qUICK rOBOTIC tORCH English Français Español installation Guide and replacement Parts Manual SM-QRTORCH cover drawing 1 GTAW SMAW PHASE 50 Hz 60 INVERTER Version No: AA:01 Issue Date: June 30, 2006 115 V 230 DC CC V 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.
! 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.
Quick Robotic Torch 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...
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.
Quick Robotic Torch 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. WARNING SMOKE, FUMES AND GASES CAN BE DANGEROUS TO YOUR HEALTH. 21. Flammable hair preparations should not be used when welding or cutting. Wear ear plugs to protect ears from sparks. 11.
Quick Robotic Torch 1.02 Principal Safety Standards 1.03 Safety and Health 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. ! ! WARNING 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.
Quick Robotic Torch SECTION 2: INTRODUCTION AND DESCRIPTION 2.01 How to Use this Manual 2.03 Introduction 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.
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.
Quick Robotic Torch SECTION 3: INSTALLATION AND DISASSEMBLY 3.01 Installation 6. Remove the gas diffuser, tip and nozzle from the conductor tube assembly. 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. 7. The torch and cable assembly comes with the Miller® rear connector plug installed.
Quick Robotic Torch 17. After trimming to length, remove any obstructions from the end of the conduit radius. 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. 18. Re-install the diffuser, tip and nozzle into the conductor tube assembly. 19.
Quick Robotic Torch (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. 23. Plug or wire the other end into the proper pin locations on the robot.
Quick Robotic Torch (h) Remove the steel hose clamps from the various hose assemblies. Using pliers, position the tabs on the steel clamps to allow the clamp to be held. Twist the tab clockwise until the clamp breaks apart. (d) Remove the threaded power cable connection from the block assembly. Refer to Figure 3-12. CAUTION Do not bend the nipple(s) while twisting the tab(s) to break the clamp apart. (i) Remove the cable hose connector away from the existing cartridge kit.
Quick Robotic Torch SECTION 4: WIRING Both the switch and socket are connected to a 6-wire cable that runs along the inside of the inner protective jacket. The end of this cable extends approximately 12” (304.8mm) 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. See Table 4-1. The QRA, QRW, & QRWA torches are furnished with a switch housing mounted on the front case.
Quick Robotic Torch SECTION 5: WATER-COOLED TORCH BODY AND CABLE ASSEMBLY The water-cooled torch and cable assemblies incorporate water shut-off valves allowing the conductor tube to be removed without shutting off the water supply. This reduces the chance of introducing moisture into the conductor tube and conduit. Refer to Figure 5-1 & 5-2 showing the water shut-off valves on the QRW and QRWA Series Torch Body and Cable Assembly.
Quick Robotic Torch SECTION 6: MAINTENANCE 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. Contact tips and nozzles should be cleaned frequently.
Quick Robotic Torch SECTION 7: TROUBLESHOOTING Problem Possible Cause Wire feed inconsistent or not 1. Loose drive Rollers on feeder. smooth. 2. Dirty or plugged conduit. Corrective Action 1. Tighten drive rollers. 2. Replace conduit. 3. Conduit pulled back from diffuser. 3. Reposition conduit and tighten front screw. 4. Sharp bends or kinks in conduit. 4. Remove and replace conduit. 5. Machine improperly adjusted. 5. Reset machine per machine and wire manufacturers’ recommendations. 6.
Replacement Parts 8-14 1 3 A 4 5 B 11 12 2 6 QRA & QRAS Series Replacement Parts 7 9 10 14 8 13 21 26 13 22 14 C 27 25 EURO-KWIK REPLACEMENT PARTS 15 23 24 16 17 18 19 20 Quick Robotic Torch SECTION 8: REPLACEMENT PARTS SM-QRTORCH
Quick Robotic Torch QRA & QRAS Series Replacement Parts Item No. 1 NS 2 3 4 5 6 7 8 SM-QRTORCH Part No. --QRA-1BC QRA-2BC QRA-3BC QRA-4BC QRAS-1BC QRAS-2BC QRAS-3BC QRAS-4BC QR106RLS --QTRMS-BS QR3MS-BS QR106-S --QR-SH QR-SH3 QR-SH4 QR-FCS --QR603-CH QR6035-CH QR604-CH QR6045-CH QR605-CH QR6055-CH QR606-CH QR607-CH QR608-CH QR610-CH QR612-CH QR615-CH --QR-SP QR-SPR QR-SPHD --QR-SP QR-SPHD Stock No.
Quick Robotic Torch QRA & QRAS Series Replacement Parts (cont.) Item No. 9 10 11 Part No. --QR03-CC QR035-CC QR04-CC QR045-CC QR05-CC QR055-CC QR06-CC QR07-CC QR08-CC QR10-CC QR12-CC QR15-CC --QR03-PH QR035-PH QR04-PH QR045-PH QR05-PH QR055-PH QR06-PH QR07-PH QR08-PH QR10-PH QR12-PH QR15-PH --QR03-CV QR035-CV QR04-CV QR045-CV QR05-CV QR055-CV QR06-CV QR07-CV QR08-CV QR10-CV QR12-CV QR15-CV Stock No.
Quick Robotic Torch QRA & QRAS Series Replacement Parts (cont.) Item No. 12 Part No. Stock No. Description ----Outer Cover Assembly (Includes Nylon Cable Tie – 2 ea.) QR03-LC 3045-1226 For use with 3ft. (91cm) torch QR035-LC 3045-1227 For use with 3.5ft. (1,07m) torch QR04-LC 3045-1228 For use with 4ft. ( 1,22m) torch QR045-LC 3045-1229 For use with 4.5ft. (1,37m) torch QR05-LC 3045-1230 For use with 5ft. (1,52m) torch QR055-LC 3045-1231 For use with 5.5ft. (1,68m) torch QR06-LC 3045-1232 For use with 6ft.
Quick Robotic Torch QRA & QRAS Series Replacement Parts (cont.) Item No. Part No. 24 E171-1TS 25 --26 QTR-TOOLS 27 --QRJC-010 QRJC-020 QRJC-030 QRJC-040 QRJC-050 Stock No. 2011-2172 --2062-2034 --3045-1241 3045-1242 3045-1243 3045-1244 3045-1245 Description Euro-Kwik Adapter Conduit (Refer to Page 25) Tool Kit E-stop Jumper Cable Assembly Without Connector – 3ft. (91cm) Long With Burndy (ABB®) Connector – 3ft. (91cm) Long With 4-pin Amp Connector (Motoman®) – 3ft.
SM-QRTORCH 8-19 2 7 8 9 6 1 3 12 10 13 4 A 14 15 5 B 16 17 QRW & QRWS Series Replacement Parts 34 11 18 26 27 32 18 28 19 C EURO-KWIK REPLACEMENT PARTS 31 20 33 29 B 30 21 22 23 24 25 Quick Robotic Torch Replacement Parts
Quick Robotic Torch QRW & QRWS Series Replacement Parts Item No. 1 NS 2 3 4 5 6 7 Part No. --QRW-1BC QRW-2BC QRW-3BC QRW-4BC QRWS-1BC QRWS-2BC QRWS-3BC QRWS-4BC QR106RLS --QTRMS-BS QR3MS-BS QRW106-S --QR-SH QR-SH3 QR-SH4 QR-FCS QRW-CV --QRW603-CGH QRW6035-CGH QRW604-CGH QRW6045-CGH QRW605-CGH QRW6055-CGH QRW606-CGH QRW607-CGH QRW608-CGH QRW610-CGH QRW612-CGH QRW615-CGH Stock No.
Quick Robotic Torch QRW & QRWS Series Replacement Parts (cont.) Item No. 8 9 10 11 12 Part No. --QRW603-PC QRW6035-PC QRW604-PC QRW6045-PC QRW605-PC QRW6055-PC QRW606-PC QRW607-PC QRW608-PC QRW610-PC QRW612-PC QRW615-PC --QR-SP QR-SPR QR-SPHD --QR-SP QR-SPHD QRW174 --QR03-CC QR035-CC QR04-CC QR045-CC QR05-CC QR055-CC QR06-CC QR07-CC QR08-CC QR10-CC QR12-CC QR15-CC Stock No.
Quick Robotic Torch QRW & QRWS Series Replacement Parts (cont.) Item No. 13 14 15 16 Part No. --QR03-PH QR035-PH QR04-PH QR045-PH QR05-PH QR055-PH QR06-PH QR07-PH QR08-PH QR10-PH QR12-PH QR15-PH QRW00-WO --QRW03-WI QRW035-WI QRW04-WI QRW045-WI QRW05-WI QRW055-WI QRW06-WI QRW07-WI QRW08-WI QRW10-WI QRW12-WI QRW15-WI --QR03-CV QR035-CV QR04-CV QR045-CV QR05-CV QR055-CV QR06-CV QR07-CV QR08-CV QR10-CV QR12-CV QR15-CV Stock No.
Quick Robotic Torch QRW & QRWS Series Replacement Parts (cont.) Item No. 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 Part No. --QR03-LC QR035-LC QR04-LC QR045-LC QR05-LC QR055-LC QR06-LC QR07-LC QR08-LC QR10-LC QR12-LC QR15-LC QR-RC QRW-CS R176MH R174MH R175M-N045 R174M-N045 R175M-N116 R174M-N116 176S-H 350-174H 350-174PH QTR176LH EL176LH QTR174LH XQRW174 WC174X-B2S XQRW-CS 174X-2S WC174X-1S --QTR-TOOLS --QRJC-010 QRJC-020 QRJC-030 QRJC-040 QRJC-050 400LK-QC Stock No.
Quick Robotic Torch QRW & QRWS Series Replacement Parts (cont.) Standard Fasteners These standard fasteners are not sellable items and should be purchased at a local hardware or fastener supply house. Item No. A B C Description #10-32 x 5/8” socket head cap screw #10-32 x 3/16” stainless cup point set screw M4 x .
SM-QRTORCH 8-25 1 3 A 4 5 B 14 15 2 6 7 QRWA & QRWAS Series Replacement Parts 8 10 11 12 13 9 31 16 24 29 16 25 17 C EURO-KWIK REPLACEMENT PARTS 18 30 28 26 27 19 20 21 22 23 Quick Robotic Torch Replacement Parts
Quick Robotic Torch QRWA & QRWAS Series Replacement Parts Item No. 1 NS 2 3 4 5 6 7 8 9 Part No. --QRWA-1BC QRWA-2BC QRWA-3BC QRWA-4BC QRWAS-1BC Stock No.
Quick Robotic Torch QRWA & QRWAS Series Replacement Parts (cont.) Item No. 10 11 12 Part No. --QR03-CC QR035-CC QR04-CC QR045-CC QR05-CC QR055-CC QR06-CC QR07-CC QR08-CC QR10-CC QR12-CC QR15-CC --- Stock No.
Quick Robotic Torch QRWA & QRWAS Series Replacement Parts (cont.) Item No. 13 14 15 16 17 Part No. --QRW03-WI QRW035-WI QRW04-WI QRW045-WI QRW05-WI QRW055-WI QRW06-WI QRW07-WI QRW08-WI QRW10-WI QRW12-WI QRW15-WI --QR03-CV QR035-CV QR04-CV QR045-CV QR05-CV QR055-CV QR06-CV QR07-CV QR08-CV QR10-CV QR12-CV QR15-CV Stock No.
Quick Robotic Torch QRWA & QRWAS Series Replacement Parts Item No. 18 19 Part No. R176MH R174MH R175M-N045 20 R174M-N045 R175M-N116 21 22 23 24 25 26 27 28 29 30 31 R174M-N116 176S-H 350-174H 350-174PH QTR176LH EL176LH QTR174LH --XQR403-CH XQR4035-CH XQR404-CH XQR4045-CH XQR405-CH XQR4055-CH XQR406-CH XQR407-CH XQR408-CH XQR410-CH XQR412-CH XQR415-CH XQRWA-CS 174X-2S E171-1TS --QTR-TOOLS --QRJC-010 QRJC-020 QRJC-030 QRJC-040 QRJC-050 400LK-QC Stock No.
Quick Robotic Torch QRWA & QRWAS Series Replacement Parts (cont.) Standard Fasteners These standard fasteners are not sellable items and should be purchased at a local hardware or fastener supply house. Item No. A B C Description #10-32 x 5/8” socket head cap screw #10-32 x 3/16” stainless cup point set screw M4 x .
Quick Robotic Torch SECTION 9: ROBOTIC CONDUIT LINERS MACHINED CONDUIT STOP NEOPRENE SEAL HEAT SHRINK WIRE CONDUIT R44 Series Conduits (Steel Welding Wire) Part No. Wire Size Stock No. .035” / .045” R44-3545-1 0,9mm / 1,2mm 1440-1223 .035” / .045” R44-3545-4 0,9mm / 1,2mm 1440-1224 .035” / .045” R44-3545-8 0,9mm / 1,2mm 1440-1225 .035” / .045” R44-3545-15 0,9mm / 1,2mm 1440-1226 .052” / 1/16” R44-116-1 1,53mm / 1,6mm 1440-1228 .052” / 1/16” R44-116-4 1,53mm / 1,6mm 1440-1229 .
Quick Robotic Torch SECTION 10: 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.
Statement of Warranty LIMITED WARRANTY: THERMADYNE® warrants that its products will be free of defects in workmanship or material.
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 Scout®, Raider®, Explorer™ Original Main Power Stators and Inductors Original Main Power Rectifiers, Control P.C.
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 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 Canada 2070 Wyecroft Road Oakville, Ontario Canada, L6L5V6 Telephone: (1) 905-827-9777 Fax: (1) 905-827-9797 Thermadyne Australia 71 Gower Street Prest
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.
