nozzle cleaning station

Transcription

1 qrc TM nozzle cleaning station English Français Español installation and Operation guide SMAW GTAW Version No: AA.01 Issue Date: July 1, 2006 Manual No: SM-QRC-2000

2 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, 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 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. SMAW GTAW

3 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. Nozzle Cleaning Station Installation and Operation Guide Instruction Manual Number SM-QRC-2000 Published by: Tweco Products Inc Airport Road Denton, TX (940) Copyright 2006 by Thermadyne Industries Inc. All rights reserved. Reproduction of this work, in whole or in part, without written permission of the publisher is prohibited. The publisher does not assume and hereby disclaims any liability to any party for any loss or damage caused by any error or omission in this Manual, whether such error results from negligence, accident, or any other cause. Publication Date: July 1, 2006 Record the following information for Warranty purposes: Where Purchased: Purchase Date: Equipment Serial #: i

4 nozzle cleaning station Table of Contents SECTION 1: SAFETY INSTRUCTIONS AND WARNINGS Welding Hazards Principal Safety Standards Safety and Health SECTION 2: INTRODUCTION AND DESCRIPTION How to Use this Manual Receipt of Equipment Introduction SECTION 3: INSTALLATION AND OPERATION Installation Mounting the QRC TM Nozzle Cleaning Station Air Supply, Connections, and Lubrication Requirements QRC TM Wiring Interface Electrical and Pneumatic Controls Access Logic Inverse LED Indicators Reamer Blade and Clamp Block Selection Tweco Robotic Nozzles vs. Clamp Block Air Flow Control Valve Nozzle and Insertion Parameter Section 4: Wiring and PNEUMATIC Wiring for the QRM-100 and QRM-3 Anti-spatter Mist Applicator Wiring Diagram Pneumatic Diagram QRM-100 and QRM Section 5: Maintenance Maintenance Schedule Component Replacement Instructions Manual Setup Section 6: Troubleshooting Section 7: Replacement Parts Statement of Warranty Warranty SCHEDULE GLOBAL CUSTOMER SERVICE CONTACT INFORMATION ii SM-QRC-2000

5 SECTION 1: SAFETY INSTRUCTIONS AND WARNINGS nozzle cleaning station 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 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. 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. 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. WARNING SMOKE, FUMES, AND GASES CAN BE DANGEROUS TO YOUR HEALTH. SM-QRC SAFETY INSTRUCTIONS AND WARNINGS

6 nozzle cleaning station 11. Keep smoke, fumes, and gases from the breathing area. 12. Fumes from the welding or cutting process are of various types and strengths, depending on the kind of base metal being worked on. To ensure your safety, do not breathe these fumes. 13. Ventilation must be adequate to remove smoke, fumes, and gases during the operation to protect operators and other personnel in the area. 14. Vapors of chlorinated solvents can form the toxic gas Phosgene when exposed to ultraviolet radiation from an electric arc. All solvents, degreasers, and potential sources of these vapors must be removed from the work area. 15. Fumes produced by welding or cutting, particularly in confined places, can cause discomfort and physical harm if inhaled over an extended period of time. 16. Provide adequate ventilation in the welding or cutting area. Use air-supplied respirators if ventilation is not adequate to remove all fumes and gases. Never ventilate with oxygen. Oxygen supports and vigorously accelerates fire. 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-ofposition 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. SAFETY INSTRUCTIONS AND WARNINGS 1-4 SM-QRC-2000

7 nozzle cleaning station 1.02 Principal Safety Standards SAFETY AND OPERATING REFERENCES 1. Code of Federal Regulations. (OSHA) Section 29 Part , 132, 133, 134, 139, 251, 252, 253, 254 and U.S. Government Printing Office, Washington, DC 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 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 , Miami FL NFPA 51B Fire Prevention in Cutting and Welding Processes. 8. NFPA-7 National Electrical Code. National Fire Protection Association, Battery Park, Quincy, MA CSA W117.2, Safety in Welding, Cutting and Allied Processes. Canadian Standards Association, 178 Rexdale Blvd., Rexdale, Ontario, Canada M9W 1R 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. SM-QRC SAFETY INSTRUCTIONS AND WARNINGS

8 nozzle cleaning station 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 annotetions are easily recognized as follows: WARNING A WARNING gives information regarding possible personal injury. SECTION 2: INTRODUCTION AND DESCRIPTION 2.03 Introduction Before installing or operating the QRC TM Nozzle Cleaning Station, please read and understand all safety precautions included with this product and instructions listed in this manual. Failure to follow all instructions and safety warnings can result in personal injury or equipment damage. The Tweco Robotics QRC TM Nozzle Cleaning Station was designed to provide the user with high quality nozzle/ tip cleaning that fits well in a robotic work cell. This durable product is a proven performer in the rigorous environment associated with a continuous operating robotic station. CAUTION A CAUTION refers to possible equipment damage. NOTE A NOTE offers helpful information concerning certain operating procedures 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: introduction and description 2-6 SM-QRC-2000

9 3.01 Installation The Tweco Robotics QRC TM Nozzle Cleaning Station is easy to install. The following are instructions to aid in mounting and making all necessary connections to your cleaning station. If you have any questions concerning these instructions, contact Tweco Robotics Technical Services for further assistance. SECTION 3: INSTALLATION AND OPERATION nozzle cleaning station 4.3 [108] 1.4 [36] 3.02 Mounting the QRC TM Nozzle Cleaning Station Install the nozzle cleaning station inside the robot work cell to make it easy to access. The nozzle cleaning station should be mounted to allow easy access to the robot arm, but in a manner that will not interfere with other operations like loading and unloading fixtures. The drawing shows the hole pattern required to mount the QRC TM as well as important clearance dimensions. The nozzle cleaning station is mounted using four 3/8 diameter bolts in the holes provided on the base. The unit should be leveled. reset switch 16.4 [416] in [mm] 13.1 [334] [63.5] 16.4 [416] 17.8 [452].625 [15,88] [213,61] [204,01] [228,6] 9.8 [249] in [mm] Figure [12,7] [33,5] [93,5] [127].912 [23,16].535 [13.59] in [mm] SM-QRC installation and operation

10 nozzle cleaning station 3.03 Air Supply, Connections, and Lubrication Requirements The air supply for the QRC TM nozzle cleaning station should be filtered, unlubricated air. This unit requires CFM ( LPM). The air supply line should be a minimum of 1/4 I.D. with a male 1/4 NPT connection to fit the female connection in the side of the logic cover. The air motor is lubricated through a servo meter located below the lubricator reservoir. The servo meter injects a quantity of oil directly into the solenoid valves and air motor during each cleaning cycle. The lubrication should be done using a light grade hydraulic oil with a viscosity rating of 150 VC (SAE 5W). When filling the reservoir for the first time or refilling an empty reservoir, you must manually prime the pump to distribute the oil through the system. The servo meter has an adjustment that goes from 0 (-) to 45 (+) clicks and a push button to prime the lubricant oil. Refer to Figure 2. Pull the servo meter knob to the unlock position (A). Set the servo meter knob at 45 (+) and press the button appromimately 50 to 60 times. Turn the servo meter knob counter-clockwise to 0 (-) and set at 3 (+) clicks. Push the servo meter knob back into the locked position (C). The amount of lubricant can be adjusted by turning the adjustment knob located on the servo meter. Note The QRC2000 nozzle cleaning station is factory preset at 3 (+) clicks. Note Do not run unit without lubricant oil. If unit runs out of lubricant oil, the motor will lock up and the solenoid valves will stick. When lubricant oil is added you must prime the unit and check operation of the solenoid valves. Permanent damage can be caused to the solenoid valves if the unit is allowed to run out of lubricant oil. Note Lubricator Reservoir oil must have a vent in the open position. If not, oil will not flow QRC TM Wiring Interface The QRC TM Nozzle Cleaning Station wiring interface requires a five wire connection. Each wire is color-coded. The drawing below shows the wire color to its connector pin/socket number and function. Robotic Control red: +24 volts dc supply Green: Unclamp Symbol white: supply common orange: +24 volts dc start signal black: spare/option lubricator reservoir servo meter ensure proper interface has been made or damage may occur 3. jaws unclamped (green) vdc supply (read) 4. start signal (orange) 5. option (black) 1. common (white) Turn (Adjust) Figure 2 servo meter knob primer push button Figure 3 The Following Connections are Required for Proper Unit Operation: Red Lead Connection: Operates internal logic with a +24 V DC supply. Green Lead Connection: Cycle complete output signal (+24 V DC for sourcing logic signal; 0 V DC for sinking logic signal). White Lead Connection: Supply common. Orange Lead Connection: Cycle start input signal +24 V DC for sourcing logic signal; 0 V DC for sinking logic signal. ( second pulse signal) Black Lead: Spare wire (optional connection). installation and operation 3-8 SM-QRC-2000

11 3.05 Electrical and Pneumatic Controls Access Ensure that the power is off and disconnected, and air supply is off before removing logic cover. To gain access to the circuit board and pneumatic manifold, the logic cover must be removed. To free the logic cover loosen four button head screws and slide cover away from cleaning station being careful not to disconnect the interface connections from circuit board. sw2 nozzle cleaning station switch 2 (SW2) output jaws unclamped sinking (up) sourcing (down) sourcing (up) sinking (down) sw1 switch 1 (SW1) input start signal logic cover no x 1/2 1/2 lg. lg. button head button screw head (4 ea.) screw (4 ea.) solenoid valve (2 ea) Figure Logic Inverse The QRC TM Nozzle Cleaning Station comes from the factory set for sourcing (high) +24 V DC input or output. Some installations may require the opposite of this or 0 V DC sinking (low) input or output. Accessing the circuit board is necessary to switch from sourcing to sinking input/output. On the lower right hand corner of the circuit board are two switches that need to be set to correspond to the input/output signal requirement as shown. caution Do not switch circuit board sourcing and sinking switches with power on. Damage will occur. Only move switches with power off. circuit board no. 10x1/2 lg thread forming screw (2 ea) To operate the unit ON sinking connection, switch SW1 must be in the down position, and switch SW2 must be in the up position. To operate the unit ON sourcing connection, reverse the position of the switches. Refer to diagram shown on Figure 5. Figure LED Indicators The LED indicators located on the side of the logic cover, supply visual information regarding cycle status. This information may be used for both installation and maintenance to verify proper operation. The LED indicates the cleaning sequence as follows: Unclamped - On Indicates that the clamp cylinder is fully extended, opening the nozzle clamp block and supplying an output signal that the reamer cycle is complete. Reamer Ahead - Off Indicates that the lift cylinder is fully extended putting the reamer blade at the top of its reaming stroke and activating the upper limit switch on the circuit board. Reamer Home - On Indicates that the lift cylinder has fully retracted, placing the reamer blade at the bottom of its stroke (home position), and has activated the lower limit switch on the circuit board. Note Both the Unclamped and Reamer Home Lights must be on for the unit to start the cleaning process. CLEANING SEQUENCE UNCLAMPED REAMER AHEAD REAMER HOME CAUTION ENSURE PROPER INTERFACE HAS BEEN MADE OR DAMAGE MAY OCCUR. READ TECHNICAL GUIDE BEFORE START-UP. SM-QRC Figure 6 installation and operation

12 nozzle cleaning station 3.08 Reamer Blade and Clamp Block Selection To ensure that proper nozzle and tip cleaning occurs without loss of tip alignment, each application must be customized to fit the specific robotic gun, contact tip, and nozzle configuration. The chart below will help you select the best reamer blade for your particular application. The reamer blade O.D. (outside diameter) selected will depend on the I.D. (inside diameter) of the nozzle being used. The reamer blade I.D. used would depend on the O.D. of the contact tip. All QRC TM Nozzle Cleaning Stations come from Tweco Robotics with the QRC TM -100 reamer blade (.620 /15,7mm O.D. x.422 / 10,7mm I.D.). Figure 7 Table 1: QRC TM Reamer Blades List Part No. Stock No. Reamer O.D. (A) Reamer I.D. (B) Reamer Length (C) Nozzle Bore Contact Tip QRC (15,7mm).422 (10,7mm) 1.25 (31,7mm) 5/8 (15,9mm) A, B, C, & D QRC (12,5mm).344 (8,7mm) 1.25 (31,7mm) 1/2 (12,7mm) A & B QRC (12,3mm).344 (8,7mm) 1.12 (28,4mm) 1/2 (12,7mm) A & B QRC (9,3mm).281 (7,1mm).94 (23,8mm) 3/8 (9,5mm) A QRC (18,6mm).530 (13,5mm) 2.08 (52,8mm) 3/4 (19,1mm) A, B, C, & D QRC (15,7mm).344 (8,7mm) 1.25 (31,7mm) 5/8 (15,9mm) A & B QRC (9,3mm).270 (6,9mm).94 (23,8mm) 3/8 (9,5mm) A QRC (15,3mm).438 (11,1mm) 1.25 (31,7mm) 5/8 (15,9mm) A, B, C, & D QRC (12,8mm).344 (8,7mm) 1.27 (32,2mm) 5/8 (15,9mm) A & B QRC (15,7mm).344 (8,7mm) 1.25 (31,7mm) 5/8 (15,9mm) A & B QRC (15,7mm).296 (7,5mm) 1.25 (31,7mm) 5/8 (15,9mm) A & B QRC (18,6mm).296 (7,5mm) 1.84 (46,7mm) 3/4 (19,1mm) A & B QRC (15,7mm).360 (9,1mm) 1.00 (25,4mm) 5/8 (15,9mm) A, B, & C QRC (18,6mm).360 (9,1mm) 1.84 (46,7mm) 3/4 (19,1mm) A, B, & C QRC (15,7mm).390 (9,9mm) 1.25 (31,7mm) 5/8 (15,9mm) A, B, C, & D QRC (18,6mm).390 (9,9mm) 1.84 (46,7mm) 3/4 (19,1mm) A, B, C, & D QRC (12,5mm).359 (9,12mm) 1.08 (27,4mm) 1/2 (12,7mm) A, B, & C QRC (15,7mm).312 (7,9mm) (26,7mm) 5/8 (15,9mm) A & B QRC (15,7mm).312 (7,9mm) (28,6mm) 5/8 (15,9mm) A & B QRC (12,3mm).312 (7,9mm).73 (18,5mm) 1/2 (12,7mm) A & B QRC-121S (12,3mm).374 (9,5mm).84 (21,3mm) 1/2 (12,7mm) A, B, & C QRC (15,7mm).390 (9,9mm) 1.25 (31,7mm) 5/8 (15,9mm) A, B, C, & D QRC (14,2mm).390 (9,9mm) 2.26 (57,4mm) 5/8 (15,9mm) A, B, C, & D QRC (12,3mm).344 (8,7mm)?.84 (21,3mm) 1/2 (12,7mm) A & B QRC (12,3mm).390 (9,9mm) 1.25 (31,7mm) 1/2 (12,7mm) A, B, C, & D QRC (12,3mm).360 (9,1mm) 1.08 (27,4mm) 1/2 (12,7mm) A, B, C QRC (13,4mm).360 (9,1mm) 1.08 (27,4mm) 5/8 (15,9mm) A, B, C QRC-ABZ Adapter for use on Binzel cleaning station in order to use Tweco Robotics reamer blades. Contact Tips (Reference Table 1) A 11, 14, 14T, EL11 & AL (O.D. =.250 / 6,3mm) B 11H, 11RS, 14H. 14RS, 14RZ & AL (O.D. =.283 / 7,1mm) C EL16, EL16RS, & AL (O.D. =.345 / 8,7mm) D 16S, 16RS, 16RZ & AL (O.D. =.375 / 9,5mm) installation and operation 3-10 SM-QRC-2000

13 The other variable part in the QRC TM Nozzle Cleaning Station is the clamp block set. There are five clamp blocks available. Please refer to Tables 2 and 3. The clamp block B comes assembled on all QRC TM Nozzle Cleaning Station. Clamp blocks A, C, D, and E are also supplied with the unit. Table 2: QRC TM Clamp Blocks List Clamp Block O. D. QRC2102-A QRC2102-B QRC2102-C QRC2102-D QRC2102-E QRC2102-F Fits Nizzels.938 (23,8mm) 1 (25,4mm) (27,0mm) (28,6mm).875 (22,2mm).787 (20,0mm) Table 3: Tweco Robotic Nozzles vs. Clamp Block Nozzle Nozzle O.D. Clamp Block REL21 Series.875 (22,2mm) QRC-2102-E REL24CT Series 1 (25,4mm) QRC-2102-B RWC24 Series 1 (25,4mm) QRC-2102-B RWC26 Series (27,0mm) QRC-2102-C 3.09 Tweco Robotic Nozzles vs. Clamp Block Program the robot to position the Mig nozzle directly above and centered to the reamer blade above the QRC TM Insert the nozzle to the required depth to allow complete cleaning of the tip and nozzle without damaging the torch consumable parts. (Please refer to section 3.11). At this time the cycle start signal (pulse.5 to 1.0 seconds) should be sent to the QRC TM from the robotic controller. Then the QRC TM will clamp the nozzle and perform the cleaning operation. Once the reamer completes the cleaning cycle, the cleaning station will send a cycle complete signal back to the robot controller. At this time, the torch is removed from the QRC TM and the work cycle continues Air Flow Control Valve The air flow control valve provides an adjustment for the reamer blade feed rate. The amount of spatter buildup will determine the required reamer blade feed rate. The heavier the spatter, the slower the reamer blade feed rate that should be used. If a smaller amount of spatter accumulates, the feed rate can be set faster. Adjusting the air flow control valve: There is an air flow control valve inside the unit as shown in Figure 8. The feed rate may require adjusting for different applications. locking nut nozzle cleaning station To increase the reamer blade feed rate, unscrew the nut and rotate the valve knob counter-clockwise. After the adjustment, lock the valve knob nut. To decrease the reamer blade feed rate, unscrew the nut and rotate the valve knob clockwise. After the adjustment, lock the valve knob nut. Figure 8 adjusting knob increase feed rate decrease feed rate 3.11 Nozzle and Insertion Parameter All QRC TM Nozzle Cleaning Stations come from Tweco Robotics with the QRC-100 reamer blade (.620 /15,7mm O.D. x.422 / 10,7mm I.D.) and clamp block B (QRC2102-B / 1 (25,4mm)). Please make sure that the reamer blade and clamp block fit the need of your application. Setting up the Torch with Gauges There are three sizes of gauges (1/2 (12,7mm), 5/8 (15,9mm) and 3/4 (19,1mm)). These gauges are available as a set under Part No. QRC TM -PG2. Determine O.D. of reamer blade being used. Slip proper gauge on O.D. of reamer blade. Screw in tip index shaft. Determine O.D. of contact tip being used. Slip proper alignment sleeve on pointer. Bring torch down to where the I.D. of contact tip touches pointer, push alignment sleeve up and over contact tip to gauge if torch is set at 90 degrees. Once this is established, back the torch off from the pointer to allow room to remove the pointer and alignment sleeve. Bring the torch back down to where the nozzle touches top of the gauge. This allows the programmer to set up for the stroke of the reamer blade in the cleaning sequence. Note Using a flush or protruded nozzle, adjust the reamer blade stroke, leaving a gap between the nozzle and the top of the gauge. For flush nozzles: leave a 1/8 (3,2mm) gap. For protruded nozzles: leave a 1/4 (6,4mm) gap. SM-QRC installation and operation

14 nozzle cleaning station contact tip alignment sleeve tip index shaft programming gauge reamer blade Figure 9 nozzle programming gauge reamer blade Figure 10 installation and operation 3-12 SM-QRC-2000

15 Section 4: Wiring and PNEUMATIC 4.01 Wiring for the QRM-100 and QRM-3 Anti-spatter Mist Applicator The drawings below show the QRM-100 and QRM-3 wiring connections. nozzle cleaning station For a sinking connection, the wires must be connected to positions 5 and 2. For sourcing connection, the wires must be connected to positions 5 and 3. To operate the QRM-100 Anti-Spatter Mist Applicator, a timed 24 V DC signal must be applied to the black lead (spare) of the interface receptacle. motor & clamp solenoid valve motor & clamp solenoid valve spindle lift solenoid valve spindle lift solenoid valve pin #5 pin #3 antispatter unit 24DC pin #5 pin #2 antispatter unit 24DC Sourcing Sinking Figure 11: Pin #1 on Top/Pin #6 on Bottom 4.02 Wiring Diagram clamp return limit switch upper limit switch lower limit switch see 5 pin connector wiring Not used start signal common +24vdc jaws unclamped optional equipment pin #4 (ORG) start signal pin #3 (grn) jaws unclamped pin #2 (red) +24 VDC reset switch pin #5 (blk) option pin #1 (wht) common motor and clamp solenoid valve external view of 5-pin connector spindle lift solenoid valve optional equipment Figure 12 SM-QRC Wiring and PNEUMATIC

16 nozzle cleaning station 4.03 Pneumatic Diagram 1/8-27 npt x 5/32 tube elbow 1/4-18 npt x 1/4 tube elbow 1/4-18 npt x 1/4 tube elbow 1/4-18 npt x 1/4 tube adapter feed rate control x 5/32 tube adapter 1/8-27 npt x 1/4 tube elbow (5 ea.) 5/32 tube x 5/32 tube elbow 1/4 tube x 1/4 tube elbow 1/4 tube y connector Figure QRM-100 and QRM-3 Figure 14: QRM-100 Figure 15: QRM-3 Wiring and PNEUMATIC 4-14 SM-QRC-2000

17 5.01 Maintenance Schedule The QRC TM will require a periodic maintenance schedule to ensure an optimum service life. The following maintenance checks are required. Depending on the use of the unit, each specific application could require a more extensive schedule. Daily Ensure incline housing area is clear of excessive spatter. Visually check oil level in lubricator reservoir. Weekly Quarterly Yearly Ensure incline housing area is clear of excessive spatter. Visually check lubricating oil level in lubricator reservoir. The life of the air motor is dependent on a sufficient supply of lubricating oil. Replenish this oil as needed. Inspect air lines and connections for leaks. Check interface cables for frayed connections or bad wiring. The QRC TM reamer blade life will depend on the application. At least quarterly the reamer blade should be inspected for dullness, clogging and breakage. Visually check lubricating oil level in lubricator reservoir. Ensure incline housing area is clear of excessive spatter. The clamp block should be cleaned and inspected for excessive wear and replaced if needed. Visually check lubricating oil level in lubricator reservoir. Replenish this oil as needed. Inspect air lines and connections for leaks. Check interface cables for frayed connections or bad wiring. Remove top plate and apply grease on cam slides on top (V-Block) and side plates Component Replacement Instructions Upper, Lower, and Jaw Stop Limit Switches Ensure that the power is off and disconnected, and the air supply is off before replacing the limit switches. To replace the limit switches, loosen the screws that connect the limit switch bracket to the manifold. Disconnect the wiring for the limit switch that is being replaced. Remove the nut that connects the limit switch to the limit switch bracket. Replace the limit switches in reverse order Section 5: Maintenance nozzle cleaning station Note Be sure to review the wiring diagram when rewiring and disconnecting the limit switch (see Figure 12). The limit switches are adjusted at the factory. If an adjustment needs to be made, please contact our factory technical center. Reset Switch Unscrew the nut that connects the limit switch to bracket. Disconnect the wiring from the circuit board and replace it. Note Be sure to review the wiring diagram (Figure 12) when rewiring and disconnecting the reset switch. lower limit switch bracket screw locking nut switch bracket Circuit Board Ensure that the power and air supply are off and disconnected before replacing the circuit board. Replace the circuit board in the following manner: Figure 16 Once the power and air are disconnected from the QRC TM -2000, carefully unplug all connectors from the board. Unscrew the two screws located on the circuit board. (Fig. 17) The circuit board can now be replaced. Install the new circuit board on the board insulator. Once this has been completed, tighten the two circuit board mounting screws. Reconnect the connectors while referring to wiring diagram to be sure the connections are in the proper location. Caution jaw clamp limit switch reset switch upper limit switch Do not switch circuit board sourcing and sinking switches with the power on. Damage will occur. Only move the switches with the power off. SM-QRC maintenance

18 nozzle cleaning station j3 connector j1 connector j2 connector j4 connector j5 connector circuit board sw2 switch sw1 switch Remove the seven screws on three top plate. Remove the top plate to the cleaning station. Lift and rotate the clamp block so that the desired sizes face the jaws. Clean the components thoroughly and lubricate with grease before reassembling them. Note Part numbers are stamped on clamp blocks. Please refer to Table 4 - QRC TM 2000 clamp block list for the outside diameter of the nozzle. circuit board insulator Figure 17 no. 10 s 1/2 lg. thread-forming screw (2 ea.) Clamp Block Ensure that the power and air supply are off and disconnected before replacing the clamp block. Certain applications or normal wear may cause the need to replace the QRC TM clamp block. There are five clamp blocks available. QRC TM Reamer Blade To remove the reamer blade, place the 9/16 (14mm) spanner wrench, part no. QRC-440, on the hex flats at the end of the extension shaft and the QRC-441 wrench on the top of the reamer blade. The cutter is removed by turning counterclockwise when viewed from above. Considerable force may be required to loosen the reamer blade since it tightens naturally as the reamer operates. Please refer to Table 1 for reamer blade options. Table 4: ORC TM Clamp Blocks List Clamp Block O.D. Fits Nozzles QRC2102-A.938 (23,8mm) QRC2102-B 1 (25,4mm) QRC2102-C (27,0mm) QRC2102-D (28,6mm) QRC2102-E.875 (22,2mm) QRC2102-F.787 (20,0mm) Clamp block B comes assembled on all QRC TM Nozzle Cleaning Station. The clamp blocks A, C, D, and E are also supplied with the unit. top plate screws (7 ea) t-wrench reamer blade 9/16 spanner wrench Figure 19 locator spacer clamp block clamp block locator pin reamer blade Figure 18 maintenance 5-16 SM-QRC-2000

19 nozzle cleaning station Air Solenoids Ensure that the power is off and disconnected, and air supply is off before replacing the air solenoids. Refer to section 5.02 to remove the circuit board. Remove and replace one solenoid at a time. Unscrew the two screws on the air solenoid and unplug the wire connectors. Remove solenoid. Install the new solenoid with the gasket and rewire. Repeat sequence for the other air solenoid. solenoid valve right button activates (Spin and clamp) Note Be sure to review the wiring and pneumatic diagram when rewiring and disconnecting air solenoids. Figure 21 left button activates (reamer blade up and down) m3 x 0.5 screw air solenoid gasket air solenoid electrical wires Figure Manual Setup To manually operate the QRC TM Nozzle Cleaning Station without electricity, connect air in proper place and manually activate the two air valve buttons located on the solenoid valves. Each solenoid valve has a red button. Manually press each button to activate the unit. A) The left air valve button activates the up and down lift movement of the reamer blade. B) The right air valve button activates the spin and clamp. Note The reset button should be pressed prior to manual setup to reset all circuitry. SM-QRC maintenance

20 nozzle cleaning station LED signals not activating Section 6: Troubleshooting Problem Cause Solution Reamer Blade/Air Motor stops during operation (see also Pneumatic functions not operating properly) Pneumatic functions not operating properly Broken Reamer Blade Reamer Blade stays in down position Reamer Blade stays in up position 1. The unit is not receiving power. 1. Turn power on. 2. The unit is not getting air. 2. Turn air on. 3. Input voltage is incorrect. 3. Check input voltage and change if required. 1. Cutter feed rate is too fast. 1. Reduce cutter feed rate (see section 3.10). 2. Excessive spatter buildup. 2. Clean affected area and adjust weld parameters. Apply or increase anti-spatter. Clean more often. 3. Incorrect air supply. 3. Adjust air supply (See section 3.03). 1. Incorrect air supply. 1. Adjust air supply (see section 3.03). 2. Air line damage or obstructed and air leaks. 2. Check lines for leaks and replace hose if damaged. 3. Faulty reset switch. 3. Repair or replace reset switch. 1. Wrong size reamer blade or clamp block. 2. Reamer blade feed rate was set too high. 1. Check sizing (see section 3.08). 2. Reduce cutter feed rate. (see section 3.10). 3. Excessive spatter buildup. 3. Clean affected area and adjust weld parameters. Apply or increase anti-spatter. Clean more often. 1. Damaged lift cylinder or air lines. 1. Reset switch defective. 2. Faulty or contaminated lift solenoid. 2. Check solenoid valves. Fix or replace faulty solenoid. 3. Reset switch defective. 3. Replace reset switch. 4. Damaged limit switch. 4. Identify and replace faulty switch. 1. Reamer Blade is jammed. 1. Press Reset button and Inspect Reamer Blade. 2. Faulty air solenoid. 2. Replace air solenoid. 3. Bad or dirty lift cylinder. 3. Fix or replace cylinder. 4. Cycle start signal held on. 4. Adjust cleaning cycle program. 5. Faulty limit switch. 5. Replace limit switch. Cycle complete signal does not activate 1. Faulty limit switch on lift cylinder or clamping cylinder. 1. R e p l a c e o r r e a l i g n r e a d switch(es). 2. Unit is not wired correctly. 2. Check wiring (see section 4). Troubleshooting 6-18 SM-QRC-2000

21 Section 7: Replacement Parts nozzle cleaning station Table 5: QRC TM Replacement Parts SM-QRC-2000 Figure 23 Item No. Part No. Stock No. Description 1 QRC Jaws Assembly QRC-2102A Clamp Block (23,8mm).O.D. Nozzles QRC-2102B Clamp Block (25,4mm).O.D. Nozzles 2 QRC-2102C Clamp Block (27,0mm).O.D. Nozzles QRC-2102D Clamp Block (28,6mm).O.D. Nozzles QRC-2102E Clamp Block (22,2mm).O.D. Nozzles QRC-2102F Clamp Block.787 (20mm) O.D. Nozzle 3 See Table 1 See Table 1 Reamer Blades 4 QRC Limit Switch Kit (4 Switches Included) 5 QRC Drive Lift Assembly 6 QRC-PG Programming Sleeve and Gauges 7 QRC Solenoid Valve Assembly 8 QRC Circuit Board 9 QRC Shroud and.screws 10 QRC Interface Power Cord 11 QRC /16 (14mm) Flat Wrench 12 QRC T Wrench 13 QRC fl. oz. (292 ml) Lubricator Reservoir 14 QRC Clamp Cylinder QRC TM Packaging List 1 ea. QRC TM ea. Lubricator Oil Reservoir Assembly 1 ea. QRC TM -PG2 Programing Sleeves and Gauges 1 ea. Set of Clamp Blocks (A,B,C, D, and E). 1 ea. QRC TM /16 (14mm) Wrench ea. QRC TM -441 T Wrench 1 ea. SuperLube 1 ea. Yellow Power Cable Safeguards, Assembly, and Operation Manual Replacement Parts

22 nozzle cleaning station 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 SM-QRC-2000

23 Warranty SCHEDULE nozzle cleaning station 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. Boards All Other Original Circuits and Components Including, but not Limited to, Relays, Switches, Contactors, Solenoids, Fans, Power Switch Semi-Conductors 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. GMAW/FCAW (MIG) Welding Equipment 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 Original Main Power Rectifiers, Control P.C. Boards, Power Switch Semi-Conductors All Other Original Circuits and Components Including, but not Limited to, Relays, Switches, Contactors, Solenoids, Fans, Electric Motors GTAW (TIG) & Multi-process Inverter Welding Equipment 160TS, 300TS, 400TS, 185AC/DC, 200AC/DC, 300AC/DC, 400GTSW, 400MST, 300MST, 400MSTP Original Main Power Magnetics Original Main Power Rectifiers, Control P.C. Boards, Power Switch Semi-Conductors All Other Original Circuits and Components Including, but not Limited to, Relays, Switches, Contactors, Solenoids, Fans, Electric Motors Plasma Welding Equipment Ultima 150 Original Main Power Magnetics Original Main Power Rectifiers, Control P.C. Boards, Power Switch Semi-Conductors Welding Console, Weld Controller, Weld Timer All Other Original Circuits and Components Including, but not Limited to, Relays, Switches, Contactors, Solenoids, Fans, Electric Motors, Coolant Recirculators SMAW (Stick) Welding Equipment Dragster 85 Original Main Power Magnetics Original Main Power Rectifiers, Control P.C. Boards All Other Original Circuits and Components Including, but not Limited to, Relays, Switches, Contactors, Solenoids, Fans, Power Switch Semi-Conductors 160S, 300S, 400S Original Main Power Magnetics Original Main Power Rectifiers, Control P.C. Boards All Other Original Circuits and Components Including, but not Limited to, Relays, Switches, Contactors, Solenoids, Fans, Power Switch Semi-Conductors General Arc Equipment Water Recirculators Plasma Welding Torches Gas Regulators (Supplied with Power Sources) MIG and TIG Torches (Supplied with Power Sources) Replacement Repair Parts MIG, TIG and Plasma Welding Torch Consumable Items Gas Welding and Cutting Equipment Victor Professional Oxygen Conservers Aluminum Cylinders Cutting Machine Motors HP&I Brass Regulators/Manifolds HP&I Stainless Regulators/Manifolds HP&I Corrosive Gas Regulators/Manifolds TurboTorch CutSkill Steel Cylinders Victor Medical Victor VSP Firepower MIG Welders Transformers Parts Used in Rental Applications MIG Torches and Arc Accessories Arcair N6000 Eliminator Spool and Pull Guns Robotic Deflection Mounts QRM-100 Anti-Spatter Applicator TC and TCV Water Coolers TSC-96 Smoke Collector ESG-1, EPG-CR1, EPG-CR2 Control Boxes for Eliminator Spool & Pull Guns QRC-2000 Nozzle Cleaning Stations All other products 30 days from date purchaser purchases from seller. Plasma Cutting Systems Automated Plasma CutMaster PakMaster XL PLUS Drag-Gun Drag-Gun Plus Torches Consoles, Control Equipment, Heat Exchangers and Accessory Equipment Parts / Labor 3 years / 3 years 3 years / 3 years 1 year / 1 year See the Engine Manufacturers Warranty for Details Parts / Labor 5 years / 3 years 3 years / 3 years 1 year / 1 year Parts / Labor 5 years / 3 years 3 years / 3 years 1 year / 1 year Parts / Labor 5 years / 3 years 3 years / 3 years 3 years / 3 years 1 year / 1 year Parts / Labor 1 year / 1 year 1 year / 1 year 1 year / 1 year 5 years / 3 years 3 years / 3 years 1 year / 1 year Parts / Labor 1 year / 1 year 180 days / 180 days 180 days / NA 90 days / NA 90 days / NA NA / NA Parts / Labor 5 years / NA 2 years / NA Lifetime / NA 1 year / NA 2 years / NA 1 year / NA 90 days / NA 3 years / NA 2 years / NA 1 year / NA 6 years / NA 2 years / NA years / NA 5 years / NA 1 year from date sold by seller to authorized distributor Parts / Labor 90 days / NA 90 days / NA 90 days / NA 90 days / NA 1 year / NA 1 year / NA 1 year / NA 1 year / 1 year 30 days / NA Parts / Labor 2 years / 1 year 3 years / 3 years 3 years / 1 year 1 year / 1 year 2 years / 1 year 1 year / 1 year 1 year / 1 year SM-QRC

24 GLOBAL CUSTOMER SERVICE CONTACT INFORMATION Thermadyne USA 2800 Airport Road Denton, TX USA Telephone: (1) Fax: (1) Thermadyne Canada 2070 Wyecroft Road Oakville, Ontario Canada, L6L5V6 Telephone: (1) Fax: (1) Thermadyne Europe Europe Building Chorley North Industrial Park Chorley, Lancashire England, PR6 7Bx Telephone: (44) Fax: (44) Thermadyne, China RM 102A 685 Ding Xi Rd Chang Ning District Shanghai, PR, Telephone: Fax: Thermadyne Asia Sdn Bhd Lot 151, Jalan Industri 3/5A Rawang Integrated Industrial Park - Jln Batu Arang Rawang Selangor Darul Ehsan West Malaysia Telephone: Fax : Thermadyne Australia 71 Gower Street Preston, Victoria Australia, 3072 Telephone: Fax: Thermadyne Italy OCIM, S.r.L. Via Benaco, S. Giuliano Milan, Italy Tel: (39) Fax: (39) Thermadyne International 2070 Wyecroft Road Oakville, Ontario Canada, L6L5V6 Telephone: (1) Fax: (1)

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26 World Headquarters Thermadyne Holdings Corporation Suite 300, Swingley Ridge Road St. Louis, MO Telephone: (636) Fascimile: (636)