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
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
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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