise levels exceed OSHA standards. Adequate
hearing protection devices must be worn by operators and
surrounding personnel to ensure personal protection against
noise.

eld or cut containers that have held combustibles.

WARNING

NOISE CAN DAMAGE HEARING.

SM-QRLTORCH

SAFETY INSTRUCTIONS AND WARNINGS

1-2

!

1.02 Principal Safety Standards

1.03 Safety and Health

NOTICE

Quick ROBOtics light weight tORch

Be sure to read and fully comprehend the safety
instuctions and warnings contained within section
1 of this manual before performing any welding
or cutting operations.

Serious injury or death may result if welding and
cutting equipment is not properly installed, used
and maintained. Misuse of this equipment, or other
unsafe practices, can be hazardous.

Electric shock can cause injury or death.

•
Smoke, fumes, and gases can be dangerous to your

•
health.
Arc rays, hot slag, and sparks can injure or burn

•
unprotected eyes and skin.
Welding sparks can cause fires and explosions.

•
Excessive noise can damage your hearing.

•

WARNING

SM-QRLTORCH

1-3

SAFETY INSTRUCTIONS AND WARNINGS