Tweco Quick Fixed User Manual

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AUTOMATION

SERIES TORCHES

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Installation Guide and

Replacement Parts Manual

Version No: AA:01 Issue Date: June 30, 2006 Manual No: SM-QFTORCH (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 Manual has been designed to instruct you on the correct
installation and use 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 market­leading, 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 Robotics Torch
Installation Guide and Replacement Parts Manual
Instruction Manual Number SM-QFTORCH

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 #: ________________________

Registered Trademarks Miller® Lincoln® Panasonic® and Kevlar® are the respective property of their owners, not Thermadyne Industries, Inc.

i

Quick fixed automation series 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 ................................................. 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 ......................................................................................2-4

2.05 Description ................................................................................................ 2-4

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

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

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

SECTION 4: WATER-COOLED TORCH BODY AND CABLE ASSEMBLY .......................... 4-9

2-4

SECTION 5: MAINTENANCE .........................................................................5-10

SECTION 6: TROUBLESHOOTING .................................................................. 6-11

SECTION 7: REPLACEMENT PARTS ................................................................7-12

QFA Replacement Parts ...................................................................................7-12

QFW Series Replacement Parts ....................................................................... 7-15

SECTION 8: FIXED AUTOMATION CONDUITS LINERS ........................................... 8-18

SECTION 9: FACTORY REPAIR CENTER ........................................................... 9-19

LIMITED WARRANTY ................................................................................9-20

GLOBAL CUSTOMER SERVICE CONTACT INFORMATION ....................................... 9-21

ii

SM-QFTORCH

Quick fixed automation series 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.

insta ll an d mainta in equip ment 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.

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.

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

smoKe, fumes and gases can be dangerous
to your health.

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.

SM-QFTORCH

1-1

SAFETY INSTRUCTIONS AND WARNINGS

Quick fixed automation series torches

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-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.

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 weld 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.

27. Never use oxygen in a welding torch. Use only inert 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.

WARNING

Welding sparKs can cause fires and
eXplosions.

SAFETY INSTRUCTIONS AND WARNINGS

1-2

SM-QFTORCH

1.02 Principal Safety Standards

!

SAFETY AND OPERATING REFERENCES

1. Code of Federal Regulations. (OSHA)
Section 29 Part 1910.95, 132, 133, 134, 139, 251, 252, 253, 254 and 1000.
U.S. Government Printing Office, Washington, DC. 20402.

2. ANSl Z49.1 "Safety In Welding and Cutting."

3. ANSI Z87.1 "Practice for Occupational and Educational Eye and Face Protection."

4. ANSl Z88.2 "Standard Practice for Respiratory Protection."
American National Standards Institute, 1430 Broadway, New York, NY. 10018.

5. AWS F4.1 "Recommended Safe Practices for Welding and Cutting Containers."

6. AWS C5.3 "Recommended Practices for Air Carbon-Arc Gouging and Cutting."
The American Welding Society, 550 NW Lejeune RD., P.O.Box 351040, Miami FL. 33135

7. NFPA 51B “Fire Prevention in Cutting and Welding Processes.”

8. NFPA-7 “National Electrical Code.”
National Fire Protection Association, Battery Park, Quincy, MA. 02269.

9. CSA W117.2, "Safety in Welding, Cutting and Allied Processes."
Canadian Standards Association, 178 Rexdale Blvd., Rexdale, Ontario, Canada M9W 1R3.

1.03 Safety and Health

NOTE

Quick fixed automation series torches

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.

•

SM-QFTORCH

WARNING

1-3

SAFETY INSTRUCTIONS AND WARNINGS

Quick fixed automation series torches

!

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
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 possible eq uipment
damage.

WARNING, CAUTION, and

WARNING

CAUTION

NOTE

2.04 Standard features

Quick conductor tube lock for easy conductor tube

•
replacement.
Inner cable protective jacket.

•
Heavy cable support springs on both front and rear.

•
Kevlar®/Nylon outer protective cable cover.

•
Water-cooled cables have built in water shut-off valves

•
in the front housing.
Quick hose connections on all water-cooled cables.

•
Internal purge hose for spraying anti-spatter through

•
the conductor tube and nozzle.
All cable assemblies are furnished with a Tweco®,

•
Miller®, and Lincoln® rear connector plug.

2.05 Description

QF Series Air-cooled Torch Body and Cable Assembly

The air-cooled QFA cable assembly uses QTR66 air-cooled
conductor tubes. It has an air-cooled power cable rated at
600 amperes @ 60% duty cycle.

A NOTE offers helpful information concerning
certain operating procedures.

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.

2.03 Introduction

The Tweco® Robotics Quick Fixed Automation Torch series
are offered in either air-cooled or water/air-cooled cable
assemblies. Both series of the Quick Fixed Automation Torches
are offered in lengths 4ft. (91cm) – 15ft. (5m).

INTRODUCTION AND DESCRIPTION

2-4

SM-QFTORCH

Quick fixed automation series torches

Figure 2-1: QF Series (Air-cooled)

QF Series Water/ Air-cooled Torch Body and Cable Assembly

The QFW cable assembly is a hybrid using QTRW63, QTRW64, or QTRW66 water-cooled conductor tubes but it utilizes an
air-cooled power cable assembly rated up to 600 amperes @ 80% duty cycle. If water flow is interrupted, amperage rating
is decreased. This provides a torch that has water-cooling of the front consumables while providing a trouble free rugged
air-cooled cable assembly.

Figure 2-2: QF Series (Water/Air-cooled)

A wide variety of conductor tube and front-end consumables are also offered. Contact your local welding distributor and or
Tweco® Customer Care Department (1-800-426-1888) for assistance in choosing the correct conductor tube and consumables
for your welding application.

SM-QFTORCH

2-5

INTRODUCTION AND DESCRIPTION