Tweco QFW600 User Manual

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QFA600

QFW600 TORCH

QFA600 TORCH

QFW600

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QUICK FIXED

AUTOMATION DIRECT

PLUG TORCHES

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Qfa600 Torch

Qfw600 Torch

Installation Guide and

Replacement Parts List

Version No: AA.01 Issue Date: July 1, 2006 Manual No: SM-QFDP

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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, please contact a representative at
the address and phone number in your area listed on the inside back
cover of this manual, 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.

Quick Fixed Automation Direct Plug Torches
Installation and Operation Guide
Instruction Manual Number SM-QFDP

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: July 1, 2006

Record the following information for Warranty purposes:

Where Purchased: ________________________

Purchase Date: ________________________

Equipment Serial #: ________________________

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quick fixed automation direct plug torches

Table of Contents

SECTION 1: SAFETY INSTRUCTIONS AND WARNINGS .......................................... 1-1

1.01 Welding Hazards ....................................................................................... 1-1

1.02 Principal Safety Standards ........................................................................ 1-3

1.03 Safety and Health ...................................................................................... 1-3

SECTION 2: INTRODUCTION AND DESCRIPTION ................................................. 1-4

2.01 How to Use this Manual ............................................................................ 1-4

2.02 Receipt of Equipment ................................................................................1-4

2.03 Introduction .............................................................................................1-4

SECTION 3: INSTALLATION AND OPERATION ..................................................... 3-6

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

3.02 Disassembly ..............................................................................................3-7

3.03 Water-Cooled Torch Assembly ..................................................................3-7

SECTION 4: MAINTENANCE ..........................................................................

SECTION 5: REPLACEMENT PARTS .................................................................

SECTION 5: FACTORY REPAIR CENTER ........................................................... 6-11

LIMITED WARRANTY ................................................................................6-12

GLOBAL CUSTOMER SERVICE CONTACT INFORMATION .......................................6-13

4-8

5-9

SM-QFDP

ii

quick fixed automation direct plug torches

!

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

ELECTRIC 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.
Do not touch an electrode with bare skin and electrical

2.
ground at the same time.

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

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.

NOTE

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-QFDP

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

1-1

WARNING

SAFETY INSTRUCTIONS AND WARNINGS

quick fixed automation direct plug torches

11. Keep smoke, fumes, and gases away 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 produces 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-of­position 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

eld or cut containers that have held combustibles.
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.

WARNING

NOISE CAN DAMAGE HEARING.

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.

SM-QFDP

SAFETY INSTRUCTIONS AND WARNINGS

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