50
60
Hz
1
PHASE
GTAW
SMAW
INVERTER
CC
DC
115V230
V
LIGHT WEIGHT
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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
(940) 566-2000
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 #: ________________________
i
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
Quick ROBOtics light weight tORch
!
SECTION 2:
INTRODUCTION AND DESCRIPTION
2.01 How to Use this Manual
To ensure safe operation, read the entire manual, including
the chapters on safety instructions and warnings.
Throughout this manual, the words WARNING, CAUTION, and
NOTE may appear. Pay particular attention to the information
provided under these headings. These special annotations
are easily recognized as follows:
A WARNING GIVES INFORMATION REGARDING
POSSIBLE PERSONAL INJURY.
A CAUTION refers to possibl e equipment
damage.
A NOTE offers helpful information concerning
certain operating procedures.
WARNING
CAUTION
NOTE
2.03 Introduction
The new Tweco® Robotics Quick Robotic Light Weight Torch
(QRL) offers the ideal torch for “Table Top” robots. It is designed
for everyday applications that require a lighter weight and
smaller profile for robotic welding torch functions.
This factor is made possible due to the combination of a notable
reduction in the overall weight and size of the torch without
any affect on its superior reliability and repeatability.
The Quick Robotic Light Weight Torch gives the consumer the
same quality that is expected from all Tweco® Robotics QRA
series torches, with close to half the weight and a significant
reduction in size.
2.04 Standard Features
Quick conductor tube lock for easy conductor tube
•
replacement.
40% lighter than the QRA series torch.
•
Lighter weight reduces the inertial effects on the torch
•
head and whipping action on the power cable giving
the torch more accuracy at arc initiation.
Smaller physical profile allows greater access to
•
confined spaces.
Uses proven components of the QRA series.
•
Uses existing conductor tubes and consumables.
•
Compatible with existing mount arms.
•
OPTIONAL - Light Weight mount arm designed for the
•
Quick Robotic Light Weight Torch. Refer to Table 1.
2.02 Receipt of Equipment
When you receive the equipment, check it against the invoice
to make sure it is complete and inspect the equipment for
possible damage due to shipping. If there is any damage,
notify the carrier immediately to file a claim. Furnish complete
information concerning damage claims or shipping errors to
the location in your area listed in the inside back cover of this
manual. Include a full description of the parts in error.
If you want additional or replacement copies of this CD,
please contact Tweco® Robotics at the address and phone
number in your area listed on the inside back cover of this
manual. Include the Manual number (from page i) and CD
part number: 64-2601.
SM-QRLTORCH
INTRODUCTION AND DESCRIPTION
2-4
Quick ROBOtics light weight tORch
Table 1: Light Weight Mount Arms
Part No. Stock No. Description
RDML - A -180 3500-1460 180° RDM Light Weight Mount Arm
RDML - A -180L 3500-1461 180° (Long) RDM Light Weight Mount Arm
RDML - A - 22 3500-1462 22° RDM Light Weight Mount Arm
RDML - A - 22L 3500-1463 22° (Long) RDM Light Weight Mount Arm
QRL Air-cooled Torch Assembly
The air-cooled QRL torch assembly uses the QTR 66 series air-cooled conductor tubes. The air-cooled power cable is rated
for 400 amperes with a 60% duty cycle.
• Sold Separately - RDML-2000-JC E-Stop Jumper Cable.
This cable enables the connection of the QRL Torch to the
RDM 2000 series “Tweco® Robotics Deflection Mount”.
Figure 1: QRL Series “Air-cooled” Assembly
(Stock No. 3044-1860)
SM-QRLTORCH
2-5
INTRODUCTION AND DESCRIPTION
Quick ROBOtics light weight tORch
COVER TO CONCEAL
LOCKING SCREW
WHEN CONDUCTOR TUBE IS FULLY SEATED,
GROOVE ON TUBE SHOULD LINE UP
WITH EDGE OF INSULATING
SLEEVE
SECTION 3:
INSTALLATION AND DISASSEMBLY
3.01 Installation
1. Remove the torch and cable assembly from the carton,
and lay the assembly in a straight and untwisted position
on a workbench or floor.
2. Check to ensure all items, shown in Figure 1 are located
and identified. If any of the component parts are missing,
please notify the local Tweco® Welding Distributor or
Tweco® Products Customer Care Department at 1-800426-1888.
3. Verify that the overall cable length is correct to fit between
the feeder - torch mount combination.
4. Lift rubber cover to expose the conducter tube locking screw
located in the torch block assembly. Insert the factory supplied
5/32” T-handle allen wrench into the locking screw and rotate
counterclockwise until it stops.
5. Insert the conductor tube assembly into the torch block
assembly. The conductor tube is positively located into
the torch body by the use of two stainless steel alignment
pins.
6. Push the conductor tube assembly into place until the
locking screw can drive the back plug on the conductor tube
into its locked operating position. The conductor tube has
a machined locating groove around its rear diameter. This
groove will be flush with the front housing when properly
installed as shown in Figure 3.
NOTE
The QRL torch and cable assemblies are furnished
with a 1-5/8” (41,28mm) Ø mounting diameter
and can be keyed in place into a fixture if so
desired.
Figure 2: Conductor Tube Locking Screw
Figure 2 - Conductor Tube Locking Screw
7. Remove the gas diffuser, tip and nozzle from the conductor
tube assembly.
8. The QRL torch assemblies are furnished with R45-3545
conduit and the rear connector plugs to fit this series of
conduit. If a different conduit is required, refer to Page 7-1
listing the various conduits that are available.
Figure 3: Conductor Tube Installation
FIGURE 3 - CONDUCTOR TUBE INSTALLATION
SM-QRLTORCH
INSTALLATION AND DISASSEMBLY
3-6
CAUTION
MILLER PLUG
CONDUIT ASSEMBLY
PLUG NIPPLE
SET SCREW
TWECO PLUG
CONDUIT ASSEMBLY
Bending or distorting the conduit can cause wire
feed problems.
Quick ROBOtics light weight tORch
11. Insert the factory-supplied 5/32” T-handle allen wrench
through the hole on the aluminum front handle cap,
identified as “Conduit Set Screw” on the label, and rotate
the set screw counterclockwise until it stops rotating (see
figure 5).
12. Insert the exposed raw coil end of the conduit, factory
supplied, into the rear connector plug. Feed the conduit
through the gun and conductor tube assembly. If the conduit
attempts to hang up, rotate the conduit liner counterclockwise
while gently pushing.
Figure 4a: Conduit Installation with Set Screw
9. Remove the conduit from the package and uncoil
carefully.
®
10. Loosen the set screw located on the Tweco
, Panasonic
or Lincoln® rear connector plug to ensure the conduit will
feed through properly. For Miller style plug, remove the
threaded connector plug nipple from the rear connector
plug on the torch assembly. Refer to Figures 4A & 4B.
Figure 4b: Conduit Installation with Set Screw
13. When the conduit is completely through the torch and
conductor tube assembly, seat the brass conduit stop firmly
®
,
against the connector plug.
14. Tighten the set screw on the Tweco
®
, Panasonic®, or
Lincoln® rear connector plug. For Miller style rear connector
plug, re-install the threaded connector plug nipple. This
connection should be wrench tight.
15. Re-insert the factory-supplied 5/32” T-handle allen wrench
into the hole labeled “Conduit Set Screw” on the front
handle cap and rotate the set screw clockwise. The set
screw should be hand tight. Over tightening may cause
wire feed ability problems (reference Figure 5 for hole
location.
SM-QRLTORCH
CONDUIT SET SCREW
Figure 5: Access Hole for Conduit Set Screw
3-7
INSTALLATION AND DISASSEMBLY
Quick ROBOtics light weight tORch
1 5/16”
METHOD “A” METHOD “B”
16. Trim the conduit extending from the front of the conductor
tube assembly by following the steps below:
Method “A” – Using a tape measure or scale, mark
•
and cut the conduit to the cut length (1 5/16").
Refer to Figure 6 — Method “A”.
Method “B” – The diffusers have a machined
•
groove around the outer diameter. Position the
diffuser as shown in Figure 6 — Method “B” and
mark and cut the conduit.
3.02 Disassembly
To disassemble the torch and cable assembly from the fixture,
reverse the steps noted in Section 3.01.
CUT LINE
Figure 6: Conduit Cut Length
17. After trimming to length, remove any obstructions
from the end of the conduit radius.
18. Re-install the diffuser, tip and nozzle onto the
conductor tube assembly.
19. Loosen the fixture connection and insert the torch and
conductor tube assembly into position. The key located
on the torch body should be placed into the mating
keyway on the fixture until it bottoms out against the
fixture plate. Tighten the connection to secure the
assembly in place.
KEY
Figure 7: Locating Key
20. Install the rear connector plug into the feeder.
21. Connect the rear control cable and front e-stop jumper
cable assemblies, if applicable.
22. The torch is now ready to place into operation.
SM-QRLTORCH
INSTALLATION AND DISASSEMBLY
4-8
Quick ROBOtics light weight tORch
PIN 1
RED
NORMALLY OPEN
PIN 2
WHITE
COMMON
PIN 3
BLACK
NORMALLY CLOSED
PIN 4
---
---
PIN 5
---
---
PIN 6
---
---
PIN 7
---
---
PIN 8
---
---
PIN 9
---
---
CONTROL CABLE ASSEMBLY - (QRLXX-CC-F)
E-STOP ASSEMBLY - (QRL-RH-F)
PIN
SOCKET
BLUE
BLACK
BROWN
WHITE
RED
BLACK
RECEPTACLE AMP 206705-2
HOUSING AMP
207008-1
E-STOP
CONNECTOR
BLUE
BROWN
BLACK
SECTION 4:
WIRING
The QRL torch is furnished with a receptacle housing mounted
on the front case. The 3-pin socket receptacle will accept
the RDML-2000-JC E-Stop Jumper Cable from the robot
deflection mount.
Connection Part No. Stock No.
Without Connector QRJC-010 3045-1241
Burndy (ABB) QRJC-020 3045-1242
4-pin Amp (Motoman) QRJC-030 3045-1243
5-pin DDK (Fanuc) QRJC-040 3045-1244
Table 2: E-Stop Adapter Jumper Cables
The receptacle is connected to a 3-wire cable that runs along
the inside of the inner protective jacket. The end of this cable
extends approximately 1ft. (.3m) out of the rear case and
comes standard with a 9-pin amp plug. Adapter jumper cables
are available to connect this cable to most robots (Table 2).
Wiring Schematic for E-Stop Cable
SM-QRLTORCH
4-9
WIRING
Quick ROBOtics light weight tORch
Each Use
Visual check of torch
Consumable parts
Weekly
Visually inspect the torch
body and consumables
Visually inspect the
cables and leads.
Replace as needed
3 Months
Clean
exterior
of power supply
6 Months
Replace all
broken parts
Visually check and
use a vacuum to carefully
clean the interior
Gas and
air lines
Visually inspect the Wire
feed mechanisms
Warning!
Disconnect input power before maintaining.
Maintain more often
if used under severe
conditions.
Visual check of
regulator and pressure
SECTION 5:
MAINTENANCE
Contact tips and nozzles should be cleaned frequently.
Spatter buildup may cause bridging between nozzle and tip.
This could cause electrical shorting between the nozzle and
work piece as well as restricting gas flow.
Regularly inspect the conductor tube, torch and cable
assembly for abrasions, cuts and undue wear. Replace or
repair any parts as needed.
The torch and conductor tube assemblies have o-rings for
seals. Lubrication of these o-rings should be done periodically
and periodical inspections should be made to ensure that the
o-rings do not degrade, allowing water and or shielding gas
leaks to occur. When removing the conductor tube from the
torch assembly, be sure the single o-ring located in the bottom
of the hole remains in place.
MAINTENANCE
SM-QRLTORCH
5-10
Problem Possible Cause Corrective Action
Wire feed inconsistent or not
smooth.
SECTION 6:
TROUBLESHOOTING
1. Loose drive Rollers on feeder.
2. Dirty or plugged conduit.
Quick ROBOtics light weight tORch
1. Tighten drive rollers.
2. Replace conduit.
Torch and cable assembly is
running hot.
3. Conduit pulled back from diffuser.
4. Sharp bends or kinks in conduit.
5. Machine improperly adjusted.
6. Spatter buildup on end of contact tip.
7. Loose contact tip or diffuser.
8. Excessively worn contact tip.
9. Loose ground cable or ground clamp.
1. Loose power connection.
2. Loose or undersize ground cable or
ground clamp.
3. Conductor tube not tight in torch block.
4. Loose contact tip or diffuser.
5. Operating torch and cable assembly
above recommended amperage rating.
3. Reposition conduit and tighten front
screw.
4. Remove and replace conduit.
5. Reset machine per machine and wire
manufacturers’ recommendations.
6. Clean or replace contact tip.
7. Tighten contact tip and diffuser plier
tight.
8. Replace contact tip.
9. Tighten or replace as required.
1. Inspect complete torch and cable for
loose connections and tighten.
2. Tighten or replace as required.
3. Tighten stainless setscrew in torch
block.
4. Tighten contact tip and diffuser.
5. Readjust machine to correct setting for
size of torch being used.
6. Power cable assembly damaged.
7. Restricted water flow (only QRW and
QRWA series torch).
Robot will not start. 1. Deflection mount not at “home”
position.
2. Check E-stop cable connection.
Porous weld. 1. Poor or improper gas flow.
2. Moisture from torch/conductor tube.
3. Dirty or contaminated wire.
4. Base metal contamination.
6. Inspect and replace accordingly.
7. Inspect water lines for any excessive
bends.
1. Check to ensure the mount arm and
mount location.
2. Check E-stop cable connection.
1. Check gas flow out of conductor tube
nozzle. Check for leaks or restrictions
in gas hoses and connections.
2. Check O-rings on conductor tube and
torch block. Check the torch block for
any scarring, gouges to the surface.
3. Change wire.
4. Replace base metal.
SM-QRLTORCH
6-11
TROUBLESHOOTING
Quick ROBOtics light weight tORch
20
21
22
23
15
D
16
14
17
19
18
13
8
12
10
9
3
5
3
5
26
11
25
1
2
6
7
24
4
C
B
A
B
E
E
E
F
F
SECTION 7:
QRL REPLACEMENT PARTS
QRL Series Replacement Parts
Item No. Part No. Stock No. Description
1 QRLMS 3045-1709 QRL Mount Sleeve (Includes 4, A & B)
2 QRLH 3045-1710 QRl Case
3 QR106-RLS 3045-1341 Conductor Tube Locking Screw (Qty. 5)
4 QTRMS-BS 3045-1156 Woodruff Keys (Qty. 5)
5 QRL106S 3045-1347 Conduit Screw
6 QRLRH 3045-1706 QRL Receptacle Housing Assembly (Includes C)
7 QRLCS 3045-1700 Locking Screw Cover for QRL series
SM-QRLTORCH
QRL REPLACEMENT PARTS
7-12
Quick ROBOtics light weight tORch
QRL Series Replacement Parts (cont.)
Item No. Part No. Stock No. Description
8 QRL1004PC 3045-1702 QRL Series Front Block & Cable (4 ft. long) (Includes 3, E & 5)
QRL1006PC 3045-1703 QRL Series Front Block & Cable (6 ft. long) (Includes 3 , E & 5)
9 QRL-SPS 3045-1199 Front Strain Relief Spring (Includes B & F)
10 QRLRCS 3045-1701 QRL Strain Relief Cap & Spring
11 QRL04CC 3045-1704 QRL Control Cable Assembly (4 ft. long) (Includes E)
QRL06CC 3045-1705 QRL Control Cable Assembly (6 ft. long) (Includes E)
12 QRL04J 3045-1707 QRL Cable Cover (4 ft. long) (Includes F)
QRL06J 3045-1708 QRL Cable Cover (6 ft. long) (Includes F)
13 QRA-CS 3045-1239 Rear Case Assembly
14 R174MH 2035-2109 Miller Connector Plug
R176MH 2060-2184 Miller Connector Plug
15 R175M-N045 2050-2181 Miller Plug Nipple, 0.045” (1,0mm) Wire (Use w/R176MH)
R174M-N045 2040-2192 Miller Plug Nipple, 0.045” (1,0mm) Wire (Use w/R174MH)
16 R175M-N116 2050-2182 Miller Plug Nipple, 0.062” (1,6mm) Wire (Use w/R176MH)
R174M-N116 2040-2191 Miller Plug Nipple, 0.062” (1,6mm) Wire (Use w/R174MH)
17 176S-H 2060-2177 Tweco® Connector Plug
350-174H 2035-2110 Tweco® Connector Plug (Uses R44 series Conduit)
18 QTR176LH 2086-2624 Lincoln Connector Plug (2.71” - 68,83mm OAL.)
EL176LH 2060-2680 Lincoln Connector Plug (3.84” - 97,54mm OAL.)
19 350-174PH 2035-2172 Panasonic Connector Plug (Uses R44 series Conduit)
20 XQRL1004PC 3045-1395 QRL Front Block & Cable (4 ft. long-Euro) (Includes 3, E & 5)
XQRL1006PC 3045-1396 QRL Front Block & Cable (6 ft. long-Euro) (Includes 3, E & 5)
21 XQRA-CS 3045-1240 Rear Case Assembly (Includes D)
22 174X-2S 2040-2177 Euro-Kwik Nut
23 E171-1TS 2011-2172 Euro-Kwik Adapter
24 -- -- Conduit (Refer to page 7-1)
25 QTR-TOOLS 2062-2034 Tool Kit
26 -- -- E-stop Jumper Cable Assembly
QRJC-010 3045-1241 Without Connector - 3 ft. (91cm) Long
QRJC-020 3045-1242 With Burndy Connector - 3 ft. (91 cm) Long
QRJC-030 3045-1243 With 4-pin Amp Connector - 3 ft. (91 cm) Long
QRJC-040 3045-1244 With 5-pin DDK Connector - 3 ft. (91 cm) Long
Standard Non-Sellable Parts
These standard parts are not sellable items and should be purchased at a local hardware or fastener supplier.
Item No. Description
A 1/4 - 20 x 3/8 Half Dog Point Set Screw
B 1/4 - 20 x 1/4 Flat Point Socket Head Set Screw
C 10 - 32 x 1/2 SS Socket Head Cap Screw
D M4 x 0.7 x 5.9 Cheese Head Screw
E 7.6L x 0.190W Cable Tie Panduit CBR2S
F 4.1L x 0.098W Cable Tie Panduit CBR1M
SM-QRLTORCH
7-13
QRL REPLACEMENT PARTS
Quick ROBOtics light weight tORch
MACHINED CONDUIT STOP
WIRE CONDUIT
NEOPRENE SEAL
HEAT SHRINK
SECTION 8:
CONDUIT LINERS
R45 SERIES CONDUITS
STEEL WELDING WIRE ALUMINUM WELDING WIRE
Part No. Part No.
Wire Size Stock No. Length Wire Size Stock No. Length
.035in / .045
mm
0.9
/ 1.2
.035in / .045
0.9mm / 1.2
.035in / .045
0.9mm / 1.2
.035in / .045
0.9mm / 1.2
.052in / 1/16
mm
1.53
/ 1.6
in
.052
/ 1/16
mm
1.53
/ 1.6
in
.052
/ 1/16
mm
1.53
/ 1.6
in
.052
/ 1/16
mm
1.53
/ 1.6
in
R45-3545-1 1
mm
1450-1023 .3
in
R45-3545-4 4
mm
1450-1024 1.2
in
R45-3545-8 8
mm
1450-1025 2.4
in
R45-3545-15 15
mm
1450-1026 4.6
in
R45-116-1 1
mm
1450-1028 .3
in
R45-116-4 4
mm
1450-1029 1.2
in
R45-116-8 8
mm
1450-1030 2.4
in
R45-116-15 15
mm
1450-1031 4.6
ft
m
ft
m
ft
m
ft
m
ft
m
ft
m
ft
m
ft
m
.035in / .045
0.9
.035in / .045
0.9mm / 1.2
.035in / .045
0.9mm / 1.2
1/16
1/16
mm
1.6
1.6
/ 1.2
mm
mm
in
R45WN-3545-4 4
mm
1450-1041 1.2
in
R45WN-3545-8 8
mm
1450-1042 2.4
in
R45WN-3545-15 15
mm
1450-1043 4.6
in
R45WN-116-8 8
ft
ft
ft
ft
1450-1044 2.4
in
R45WN-116-15 15
ft
1450-1045 4.6
m
m
m
m
m
NOTE
Part/Stock numbers with a (WN) reference signify
“Wire, Nylon Wrapped”.
SM-QRLTORCH
CONDUIT LINERS
8-14
Quick ROBOtics light weight tORch
SECTION 9:
FACTORY REPAIR CENTER
Tweco® Robotics Factory Repair Center (FRC) offers a repair service for our customers on the various cable assemblies and peripheral
products. The majority of our consumers do not want to spend the time involved with repairs and generally do not have the necessary
equipment and tools to perform repairs.
Other key benefits in considering the “FRC” service repairs on your product:
All products will be rebuilt and tested following the established test procedures and specifications for the specific
•
product.
All repairs are done using original Tweco® Robotics parts to ensure maximum product performance.
•
Our FRC has highly-trained employees utilizing the appropriate tools and test equipment.
•
30-day warranty on the newly installed parts and labor on all cable assemblies.
•
30-day warranty on QRM-100, QRM-3 and RDM-2000 peripherals.
•
60-day warranty on QRC-2000 and QWT-120 peripherals.
•
Factory Repair Center
Domestic Toll Free Phone Number: 1-800-426-1888
Fax Number: 1-620-229-9926
SM-QRLTORCH
9-15
FACTORY REPAIR CENTER
Quick ROBOtics light weight tORch
Statement of Warranty
LIMITED WARRANTY: THERMADYNE® warrants that its products will be free of defects in workmanship or material. Should
any failure to conform to this warranty appear within the time period applicable to the THERMADYNE products as stated below,
THERMADYNE shall, upon notification thereof and substantiation that the product has been stored, installed, operated, and
maintained in accordance with THERMADYNE’s specifications, instructions, recommendations and recognized standard industry
practice, and not subject to misuse, repair, neglect, alteration, or accident, correct such defects by suitable repair or replacement,
at THERMADYNE’s sole option, of any components or parts of the product determined by THERMADYNE to be defective.
THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING
ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE.
LIMITATION OF LIABILITY: THERMADYNE shall not under any circumstances be liable for special or consequential damages,
such as, but not limited to, damage or loss of purchased or replacement goods, or claims of customers of distributor (hereinafter
the “Purchaser”) for service interruption. The remedies of the Purchaser set forth herein are exclusive and the liability of
THERMADYNE with respect to any contract, or anything done in connection therewith such as the performance or breach
thereof, or from the manufacture, sale, delivery, resale, or use of any goods covered by or furnished by THERMADYNE whether
arising out of contract, negligence, strict tort, or under any warranty, or otherwise, shall not, except as expressly provided
herein, exceed the price of the goods upon which such liability is based.
THIS WARRANTY BECOMES INVALID IF REPLACEMENT PARTS OR ACCESSORIES ARE USED WHICH MAY IMPAIR
THE SAFETY OR PERFORMANCE OF ANY THERMADYNE PRODUCT.
THIS WARRANTY IS INVALID IF THE PRODUCT IS SOLD BY NON-AUTHORIZED PERSONS.
This warranty is effective for the time stated in the Warranty Schedule beginning on the date that the authorized distributor
delivers the products to the Purchaser.
Warranty repairs or replacement claims under this limited warranty must be submitted by an authorized THERMADYNE repair
facility within thirty (30) days of the repair. No transportation costs of any kind will be paid under this warranty. Transportation
charges to send products to an authorized warranty repair facility shall be the responsibility of the Purchaser. All returned
goods shall be at the Purchaser’s risk and expense. This warranty supersedes all previous THERMADYNE warranties.
SM-QRLTORCH
16
Quick ROBOtics light weight tORch
WARRANTY SCHEDULE
The warranty is effective below for the time stated in the Warranty Schedule beginning on the date that the authorized distributor
delivers the products to the purchaser. THERMADYNE® reserves the right to request documented evidence of date of purchase.
Engine Driven Welders Parts / Labor
Original Main Power Stators and Inductors 3 years / 3 years
Original Main Power Rectifiers, Control P.C. Boards 3 years / 3 years
All Other Original Circuits and Components Including, but not Limited to, Relays, Switches, Contactors, Solenoids, Fans, Power Switch Semi-Conductors 1 year / 1 year
Engines and Associated Components are NOT Warranted by Thermal Arc®, Although Most are Warranted by the Engine Manufacturer. SEE THE ENGINE
MANUFACTURERS’ WARRANTY FOR DETAILS.
Fabricator® 131, 181, 190, 210, 251, 281; Fabstar® 4030; PowerMaster® 350, 350P, 500, 500P; Excel-Arc® 6045; Wire Feeders: Ultrafeed®, Porta-feed®
Original Main Power Transformer and Inductor 5 years / 3 years
Original Main Power Rectifiers, Control P.C. Boards, Power Switch Semi-Conductors 3 years / 3 years
All Other Original Circuits and Components Including, but not Limited to, Relays, Switches, Contactors, Solenoids, Fans, Electric Motors 1 year / 1 year
160TS, 300TS, 400TS, 185AC/DC, 200AC/DC, 300AC/DC, 400GTSW, 400MST, 300MST, 400MSTP
Original Main Power Magnetics 5 years / 3 years
Original Main Power Rectifiers, Control P.C. Boards, Power Switch Semi-Conductors 3 years / 3 years
All Other Original Circuits and Components Including, but not Limited to, Relays, Switches, Contactors, Solenoids, Fans, Electric Motors 1 year / 1 year
Original Main Power Magnetics 5 years / 3 years
Original Main Power Rectifiers, Control P.C. Boards, Power Switch Semi-Conductors 3 years / 3 years
Welding Console, Weld Controller, Weld Timer 3 years / 3 years
All Other Original Circuits and Components Including, but not Limited to, Relays, Switches, Contactors, Solenoids, Fans, Electric Motors, Coolant Recirculators 1 year / 1 year
Original Main Power Magnetics 1 year / 1 year
Original Main Power Rectifiers, Control P.C. Boards 1 year / 1 year
All Other Original Circuits and Components Including, but not Limited to, Relays, Switches, Contactors, Solenoids, Fans, Power Switch Semi-Conductors 1 year / 1 year
Original Main Power Magnetics 5 years / 3 years
Original Main Power Rectifiers, Control P.C. Boards 3 years / 3 years
All Other Original Circuits and Components Including, but not Limited to, Relays, Switches, Contactors, Solenoids, Fans, Power Switch Semi-Conductors 1 year / 1 year
Water Recirculators 1 year / 1 year
Plasma Welding Torches 180 days / 180 days
Gas Regulators (Supplied with Power Sources) 180 days / NA
MIG and TIG Torches (Supplied with Power Sources) 90 days / NA
Replacement Repair Parts 90 days / NA
MIG, TIG and Plasma Welding Torch Consumable Items NA / NA
Victor® Professional 5 years / NA
Oxygen Conservers 2 years / NA
Aluminum Cylinders Lifetime / NA
Cutting Machine Motors 1 year / NA
HP&I Brass Regulators/Manifolds 2 years / NA
HP&I Stainless Regulators/Manifolds 1 year / NA
HP&I Corrosive Gas Regulators/Manifolds 90 days / NA
TurboTorch® 3 years / NA
CutSkill® 2 years / NA
Steel Cylinders 1 year / NA
Victor Medical 6 years / NA
Victor VSP 2 years / NA
Firepower® MIG Welders 5-2-1 years / NA
Transformers 5 years / NA
Parts Used in Rental Applications 1 year from date sold by seller to authorized
Arcair® N6000 90 days / NA
Eliminator® Spool and Pull Guns 90 days / NA
Robotic Deflection Mounts 90 days / NA
QRM-100 Anti-Spatter Applicator 90 days / NA
TC and TCV Water Coolers 1 year / NA
TSC-96 Smoke Collector 1 year / NA
ESG-1, EPG-CR1, EPG-CR2 Control Boxes for Eliminator Spool & Pull Guns 1 year / NA
QRC-2000 Nozzle Cleaning Stations 1 year / 1 year
All other products 30 days from date purchaser purchases from seller. 30 days / NA
Automated Plasma 2 years / 1 year
CutMaster™ 3 years / 3 years
PakMaster® XL PLUS 3 years / 1 year
Drag-Gun® 1 year / 1 year
Drag-Gun Plus 2 years / 1 year
Torches 1 year / 1 year
Consoles, Control Equipment, Heat Exchangers and Accessory Equipment 1 year / 1 year
GTAW (TIG) & Multi-process Inverter Welding Equipment
Scout®, Raider®, Explorer™
See the Engine Manufacturers’ Warranty
GMAW/FCAW (MIG) Welding Equipment
for Details
Plasma Welding Equipment Parts / Labor
Ultima® 150
SMAW (Stick) Welding Equipment
Dragster™ 85
160S, 300S, 400S
General Arc Equipment
Gas Welding and Cutting Equipment Parts / Labor
distributor
MIG Torches and Arc Accessories
Plasma Cutting Systems Parts / Labor
Parts / Labor
Parts / Labor
Parts / Labor
Parts / Labor
Parts / Labor
SM-QRLTORCH
17
GLOBAL CUSTOMER SERVICE CONTACT INFORMATION
Thermadyne USA
2800 Airport Road
Denton, TX 76207 USA
Telephone: (1) 940-566-2000
Fax: (1) 800-535-0557
Thermadyne Canada
2070 Wyecroft Road
Oakville, Ontario
Canada, L6L5V6
Telephone: (1) 905-827-9777
Fax: (1) 905-827-9797
Thermadyne Europe
Europe Building
Chorley North Industrial Park
Chorley, Lancashire
England, PR6 7Bx
Telephone: (44) 1257-261755
Fax: (44) 1257-224800
Thermadyne Asia Sdn Bhd
Lot 151, Jalan Industri 3/5A
Rawang Integrated Industrial Park - Jln Batu Arang
48000 Rawang Selangor Darul Ehsan
West Malaysia
Telephone: 603+ 6092 2988
Fax : 603+ 6092 1085
Thermadyne Australia
71 Gower Street
Preston, Victoria
Australia, 3072
Telephone: 1300-654-674
Fax: 613+ 9474-7391
Thermadyne Italy
OCIM, S.r.L.
Via Benaco, 3
20098 S. Giuliano
Milan, Italy
Tel: (39) 02-98 80320
Fax: (39) 02-98 281773
Thermadyne, China
RM 102A
685 Ding Xi Rd
Chang Ning District
Shanghai, PR, 200052
Telephone: 86 21+6280-1273
Fax: 86 21+3226-0955
Thermadyne International
2070 Wyecroft Road
Oakville, Ontario
Canada, L6L5V6
Telephone: (1) 905-827-9777
Fax: (1) 905-827-9797
World Headquarters
Thermadyne Holdings Corporation
Suite 300, 16052 Swingley Ridge Road
St. Louis, MO. 63017
Telephone: (636) 728-3000
Fascimile: (636) 728-3010
Email: www.thermadyne.com
www.tweco.com
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