Tweco Quick Robotic Torch User Manual

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QUICK ROBOTIC
TORCH
Installation Guide and
Replacement Parts Manual
Version No: AA:01 Issue Date: June 30, 2006 Manual No: SM-QRTORCH (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 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 Robotics Torch Installation Guide and Replacement Parts Manual Instruction Manual Number SM-QRTORCH
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 #: ________________________
Registered Trademarks ABB® FANUC® Miller® Lincoln® Panasonic® Motoman® and Kevlar® are the respective property of their owners, not Thermadyne Industries, Inc.
i
Quick Robotic toRch
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
SECTION 3:
INSTALLATION AND DISASSEMBLY ......................................................... 3-6
Table of Contents
2-4
3.01 Installation ................................................................................................
3.02 Disassembly .............................................................................................
3.03 Changing The Cartridge Kit .......................................................................
SECTION 4:
WIRING ..........................................................................................4-10
SECTION 5:
WATER-COOLED TORCH BODY AND CABLE ASSEMBLY .................................5-11
SECTION 6:
MAINTENANCE .................................................................................6-12
SECTION 7:
TROUBLESHOOTING ..........................................................................7-13
SECTION 8:
REPLACEMENT PARTS ....................................................................... 8-14
QRA & QRAS Series Replacement Parts .........................................................8-15
QRW & QRWS Series Replacement Parts ......................................................8-19
QRWA & QRWAS Series Replacement Parts ..................................................8-25
3-6 3-8 3-8
SECTION 9:
ROBOTIC CONDUIT LINERS ..................................................................9-31
SECTION 10:
FACTORY REPAIR CENTER ................................................................. 10-32
LIMITED WARRANTY .............................................................................. 10-33
GLOBAL CUSTOMER SERVICE CONTACT INFORMATION ..................................... 10-35
ii
SM-QRTORCH
Quick Robotic 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
electRic shock can cause injuRy oR death.
ins ta l l and M aintain eq uipMen t 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
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.
SM-QRTORCH
1-1
SAFETY INSTRUCTIONS AND WARNINGS
Quick Robotic toRch
WARNING
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.
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.
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.
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.
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
SAFETY INSTRUCTIONS AND WARNINGS
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.
1-2
SM-QRTORCH
!
1.02 Principal Safety Standards
1.03 Safety and Health
Quick Robotic toRch
NOTE
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
• protected eyes and skin. Welding sparks can cause fires and explosions.
• Excessive noise can damage your hearing.
WARNING
SM-QRTORCH
1-3
SAFETY INSTRUCTIONS AND WARNINGS
Quick Robotic 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 CAU TION refers to possi ble equipment damage.
A NOTE offers helpful information concerning certain operating procedures.
WARNING
CAUTION
NOTE
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
Tweco® Robotics Quick Robotic Torch series provide many features that will enhance your robotic welding application. The Quick Robotic Torch series are offered in either air-cooled, water-cooled or water/air-cooled cable assemblies. The series also include a push button “inch-switch” positioned at the front end of the torch block that allows the welding wire to be manually fed through the torch prior to the welding sequence.
Another separate line of the Quick Robotic Torch series offer a nozzle-sensing feature which will help locate the relationship between the conductor tube nozzle to the weld joint position. All Quick Robotic Torches are offered in lengths ranging from 3ft. (91cm) – 15ft. (5m).
2.04 Standard features
Quick conductor tube lock for easy conductor tube
• replacement. E-stop cable with connections.
• 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.
INTRODUCTION AND DESCRIPTION
2-4
SM-QRTORCH
Quick Robotic toRch
QRA Series Air-cooled Robotic Torch and Cable Assembly
The air-cooled QRA cable assembly uses QTR66 air-cooled conductor tubes. It has an air-cooled power cable rated at 600 amperes @ 60% duty cycle.
QRW Series Water-cooled Robotic Torch and Cable Assembly
The water-cooled QRW cable assembly uses QTRW63, QTRW64, or QTRW66 water-cooled conductor tubes. It is furnished with a water-cooled power cable rated up to 600 amperes @ 100% duty cycle.
QRWA Series Water/ Air Robotic Torch and Cable Assembly
The QRWA 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.
QRAS, QRWS, and QRWAS Robotic Nozzle-sensing Torch Cable Assembly
This series of torch and cable assemblies incorporates the same power cables and are rated at the same amperage rating as the series mentioned above. The only difference is the torch block and the use of the QTRW64-ST series conductor tube assembly.
A wide variety of conductor tube and front-end consumables are also offered. Contact your local welding distributor and/or Tweco® Customer Service Department (1-800-426-1888) for assistance in choosing the correct conductor tube and consumables for your welding application.
SM-QRTORCH
2-5
INTRODUCTION AND DESCRIPTION
Quick Robotic toRch
ROTATE FRONT SLEEVE COVER TO EXPOSE SET SCREW. ROTATE COVER TO CONCEAL SET SCREW PRIOR TO TORCH OPERATION.
SET SCREW
(5/32" ALLEN KEY)
WHEN CONDUCTOR TUBE IS FULLY SEATED, GROOVE ON TUBE SHOULD LINE UP WITH EDGE OF INSULATING SLEEVE.
SET SCREW
TWECO PLUG
CONDUIT ASSEMBLY
MILLER PLUG
CONDUIT ASSEMBLY
PLUG NIPPLE
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. Verify that the overall cable length is correct to fit between the feeder - robot torch mount combination.
NOTE
For cable assemblies longer than 5ft. (1,52m), it is recommended incorporating a spring-loaded stabilizer bar/balancer to the robot work cell to provide support to the center of the cable assembly. This will eliminate both excessive drooping of the cable assembly and any interference with the fixtures and tooling in the work area.
3. Rotate the front sleeve cover to expose the stainless steel set screw located in the torch block assembly. Insert the factory supplied 5/32” T-handle Allen wrench into the set screw and rotate counterclockwise until it stops as shown in Figure 3-1.
6. Remove the gas diffuser, tip and nozzle from the conductor tube assembly.
7. The torch and cable assembly comes with the Miller
®
rear connector plug installed. If the feeder requires a different rear connector plug, select the correct rear connector plug for the feeder being used and thread the plug into the rear of cable assembly. This connection should be wrench tight.
8. The QR Series torch and cable assemblies are furnished with R45-116 conduit and the rear connector plugs to fit this series of conduit. If a different conduit and rear connector plug is required, refer to Page 9-31 listing the various conduits that are available.
9. Remove the conduit from the package and uncoil carefully.
CAUTION
Bending or distorting the conduit can cause wire feed problems.
10. Loosen the set screw located on the Tweco
®
, Panasonic® and 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 Figure 3-3 & 3-4.
Figure 3-1: Conductor Tube Locking Set Screw
4. 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.
5. Push the conductor tube assembly into place until the stainless steel set 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 3-2.
Figure 3-2: Conductor Tube Installation
INSTALLATION AND DISASSEMBLY
Figure 3-3: Conduit Installation with Set Screw
Figure 3-4: Conduit Installation with Plug Nipple (Miller® Style)
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.
3-6
SM-QRTORCH
12. Insert the exposed raw coil end of the conduit, factory
CONDUIT SET SCREW HOLE
A
rt # JB-00012
KEYSTOCK
CUT LINE
A
”B“ DOHTEM”A“ DOHTEM
Art # JB-00013
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.
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®, and 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 for the “Conduit Set Screw” on the front handle cap and rotate the set screw clockwise. The set screw should be hand tight. Refer to Figure 3-5.
Quick Robotic toRch
17. After trimming to length, remove any obstructions from the end of the conduit radius.
18. Re-install the diffuser, tip and nozzle into the conductor tube assembly.
19. Loosen the robot mount arm connection on the robot arm, and insert the cartridge kit of the torch and conductor tube assembly into position on the robot arm. The keystock located on the cartridge kit should be placed into the mating slot on the mount arm until the sleeve bottoms against the robot arm. Re-tighten the connection to secure the assembly in place. Refer to Figure 3-7.
Figure 3-7: Locating Keystock
NOTE
For cable assemblies longer than 5ft. (1,52m), it is recommended incorporating a spring-loaded
Figure 3-5: Access Hole for Conduit Set Screw
stabilizer bar/balancer to the robot work cell to provide support to the center of the cable assembly.
16. Trim the conduit extending from the front of the conductor tube assembly by following the steps below:
This will eliminate both excessive drooping of the cable assembly and any interference with the fixtures and tooling in the work area.
Method “A” – Using a tape measure or scale, mark and cut the
conduit to the cut length noted in the table below. Refer to Figure 3-6 — Method “A”.
Method “B” – The diffusers have a machined groove around
the outer diameter. Position the diffuser as shown in Figure 3-6 — Method “B” and mark and cut the conduit.
20. Install the rear connector plug into the feeder.
21. Install the E-stop Cable between the robot deflection mount and the cable front housing on the torch.
22. Attach an adapter cable, sold separately, to the rear connection on the yellow E-stop cable located at the rear of the cable assembly. Refer to Section 4 for detail on optional adapter cables and wiring instructions.
Conductor Tube Assy. Cut Length “A”
QTR66 Series – (For use with QRA series torch/cable assemblies) 1-5/16” (33,32mm) QTRW63 Series – (For use with QRW & QRWA series torch/cable assemblies) 15/16” (23,80mm) QTRW64 Series – (For use with QRW & QRWA series torch/cable assemblies) 1/4” (6,35mm) QTRW66 Series – (For use with QRW & QRWA series torch/cable assemblies) 5/16” (7,92mm)
SM-QRTORCH
Figure 3-6: Conduit Cut Length
3-7
INSTALLATION AND DISASSEMBLY
Quick Robotic toRch
SOCKET SET SCREW
ACCESS HOLE FOR SET SCREW
CONDUIT SET SCREW HOLE
FRONT SLEEVE COVER & SPRING
INCH SWITCH HOUSING
SOCKET HEAD CAP SCREW
ELECTRICAL CONNECTIONS
HOSE CLAMPS
CARTRIDGE KIT
23. Plug or wire the other end into the proper pin locations on the robot. Refer to the manufacturer recommendations and installation instructions.
24. If the torch being installed is a water-cooled QRW or QRWA series, a water supply providing not less than ¾ gallons/ minute (2.84 liters/minute) water flow must be used during operation. The water supply should be installed to run when the power source is turned “on” if possible to avoid any damage to the torch and cable assembly.
CAUTION
Operating a water-cooled torch and cable assembly without water or restricted flow will result in damage to the cable assembly.
25. The torch and cable assembly is furnished with a purge hose that can be used to supply inert gas and or anti­spatter through the torch block and conductor tube assembly. To use this purge hose, remove the plastic plug and connect accordingly.
26. The torch is now ready to place into operation. Be sure to check the TCP and single step the robot through the robot program to ensure that the conductor tube positioning is correct.
3.02 Disassembly
1. To disassemble the torch and cable assembly from the robot arm, reverse the steps noted in Section 3.01
(d) With the housing away from the front sleeve cover,
insert the factory-supplied 3/32” Allen wrench into the two (2) access holes for the set screws and loosen. A third set screw will need to be loosened along with the two mentioned. This set screw is located 180° from the molded housing screw hole and approximately ½” (12,7mm) below the “Conduit Set Screw” hole noted on the label. Refer to Figure 3-9.
Figure 3-9: Access Hole for Set Screw
(e) Push the 3/32” Allen wrench through the label and
insert the set screw and loosen.
(f) Slide the front sleeve cover and support spring away
from the cartridge kit. Refer to Figure 3-10.
3.03 Changing The Cartridge Kit
1. To remove and replace the correct cartridge kit, follow the steps below:
(a) Cut the metal straps holding the outer cover in place on
both ends.
(b) Pull the protective outer cover away from the cable
assembly.
(c) Remove the socket head cap screw located on the molded
inch switch housing. Once the housing is loose and can be pulled away from the front sleeve cover, pull apart the two exposed electrical connections. Refer to Figure 3-8
Figure 3-10: Exploded View of Torch
(g) Remove the heat shrink and clamp holding the inch
switch cable to the cablehoz.
Figure 3-8: Removal of Inch Switch Housing
INSTALLATION AND DISASSEMBLY
3-8
SM-QRTORCH
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