ESAB QFA600 QFW600 Quick Fixed Automation Direct Plug Torches Guide d'installation

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QUICK FIXED

AUTOMATION DIRECT

PLUG TORCHES

Installation Guide and

English

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QFA600

QFW600

Replacement Parts List

QFW600 TORCH

QFA600 TORCH

Qfa600 Torch

Qfw600 Torch

Revision: A Issue Date: November 11, 2008 Form No: SM-QFDP

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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, please contact a representative at the address and phone

number in your area listed on the inside back cover of this manual, or visit

us on the web at www.tweco.com.

This Operating Manual has been designed to instruct you on the correct use

and operation 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.

WE APPRECIATE YOUR BUSINESS!

!

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 Direct Plug Torches

Installation and Operation Guide

Instruction Manual Number SM-QFDP

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 11, 2008

Record the following information for Warranty purposes:

Where Purchased: ________________________

Purchase Date: ________________________

Equipment Serial #: ________________________

i

quick fixed automation direct plug torches

ii

SM-QFDP

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 ................................................. 1-4

2.01 How to Use this Manual ............................................................................1-4

2.02 Receipt of Equipment ................................................................................1-4

2.03 Introduction .............................................................................................1-4

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

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

3.02 Disassembly ..............................................................................................3-7

3.03 Water-Cooled Torch Assembly ..................................................................3-7

SECTION 4: MAINTENANCE ..........................................................................

4-8

SECTION 5: REPLACEMENT PARTS .................................................................

5-9

STATEMENT OF WARRANTY ........................................................................

6-11

quick fixed automation direct plug torches

1-1

SM-QFDP

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.

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.

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.

quick fixed automation direct plug torches

1-2

SM-QFDP

SAFETY INSTRUCTIONS AND WARNINGS

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 w

eld 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.

11. Keep smoke, fumes, and gases away 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.

WARNING

ARC RAYS, HOT SLAG, AND SPARKS CAN INJURE

EYES AND BURN SKIN .

17. The welding and cutting processes produces 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.

quick fixed automation direct plug torches

1-3

SM-QFDP

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.

quick fixed automation direct plug torches

1-4

SM-QFDP

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: CDROBOTICS.

!

SECTION 2:

INTRODUCTION AND DESCRIPTION

2.03 Introduction

The Tweco

®

Robotics Quick Fixed Automation Direct Plug

Torch series are offered in air-cooled and water-cooled

assemblies that accept the QTR and QTRW series robotic

conductor tubes.

Standard Features

Quick conductor tube lock for easy conductor tube

replacement.

Water-cooled torch body with built in water shut-off

valves.

Quick hose connections.

Internal purge hose for spraying anti-spatter through

the conductor tube and nozzle.

All assemblies are furnished with a Tweco

®

, Miller

®

,

and Lincoln

®

rear connector plug.

QFA — Air-cooled Torch Assembly

The air-cooled assembly uses the QTR66 robotic air-

cooled conductor tubes and is rated at 600 amperes @

60% duty cycle.

QFW — Water-cooled Torch Assembly

The water-cooled assembly uses the QTRW63, QTRW64,

or QTRW66 water-cooled conductor tubes and is rated at

600 amperes @ 100% duty cycle.

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.

•

quick fixed automation direct plug torches

1-5

SM-QFDP

INTRODUCTION AND DESCRIPTION

1

2

3

4

5

Item No. Description Qty.

1

QFA600 Torch Body With Purge Hose & Miller

®

Rear

Connector Plug

1 ea.

2 R45-116-1 Conduit Liner 1 ea.

3 Tweco

®

Rear Connector Plug 1 ea.

4 Lincoln

®

Rear Connector Plug 1 ea.

5 Installation Package With Tools 1 ea.

Figure 1A: QFA600 Air-Cooled Torch Package

Item No. Description Qty.

1

QFA600 Torch Body With Purge Hose & Miller

®

Rear

Connector Plug

1 ea.

2 R45-116-1 Conduit Liner 1 ea.

3 Tweco

®

Rear Connector Plug 1 ea.

4 Lincoln

®

Rear Connector Plug 1 ea.

5 Installation Package with Tools 1 ea.

6 Quick Hose Water Connectors 1 kit

1

2

3

4

5

6

Figure 1B: QFW600 Water-Cooled Torch Package

quick fixed automation direct plug torches

3-6

SM-QFDP

INSTALLATION AND OPERATION

SECTION 3:

INSTALLATION AND OPERATION

3.01 Installation

1. Remove the torch assembly from the carton.

2. Check to ensure all items, shown in Figure 1A or 1B are

located and identiﬁed. If any of the component parts

are missing, please notify the local Tweco Welding

Distributor or Tweco

®

Products Customer Service

Department at 1-800-426-1888.

3. The torch 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 the cable assembly. This

connection should be wrench tight.

4. The QF Series torch 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 Section 5, page

5-9 and 5-10, listing the various conduits that are

available.

5. Remove the conduit from the package.

CAUTION

Bending or distorting the conduit can cause

wire feed problems.

6. 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 2A & 2B.

8. When the conduit is completely through the torch

assembly, seat the brass conduit stop ﬁrmly against

the connector plug.

9. 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.

10. Locate the hole in the torch case providing access

to the conductor tube locking set screw. Insert the

factory supplied 5/32” T-handle allen wrench into the

set screw and rotate counterclockwise until it stops.

Refer to Figure 3.

Figure 2A: Conduit Installation With Set Screw

Figure 2B: Conduit Installation With Plug Nipple (Miller

®

Style)

7. Insert the exposed raw coil end of the conduit, factory

supplied, into the rear connector plug. Feed the

conduit through the torch assembly.

Figure 3: Conductor Tube Locking Set Screw

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

conductor tube assembly.

12. 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.

13. 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 4.

WHEN CONDUCTOR TUBE IS FULLY

SEATED, GROOVE ON TUBE SHOULD

LINE UP WITH EDGE OF INSULATING

SLEEVE.

Figure 4: Conductor Tube Installation

SET SCREW (5/32” ALLEN KEY)

quick fixed automation direct plug torches

3-7

SM-QFDP

INSTALLATION AND OPERATION

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

series, refer to Section 4 for further instructions on

water supply requirements.

15. 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 5 — Method “A”.

Method “B” – The diffusers have a machined

groove around the outer diameter. Position the

diffuser as shown in Figure 5 — Method “B” and

mark and cut the conduit.

Conductor Tube Assembly Cut Length “A”

QTR66 Series (For use with QFA)

1-5/16”

(33,32mm)

QTRW63 Series (For use with QFA)

15/16”

(23,80mm)

QTRW64 Series (For use with QFA)

1/4” (6,35mm)

QTRW66 Series (For use with QFA)

5/16”

(7,92mm)

A

Figure 5: Conduit Cut Length

METHOD “A”

METHOD “B”

CUT LINE

16. After trimming to length, radius and remove any

obstructions from the end of the conduit.

17. Re-install the diffuser, tip and nozzle into the conductor

tube assembly.

18. Install the rear connector plug into the feeder.

19. The torch 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.

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

3.02 Disassembly

1. To disassemble the torch assembly, reverse the steps

noted in Section 3.

3.03 Water-Cooled Torch Assembly

The water-cooled torch 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 6 showing the water shut-off

valves on the QFW series torch assembly.

VALVE

SPRING

WATER

PLUG

Figure 6: QFW 600 Check Valves

1. A water supply providing not less than 3/4 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.

2. Connect the water hose labeled “Water-In” on the torch

assembly to the “Water-Out” of the water supply.

3. Connect the water hose labeled “Water-Out” on

the torch assembly to the “Water-In” of the water

supply.

quick fixed automation direct plug torches

4-8

SM-QFDP

INSTALLATION AND OPERATION

SECTION 4:

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.

Problem Possible Cause Corrective Action

Wire feed

inconsistent or

not smooth.

1. Loose drive Rollers on feeder. 1. Tighten drive rollers.

2. Dirty or plugged conduit. 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. Spatter buildup on end of contact tip. 6. Clean or replace contact tip.

7. Loose contact tip or diffuser. 7. Tighten contact tip and diffuser pliers

tight.

8. Excessively worn contact tip. 8. Replace contact tip.

9. Loose ground cable or ground clamp. 9. Tighten or replace as required.

Torch assembly

is running hot.

1. Loose power connection. 1. Inspect complete torch and cable for loose

connections and tighten.

2. Loose or undersize ground cable or ground

clamp.

2. Tighten or replace as required.

3. Conductor tube not tight in torch block. 3. Tighten stainless setscrew in torch block.

4. Loose contact tip or diffuser. 4. Tighten contact tip and diffuser.

5. Operating torch and conductor tube assembly

above recommended amperage rating.

5. Readjust machine to correct setting for size

of torch being used.

6. Restricted water ﬂow (only QRW and QRWA

series torch).

6. Inspect water lines for any excessive

bends.

Porous weld.

1. Poor or improper gas ﬂow. 1. Check gas flow out of conductor tube

nozzle. Check for leaks or restrictions in

gas hoses and connections.

2. Moisture from torch/conductor tube. 2. Check o-rings on conductor tube and

torch block. Check the torch block for any

scarring, gouges to the surface.

3. Dirty or contaminated wire. 3. Change wire.

4. Base metal contamination. 4. Replace base metal.

quick fixed automation direct plug torches

5-9

SM-QFDP

REPLACEMENT PARTS

SECTION 5:

REPLACEMENT PARTS

1

2

3

7

6

54

QFA600 Air-Cooled Torch

Item No. Part No. Stock No. Description

1 QFA600BC 3045-1154 Air-cooled Block Cartridge

2

R176MH 2060-2184 Miller

®

Connector Plug (Includes Item #3) ***

R174MH 2035-2109 Miller

®

Connector Plug (Includes Item #3)

3

R175M-N045 2050-2181 Miller

®

Plug Nipple, .045” (1,0mm) Wire Use with R176MH

R174M-N045 2040-2192 Miller

®

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

R175M-N116 2050-2182 Miller

®

Plug Nipple, .062” (1,6mm) Wire Use with R176MH

R174M-N116 2040-2191 Miller

®

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

4

R45-3545-1 1450-1023 R45 Series Conduit Liner

R45-116-1 1450-1028 R45 Series Conduit Liner ***

R44-3545-1 1440-1223 R44 Series Conduit Liner

R44-116-1 1440-1228 R44 Series Conduit Liner

5

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)

6

176S-H 2060-2177 Tweco Connector Plug ***

350-174H 2035-2110 Tweco Connector Plug (Uses R44 Series Conduit)

7 QF600PH 3045-1246 Purge Hose Assembly (Includes Hose Clamp)

*** Standard on all QFA Series Torch Body Assembly

Replacement Parts: QFA600

quick fixed automation direct plug torches

5-10

SM-QFDP

REPLACEMENT PARTS

1

2

3

7

8

9

10

6

5

4

QFW600 Water-Cooled Torch

Item No. Part No. Stock No. Description

1 QFW600BC 3045-1386 Water-cooled Block Cartridge

2

R176MH 2060-2184 Miller

®

Connector Plug (Includes Item #3) ***

R174MH 2035-2109 Miller

®

Connector Plug (Includes Item #3)

3

R175M-N045 2050-2181 Miller

®

Plug Nipple, .045” (1,0mm) Wire Use with R176MH

R174M-N045 2040-2192 Miller

®

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

R175M-N116 2050-2182 Miller

®

Plug Nipple, .062” (1,6mm) Wire Use with R176MH

R174M-N116 2040-2191 Miller

®

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

4

R45-3545-1 1450-1023 R45 Series Conduit Liner

R45-116-1 1450-1028 R45 Series Conduit Liner ***

R44-3545-1 1440-1223 R44 Series Conduit Liner

R44-116-1 1440-1228 R44 Series Conduit Liner

5

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)

6

176S-H 2060-2177 Tweco Connector Plug ***

350-174H 2035-2110 Tweco Connector Plug (Uses R44 Series Conduit)

7 QF600PH 3045-1246 Purge Hose Assembly (Includes Hose Clamp)

8 QFW600-WO 3045-1324 Water Hose – OUT (Includes Hose Clamp)

9 QFW600-WI 3045-1323 Water Hose – IN (Includes Hose Clamp)

10 400LK-QC 2044-2000 Quick Connector Male & Female

*** Standard on all QFW Series Torch Body Assembly

Replacement Parts: QFW600

quick fixed automation direct plug torches

6-11

SM-QFDP

STATEMENT OF WARRANTY

LIMITED WARRANTY: THERMADYNE

®

warrants that its products will be free of defects in workmanship or material.

Should any failure to conform to this warranty appear within the time period applicable to the THERMADYNE products

as stated below, THERMADYNE shall, upon notiﬁcation thereof and substantiation that the product has been stored,

installed, operated, and maintained in accordance with THERMADYNE’s speciﬁcations, instructions, recommendations

and recognized standard industry practice, and not subject to misuse, repair, neglect, alteration, or accident, correct

such defects by suitable repair or replacement, at THERMADYNE’s sole option, of any components or parts of the

product determined by THERMADYNE to be defective.

THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING

ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE.

LIMITATION OF LIABILITY: THERMADYNE shall not under any circumstances be liable for special or consequential

damages, such as, but not limited to, damage or loss of purchased or replacement goods, or claims of customers of

distributor (hereinafter the “Purchaser”) for service interruption. The remedies of the Purchaser set forth herein are

exclusive and the liability of THERMADYNE with respect to any contract, or anything done in connection therewith such

as the performance or breach thereof, or from the manufacture, sale, delivery, resale, or use of any goods covered by or

furnished by THERMADYNE whether arising out of contract, negligence, strict tort, or under any warranty, or otherwise,

shall not, except as expressly provided herein, exceed the price of the goods upon which such liability is based.

THIS WARRANTY BECOMES INVALID IF REPLACEMENT PARTS OR ACCESSORIES ARE USED WHICH MAY IMPAIR

THE SAFETY OR PERFORMANCE OF ANY THERMADYNE PRODUCT.

THIS WARRANTY IS INVALID IF THE PRODUCT IS SOLD BY NON-AUTHORIZED PERSONS.

This warranty is effective for the time stated in the Warranty Schedule beginning on the date that the authorized

distributor delivers the products to the Purchaser.

Warranty repairs or replacement claims under this limited warranty must be submitted by an authorized THERMADYNE

repair facility within thirty (30) days of the repair. No transportation costs of any kind will be paid under this warranty.

Transportation charges to send products to an authorized warranty repair facility shall be the responsibility of the

Purchaser. All returned goods shall be at the Purchaser’s risk and expense. This warranty supersedes all previous

THERMADYNE warranties.

quick fixed automation direct plug torches

6-12

SM-QFDP

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 Parts / Labor

Scout

®

, Raider

®

, Explorer™

Original Main Power Stators and Inductors 3 years / 3 years

Original Main Power Rectiﬁers, Control P.C. Boards 3 years / 3 years

All Other Original Circuits and Components Including, but not Limited to, Relays, Switches, Contactors, Solenoids, Fans, Power Switch Semi-Conductors 1 year / 1 year

Engines and Associated Components are NOT Warranted by Thermal Arc

®

, Although Most are Warranted by the Engine Manufacturer. SEE THE ENGINE

MANUFACTURERS’ WARRANTY FOR DETAILS.

See the Engine Manufacturers’ Warranty

for Details

GMAW/FCAW (MIG) Welding Equipment Parts / Labor

Fabricator

®

131, 181, 190, 210, 251, 281; Fabstar

®

4030; PowerMaster

®

350, 350P, 500, 500P; Excel-Arc

®

6045; Wire Feeders: Ultrafeed

®

, Porta-feed

®

Original Main Power Transformer and Inductor 5 years / 3 years

Original Main Power Rectiﬁers, Control P.C. Boards, Power Switch Semi-Conductors 3 years / 3 years

All Other Original Circuits and Components Including, but not Limited to, Relays, Switches, Contactors, Solenoids, Fans, Electric Motors 1 year / 1 year

GTAW (TIG) & Multi-process Inverter Welding Equipment Parts / Labor

160TS, 300TS, 400TS, 185AC/DC, 200AC/DC, 300AC/DC, 400GTSW, 400MST, 300MST, 400MSTP

Original Main Power Magnetics 5 years / 3 years

Original Main Power Rectiﬁers, Control P.C. Boards, Power Switch Semi-Conductors 3 years / 3 years

All Other Original Circuits and Components Including, but not Limited to, Relays, Switches, Contactors, Solenoids, Fans, Electric Motors 1 year / 1 year

Plasma Welding Equipment Parts / Labor

Ultima

®

150

Original Main Power Magnetics 5 years / 3 years

Original Main Power Rectiﬁers, Control P.C. Boards, Power Switch Semi-Conductors 3 years / 3 years

Welding Console, Weld Controller, Weld Timer 3 years / 3 years

All Other Original Circuits and Components Including, but not Limited to, Relays, Switches, Contactors, Solenoids, Fans, Electric Motors, Coolant Recirculators 1 year / 1 year

SMAW (Stick) Welding Equipment Parts / Labor

Dragster™ 85

Original Main Power Magnetics 1 year / 1 year

Original Main Power Rectiﬁers, Control P.C. Boards 1 year / 1 year

All Other Original Circuits and Components Including, but not Limited to, Relays, Switches, Contactors, Solenoids, Fans, Power Switch Semi-Conductors 1 year / 1 year

160S, 300S, 400S

Original Main Power Magnetics 5 years / 3 years

Original Main Power Rectiﬁers, Control P.C. Boards 3 years / 3 years

All Other Original Circuits and Components Including, but not Limited to, Relays, Switches, Contactors, Solenoids, Fans, Power Switch Semi-Conductors 1 year / 1 year

General Arc Equipment Parts / Labor

Water Recirculators 1 year / 1 year

Plasma Welding Torches 180 days / 180 days

Gas Regulators (Supplied with Power Sources) 180 days / NA

MIG and TIG Torches (Supplied with Power Sources) 90 days / NA

Replacement Repair Parts 90 days / NA

MIG, TIG and Plasma Welding Torch Consumable Items NA / NA

Gas Welding and Cutting Equipment Parts / Labor

Victor

®

Professional 5 years / NA

Oxygen Conservers 2 years / NA

Aluminum Cylinders Lifetime / NA

Cutting Machine Motors 1 year / NA

HP&I Brass Regulators/Manifolds 2 years / NA

HP&I Stainless Regulators/Manifolds 1 year / NA

HP&I Corrosive Gas Regulators/Manifolds 90 days / NA

TurboTorch

®

3 years / NA

CutSkill

®

2 years / NA

Steel Cylinders 1 year / NA

Victor Medical 6 years / NA

Victor VSP 2 years / NA

Firepower

®

MIG Welders 5-2-1 years / NA

Transformers 5 years / NA

Parts Used in Rental Applications

1 year from date sold by seller to authorized

distributor

MIG Torches and Arc Accessories Parts / Labor

Arcair

®

N6000 90 days / NA

Eliminator

®

Spool and Pull Guns 90 days / NA

Robotic Deﬂection Mounts 90 days / NA

QRM-100 Anti-Spatter Applicator 90 days / NA

TC and TCV Water Coolers 1 year / NA

TSC-96 Smoke Collector 1 year / NA

ESG-1, EPG-CR1, EPG-CR2 Control Boxes for Eliminator Spool & Pull Guns 1 year / NA

QRC-2000 Nozzle Cleaning Stations 1 year / 1 year

QRC-3000 UltraSonic Cleaning Stations 2 years / 2 years

All other products 30 days from date purchaser purchases from seller. 30 days / NA

Plasma Cutting Systems Parts / Labor

Automated Plasma 2 years / 1 year

CutMaster™ 3 years / 3 years

PakMaster

®

XL PLUS 3 years / 1 year

Drag-Gun

®

1 year / 1 year

Drag-Gun Plus 2 years / 1 year

Torches 1 year / 1 year

Consoles, Control Equipment, Heat Exchangers and Accessory Equipment 1 year / 1 year

W O R L D H E A D Q U A R T E R S : 1 6 0 5 2 S w i n g l e y R i d g e R o a d , S u i t e 3 0 0 • S t . Lo u i s , M i s s o u r i 6 3 0 1 7 U. S . A .

A Global Cutting & Welding Market Leader

™

Denton, TX USA

U.S. Customer Care

Ph: (1) 800-426-1888

Fax: (1) 800-535-0557

Miami, FL USA

Sales Office, Latin America

Ph: (1) 954-727-8371

Fax: (1) 954-727-8376

Oakville, Ontario, Canada

Canada Customer Care

Ph: (1) 905-827-4515

Fax: (1) 800-588-1714

International Customer Care

Ph: (1) 905-827-9777

Fax: (1) 905-827-9797

Chorley, United Kingdom

Customer Care

Ph: (44) 1257-261755

Fax: (44) 1257-224800

Milan, Italy

Customer Care

Ph: (39) 0236546801

Fax: (39) 0236546840

Cikarang, Indonesia

Customer Care

Ph: 62 21+ 8983-0011 / 0012

Fax: 62 21+ 893-6067

Osaka, Japan

Sales Office

Ph: 816-4809-8411

Fax: 816-4809-8412

Melbourne, Australia

Australia Customer Care

Ph: 1300-654-674

Fax: 613+ 9474-7391

International

Ph: 613+ 9474-7508

Fax: 613+ 9474-7488

Rawang, Malaysia

Customer Care

Ph: 603+ 6092-2988

Fax: 603+ 6092-1085

Shanghai, China

Sales Office

Ph: 86-21-64072626

Fax: 86-21-64483032

Singapore

Sales Office

Ph: 65+ 6832-8066

Fax: 65+ 6763-5812

THE AMERICAS EUROPE ASIA/PACIFIC

U.S. Customer Care: ARCAIR

®

/ STOODY

®

/ THERMAL ARC

®

/ THERMAL DYNAMICS

®

/ TWECO

®

/ VICTOR

®

................... 800-426-1888 / FAX 800-535-0557

FIREPOWER

®

................. 800-858-4232 / FAX 800-535-0557 TDC AUTOMATION................... 866-279-2628 / FAX 800-535-0557

TURBOTORCH

®

............. 800-238-0282 / FAX 800-535-0557 VICTOR MEDICAL .................... 800-382-8187 / FAX 800-535-0557

VICTOR SPECIALTY PRODUCTS ................... 800-569-0547 / FAX 800-535-0557

Canada Customer Care: 905-827-4515 / FAX 800-588-1714

•

International Customer Care: 905-827-9777 / FAX 905-827-9797

CIGWELD Customer Care: 1300-654-674 / FAX 613+ 9474-7391

•

www.thermadyne.com

50

60

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SMAW

INVERTER

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CHALUMEAUX À

BRANCHEMENT DIRECT

ET RACCORDEMENT

RAPIDE AUTOMATIQUE

Guide D’installation

et D’utilisation

English

Français

Español

QFA600

QFW600

QFW600 TORCH

QFA600 TORCH

CHALAUMEAU QFA600

CHALAUMEAU QFW600

Révision: A Date d’émission: 11 novembre 2008 No de Forma: SM-QFDP

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60

Hz

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PHASE

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SMAW

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230

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VOTRE ACTIVITÉ NOUS INTÉRESSE!

Félicitations pour votre nouveau produit Tweco

®

. Nous sommes ﬁers de vous

avoir comme client et nous tâcherons de vous fournir les meilleurs services

et ﬁabilité dans l’industrie. Ce produit est soutenu par une vaste garantie et

un réseau mondial de service. Pour localiser votre distributeur ou agence

de service le plus proche, veuillez communiquer avec un représentant à

l’adresse ou au numéro de téléphone correspondant à votre région, indiqué

au verso de la couverture du manuel, ou visitez notre site web www.tweco.

com.

Ce Manuel d’utilisation a été conçu pour vous permettre d’utiliser et de

faire fonctionner correctement votre produit Tweco

®

. Votre satisfaction et

le fonctionnement en toute sécurité de votre produit sont nos principaux

soucis. Par conséquent, veuillez prendre le temps de lire tout le manuel,

spécialement en ce qui concerne les Précautions de Sécurité. Ceci vous

aidera à éviter d’éventuels accidents qui pourraient survenir en travaillant

avec ce produit.

VOUS ÊTES EN BONNE COMPAGNIE!

La Marque de Choix pour les Entrepreneurs et les Fabricants dans le Monde.

Tweco

®

Robotics est une marque globale de produits de soudage à l’arc

pour Thermadyne Industries Inc. Nous fabriquons et fournissons aux plus

grands secteurs de l’industrie de soudage dans le monde dont: Fabrication,

Construction, Exploitation Minière, Automobile, Aérospatial, Ingénierie, Rural

et Loisirs/Bricolage.

Nous nous distinguons de notre concurrence grâce à nos produits en tête du

marché, ﬁables, ayant résisté à l’épreuve du temps. Nous sommes ﬁers de

notre innovation technique, nos prix compétitifs, notre excellente livraison,

notre service clientèle et notre support technique de qualité supérieure, ainsi

que de l’excellence dans les ventes et l’expertise en marketing.

Surtout, nous nous engageons à développer des produits utilisant des

technologies de pointe pour obtenir un environnement de travail plus

sécurisé dans l’industrie de la soudure.

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ESAB QFA600 QFW600 Quick Fixed Automation Direct Plug Torches Guide d'installation

ESAB QFA600 QFW600 Quick Fixed Automation Direct Plug Torches Guide d'installation

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