ESAB Quick Fixed Automation Series Torches Guide d'installation

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AUTOMATION

SERIES TORCHES

Installation Guide and

Replacement Parts Manual

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QUICK FIXED

Art # JB-00005

Revision No: A Issue Date: November 17, 2008 Manual No: SM-QFTORCH

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.

i

!

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

(940) 566-2000

www.tweco.com

Thermadyne Industries Inc.

®

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: November 17, 2008

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.

ii

Quick fixed automation series torches

SM-QFTORCH

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 ..............................................................................................

2-4

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

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

1-1

Quick fixed automation series torches

SM-QFTORCH

SAFETY INSTRUCTIONS AND WARNINGS

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.

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.

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.

1-2

Quick fixed automation series torches

SM-QFTORCH

SAFETY INSTRUCTIONS AND WARNINGS

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-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.

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 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.

1-3

Quick fixed automation series torches

SM-QFTORCH

SAFETY INSTRUCTIONS AND WARNINGS

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.

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.

•

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.

!

WARNING

this product contains chemicals,

including lead, or otherWise produces

chemicals KnoWn to the state of

california to cause cancer, birth

defects and other reproductive harm.

Wa s h h a n d s a f t e r h a n d l i n g.

(california health & safety code § 25249.5

et seq.)

2-4

Quick fixed automation series torches

SM-QFTORCH

INTRODUCTION AND DESCRIPTION

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:

!

WARNING

a Warning gives information regarding

possible personal injury.

CAUTION

A CAUTION refers to possible equipment

damage.

NOTE

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).

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.

•

2-5

Quick fixed automation series torches

SM-QFTORCH

INTRODUCTION AND DESCRIPTION

A

rt # JB-00006

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.

Art # JB-00007

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.

3-6

Quick fixed automation series torches

SM-QFTORCH

INSTALLATION AND DISASSEMBLY

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. Check to ensure all items shown in Figure 2-1 & 2-2

on Page 2-5 are located and identiﬁed. If any of the

component parts are missing, please notify the local

Tweco

®

Welding Distributor or Tweco

®

Products Customer

Care Department at 1-800-426-1888.

3. Verify that the overall cable length is correct to ﬁt between

the feeder - torch mount combination.

4. The QF series torch and cable assemblies are furnished

with a 1-5/8” (41,28mm) Ø mounting diameter and can

be keyed in place into a ﬁxture if so desired.

5. 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.

ROTATE FRONT SLEEVE COVER

TO EXPOSE SET SCREW, ROTATE

COVER TO CONCEAL SET SCREW

PRIOR TO TORCH OPERATION.

SET SCREW

(5/32" ALLEN KEY

Art # JB-00008

Figure 3-1: Conductor Tube Locking Set Screw

6. 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.

7. 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.

WHEN CONDUCTOR TUBE IS FULLY SEATED,

GROOVE ON TUBE SHOULD LINE UP WITH

EDGE OF INSULATING SLEEVE.

Art # JB-00009

Figure 3-2: Conductor Tube Installation

8. Remove the gas diffuser, tip, and nozzle from the

conductor tube assembly.

9. 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.

10. The QF 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 8-18 listing the

various conduits that are available.

11. Remove the conduit from the package and uncoil carefully.

CAUTION

Bending or distorting the conduit can cause wire

feed problems.

12. 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.

SET SCREW

TWECO PLUG

CONDUIT ASSEMBLY

A

rt # JB-00010

Figure 3-3: Conduit Installation with Set Screw

MILLER PLUG

CONDUIT ASSEMBLY

PLUG NIPPLE

A

rt # JB-00011

Figure 3-4: Conduit Installation with Plug Nipple (Miller

®

style)

13. 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.

14. 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.

15. When the conduit is completely through the torch and

conductor tube assembly, seat the brass conduit stop

ﬁrmly against the connector plug.

3-7

Quick fixed automation series torches

SM-QFTORCH

INSTALLATION AND DISASSEMBLY

16. 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.

17. 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.

CONDUIT SET SCREW HOLE

A

rt # JB-00012

Figure 3-5: Access hole for Conduit Set Screw

18. Trim the conduit extending from the front of the conductor

tube assembly by following the steps below:

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.

Conductor Tube Assemby 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)

¼” (6,35mm)

QTRW66 Series – (For use with QRW & QRWA series torch/cable assemblies)

5/16” (7,92mm)

Table 3-1: Conductor Tube Cut Lengths

CUT LINE

A

”B“ DOHTEM”A“ DOHTEM

Art # JB-00013

19. After trimming to length, remove any obstructions from the end of the conduit radius.

20. Re-install the diffuser, tip, and nozzle onto the conductor tube assembly.

21. Loosen the ﬁxture connection and insert the cartridge kit of the torch and conductor tube assembly into position. The

keystock located on the cartridge kit should be placed into the mating slot on the ﬁxture until the sleeve bottoms against

the ﬁxture plate. Re-tighten the connection to secure the assembly in place. Refer to Figure 3-7.

KEYSTOCK

A

rt # JB-00014

Figure 3-7: Locating Keystock

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.

22. Install the rear connector plug into the feeder.

23. If the torch being installed is a water-cooled QFW 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.

Figure 3-6: Conduit Cut Length

3-8

Quick fixed automation series torches

SM-QFTORCH

INSTALLATION AND DISASSEMBLY

CAUTION

Operating a water-cooled torch and cable

assembly without water or restricted ﬂow will

result in damage to the cable assembly.

24. The torch and cable assembly is furnished with a purge

hose than can be used to supply inert gas and or anti-

spatter through the torch block and conductor tube

assembly. To use this purge hose, remove the plastic

plug and connect accordingly.

25. The torch is now ready to place into operation.

3.02 Disassembly

1. To disassemble the torch and cable assembly from the

ﬁxture, reverse the steps noted in Section 3.01.

4-9

Quick fixed automation series torches

SM-QFTORCH

WATER -COOLED TORCH BODY & CABLE ASSEMBLY

SECTION 4:

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 4-1 showing the water shut-off valves on the QFW Series Torch Body and Cable Assembly.

VALVE

SPRING

HOSE NIPPLE

Art # JB-00015

Figure 4-1: QFW Series Check Valves

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.

If the threaded power connection is removed from the QRW series block assembly make sure the component parts making up the

check valve remains inside of the block assembly. If the components are removed, make sure they are installed properly.

5-10

Quick fixed automation series torches

SM-QFTORCH

MAINTENANCE

Each Use

Visual check of torch

Consumable parts

Weekly

Visually inspect the torch

body and consumables

Visually inspect the

cables and leads.

Replace as needed

3 Months

Clean

exterior

of power supply

6 Months

Replace all

broken parts

Visually check and

use a vacuum to carefully

clean the interior

Gas and

air lines

dwg-00032

Visually inspect the Wire

feed mechanisms

Warning!

Disconnect input power before maintaining.

Maintain more often

if used under severe

conditions.

Visual check of

regulator and pressure

SECTION 5:

MAINTENANCE

Contact tips and nozzles should be cleaned frequently. Spatter

buildup may cause bridging between nozzle and tip. This

could cause electrical shorting between the nozzle and work

piece as well as restricting gas ﬂow.

Regularly inspect the conductor tube, torch and cable

assembly for abrasions, cuts, and undue wear. Replace or

repair any parts as needed.

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 de-grade, 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.

6-11

Quick fixed automation series torches

SM-QFTORCH

TROUBLESHOOTING

SECTION 6:

TROUBLESHOOTING

Problem Possible Cause Corrective Action

Wire feed inconsistent or not

smooth.

1. Loose drive rollers on feeder.

2. Dirty or plugged conduit

3. Conduit pulled back from diffuser.

4. Sharp bends or kinks in conduit.

5. Machine improperly adjusted.

6. Spatter buildup on end of contact

tip.

7. Loose contact tip or diffuser.

8. Excessively worn contact tip.

9. Loose ground cable or ground

clamp.

1. Tighten drive rollers.

2. Replace conduit.

3. Reposition conduit and tighten front

screw.

4. Remove and replace conduit.

5. Reset machine per machine and wire

manufacturers’ recommendations.

6. Clean or replace contact tip.

7. Tighten contact tip and diffuser plier

tight.

8. Replace contact tip.

9. Tighten or replace as required.

Torch and cable assembly is running hot. 1. L o o s e p o w e r c o n n e c t i o n .

2. Loose or undersize ground cable or

ground clamp.

3. Conductor tube not tight in torch

block.

4. Loose contact tip or diffuser.

5. Operating torch and cable assembly

above recommended amperage

rating.

6. Power cable assembly damaged.

7. Restricted water flow (only QFW

series torch).

1. Inspect complete torch and cable for

loose connections and tighten.

2. Tighten or replace as required.

3. Tighten stainless setscrew in torch

block.

4. Tighten contact tip and diffuser.

5. Readjust machine to correct

setting for size of torch being used.

6. Inspect and replace accordingly.

7. Inspect water lines for any excessive

bends.

Porous weld 1. Poor or improper gas flow.

2. Moisture from torch/conductor tube.

1. Dirty or contaminated wire.

2. Base metal contamination.

1. Check gas ﬂow out of conductor tube

nozzle. Check for leaks or restrictions

in gas hoses and connections.

2. Check O-rings on conductor tube and

torch block. Check the torch block for

any scarring, gouges to the surface.

1. Change wire.

2. Replace base metal.

7-12

Quick fixed automation series torches

SM-QFTORCH

REPLACEMENT PARTS

SECTION 7:

REPLACEMENT PARTS

QFA Replacement Parts

1

4

8

11

9

15

17

16

18

13

14

19

3

2

5

6 7 10 12

A

rt # JB-00016

7-13

Quick fixed automation series torches

SM-QFTORCH

REPLACEMENT PARTS

QFA Series Replacement Parts

Item No. Part No. Stock No. Description

1 --- --- Cartridge Kit - (Includes Item #2, #3, and Hose Clamps)

QRA-1BC 3045-1150 For use with 1-5/8” (41,28mm) Ø Mount – QRA Series - ***

NS QR106RLS 3045-1341 Replacement Locking Set Screw F/Torch Block (Pkg. of 5 ea.)

2 --- --- Key

QTRMS-BS 3045-1156 For use with QRA-1BC Cartridge Kit (Pkg. of 5 ea.)

3 QR106-S 3045-1158 Conduit Screw (Pkg. of 5 ea.)

4 QR-FC 3045-1161 Front Case (Includes Item “B”)

5 --- --- QFA Power Cable Assy (Includes Hose Clamps)

QR604-CH 3045-1166 For use with 4ft. ( 1,22m) torch

QR606-CH 3045-1170 For use with 6ft. (1,83m) torch

QR608-CH 3045-1172 For use with 8ft. (2,44m) torch

QR610-CH 3045-1173 For use with 10ft. (3m) torch

QR612-CH 3045-1174 For use with 12ft. (4m) torch

QR615-CH 3045-1175 For use with 15ft. (5m) torch

6 --- --- Front Spring

QR-SPR 3045-1177 For use with 4ft. (1,22m) through 7ft. (2,13m) torches

QR-SPHD 3045-1178 For use with 8ft. (2,44m) through 15ft. (5m) torches

7 --- --- Rear Spring

QTR-SP 3045-1176 For use with 3ft. (91cm) & 3.5ft. (1,07m) torches

QR-SPHD 3045-1178 For use with 4ft. (1,22m) through 15ft. (5m) torches

8 --- --- Purge Hose Assembly (Includes Hose Plug Nipple & Clamp)

QR04-PH 3045-1202 For use with 4ft. ( 1,22m) torch

QR06-PH 3045-1206 For use with 6ft. (1,83m) torch

QR08-PH 3045-1208 For use with 8ft. (2,44m) torch

QR10-PH 3045-1209 For use with 10ft. (3m) torch

QR12-PH 3045-1210 For use with 12ft. (4m) torch

QR15-PH 3045-1211 For use with 15ft. (5m) torch

9 --- --- Kevlar

®

/Nylon Cover Assembly (Includes Cable Tie – 2 each)

QR04-LC 3045-1228 For use with 4ft. ( 1,22m) torch

QR06-LC 3045-1232 For use with 6ft. (1,83m) torch

QR08-LC 3045-1234 For use with 8ft. (2,44m) torch

QR10-LC 3045-1235 For use with 10ft. (3m) torch

QR12-LC 3045-1236 For use with 12ft. (4m) torch

QR15-LC 3045-1237 For use with 15ft. (5m) torch

10 QR-RC 3045-1238 Rear Spring Cap

11 QRA-CS 3045-1239 Rear Case Assembly

12 R176MH 2060-2184 Miller

®

Connector Plug (Includes Items #16 & 17) - ***

R174MH 2035-2109 Miller

®

Connector Plug (Includes Items #16 & #17)

13 R175M-N045 2050-2181 Miller

®

Plug Nipple, .045” (1,0mm) Wire (Use w/R176MH) - ***

R174M-N045 2040-2192 Miller

®

Plug Nipple, .045” (1,0mm) Wire (Use w/R174MH)

14 R175M-N116 2050-2182 Miller

®

Plug Nipple, .062” (1,6mm) Wire (Use w/R176MH) - ***

R174M-N116 2040-2191 Miller

®

Plug Nipple, .062” (1,6mm) Wire (Use w/R174MH)

*** Standard on all QFA Series Torch Body and Cable Assemblies

7-14

Quick fixed automation series torches

SM-QFTORCH

REPLACEMENT PARTS

Item No. Part No. Stock No. Description

15 176S-H 2060-2177 Tweco

®

Connector Plug - ***

350-174H 2035-2110 Tweco

®

Connector Plug (Uses R44 series Conduit)

16 350-174PH 2035-2172 Panasonic

®

Connector Plug (Uses R44 series Conduit )

17 QTR176LH 2086-2624 Lincoln

®

Connector Plug (2.71” – 68,83mm OAL.) - ***

EL176LH 2060-2680 Lincoln

®

Connector Plug (3.84” – 97,54mm OAL)

QTR174LH 2086-2623 Lincoln

®

Connector Plug (Uses R44 series Conduit)

18 --- --- Conduit (Refer to Page 18)

19 QTR-TOOLS 2062-2034 Tool Kit

Standard Fasteners

These standard fasteners are not sellable items and must be purchased at a local hardware or fastener supply house.

Item No. Description

A #10-32 x 3/16” Stainless Cup Point Set Screw

QFA Series Replacement Parts (cont.)

*** Standard on all QFA Series Torch Body and Cable Assemblies

7-15

Quick fixed automation series torches

SM-QFTORCH

REPLACEMENT PARTS

QFW Series Replacement Parts

10

1

4

9

12

14

5

2

3

6

7 8 13 15

A

11

23

18

20

19

21

16

17

22

Art # JB-00017

7-16

Quick fixed automation series torches

SM-QFTORCH

REPLACEMENT PARTS

QFW Series Replacement Parts

Item No. Part No. Stock No. Description

1 --- --- Cartridge Kit - (Includes Item #2, #3 and Hose Clamps)

QRWA-1BC 3045-1288 For use with 1-5/8” (41,28mm) Ø Mount – QRWA Series - ***

NS QR106RLS 3045-1341 Replacement Locking Set Screw F/Torch Block (Pkg. of 5 ea.)

2 --- --- Key

QTRMS-BS 3045-1156 For use with QRA-1BC (Pkg. Of 5 ea.)

3 QR106-S 3045-1158 Conduit Screw (Pkg. Of 5 ea.)

4 QR-FC 3045-1161 Front case (Includes Item “B”)

5 QRW-CV 3045-1304 Check Valve Assembly (Includes O-rings)

6 --- --- QFW Power Cable Assy (Includes Hose Clamp)

QR404-CH 3045-1252 For use with 4ft. ( 1,22m) torch

QR406-CH 3045-1256 For use with 6ft. (1,83m) torch

QR408-CH 3045-1258 For use with 8ft. (2,44m) torch

QR410-CH 3045-1259 For use with 10ft. (3m) torch

QR412-CH 3045-1260 For use with 12ft. (4m) torch

QR415-CH 3045-1261 For use with 15ft. (5m) torch

7 --- --- Front Spring

QR-SPR 3045-1177 For use with 4ft. (1,22m) through 7ft. (2.13m) torches

QR-SPHD 3045-1178 For use with 8ft. (2,44m) through 15ft. (5m) torches

8 --- --- Rear Spring

QR-SPHD 3045-1178 For use with 4ft. (1,22m) through 15ft. (5m) torches

9 --- --- Purge Hose Assembly (Includes Hose Nipple Plug & Hose Clamp)

QR04-PH 3045-1202 For use with 4ft. ( 1,22m) torch

QR06-PH 3045-1206 For use with 6ft. (1,83m) torch

QR08-PH 3045-1208 For use with 8ft. (2,44m) torch

QR10-PH 3045-1209 For use with 10ft. (3m) torch

QR12-PH 3045-1210 For use with 12ft. (4m) torch

QR15-PH 3045-1211 For use with 15ft. (5m) torch

10 --- --- Water-Out Hose Assembly (Includes Hose Clamp)

QRW04-WO 3045-1265 For use with 4ft. ( 1,22m) torch

QRW06-WO 3045-1269 For use with 6ft. (1,83m) torch

QRW08-WO 3045-1271 For use with 8ft. (2,44m) torch

QRW10-WO 3045-1272 For use with 10ft. (3m) torch

QRW12-WO 3045-1273 For use with 12ft. (4m) torch

QRW15-WO 3045-1274 For use with 15ft. (5m) torch

11 --- --- Water-In Hose Assembly (Includes Hose Clamps)

QRW04-WI 3045-1277 For use with 4ft. ( 1,22m) torch

QRW06-WI 3045-1281 For use with 6ft. (1,83m) torch

QRW08-WI 3045-1283 For use with 8ft. (2,44m) torch

QRW10-WI 3045-1284 For use with 10ft. (3m) torch

QRW12-WI 3045-1285 For use with 12ft. (4m) torch

QRW15-WI 3045-1286 For use with 15ft. (5m) torch

*** Standard on all QFW Series Torch Body and Cable Assemblies

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ESAB Quick Fixed Automation Series Torches Guide d'installation

ESAB Quick Fixed Automation Series Torches Guide d'installation

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