500 AMP AIR-COOLED ROBOTIC MIG TORCH

Transcription

1 500 AMP AIR-COOLED ROBOTIC MIG TORCH

2 2 TABLE OF CONTENTS Thank You... General Safety... Amperage Ratings (Duty Cycle)... Part Numbering System... Lightning Gun Assembly Front... Lightning Gun Assembly Rear... Wiring Diagram... Troubleshooting... Maintenance THANK YOU GENERAL SAFETY For selecting the American Torch Tip Lightning Gun. The Lightning Gun is for welding professionals who want durability and comfort while working in harsh welding environments. Lightning guns are available with Lightning, or Tregaskiss, consumables. This technical guide with instructions and illustrations is designed to make it easy to maintain your Lightning Gun. Please read and follow all the safety procedures. For technical support, please call The American Torch Tip Customer Service department between 8:30 AM and 5:00 PM EST daily. American Torch Tip is committed to providing the best quality products and services. We are constantly working to improve our products and would appreciate hearing your suggestions. 1. Disconnect all power before servicing or changing Lightning welding gun components. Failure to disconnect power can lead to dangerous electrical shock which can kill. 2. Smoke, fumes and gases can be dangerous to your health. Keep smoke, fumes and gases from the breathing area. Fumes from welding are of various types and strengths, depending on the kind of base metal being welded. 3. Arc welding produces dangerous light radiation. Adequate eye protection must be worn. 4. All exposed skin must be covered with flame resistant, protective clothing. Do not wear clothing made from flammable synthetic fibers. 5. Protective screens or barriers should be used to protect others from spatter, flash and glare while welding.

3 3 AMPERAGE RATINGS (Duty Cycle) LIGHTNING 100% DUTY CYCLE 60% DUTY CYCLE CO2 MIXED CO2 MIXED 500 AMP 500 AMP 350 AMP 650 AMP 500 AMP STANDARD ROBOTIC GUN PART NUMBERING SYSTEM CONSUMABLE PARTS L - Lightning T - Tregaskiss (see below) PLUGS 5T - Tweco #5 B - Bernard D - Daiden E - Euro Connector H - Hitachi LN - Lincoln Power Pin M - Miller Power Pin P - Panasonic T - Treg/Tweco/Std. TH - Thermal Arc 2410 T M GUN MODEL No amp WIRE SIZE /64 al / / /32 LENGTH feet 04-4 feet 06-6 feet 08-8 feet feet feet SPECIAL ROBOTIC GUN NUMBERING SYSTEM SETUP DESCRIPTION special consumable setups GOOSENECK SIZES amp amp TM AJ x GOOSENECK ANGLES Degree (standard Degree Degree Degree SPECIAL CONTROL CABLE TBD SPECIAL FEATURES A-Air Blast J-Jog Button S-Basic Whip ( No Electric Switch) Additional Features On Request ROBOTIC 500 AMP STANDARD SHORT ARC HEAVY DUTY TAPERED CONSUMABLES NOZZLE CONTACT DIFFUSER NOZZLE CONTACT DIFFUSER NOZZLE CONTACT DIFFUSER SHOCK WASHER LIGHTNING xx xx xx TREGASKISS xx xx xx

4 4 FRONT END - ROBOTIC MIG TORCH AMP AIR-COOLED AS AS AS AIR BLAST HOSE 65-R148 PLUG 65-R170 DIFFUSER NOZZLE CONTACT TIP SHOCK WASHER QC ROBOTIC GOOSENECK BEND ALIGNMENT FIXTURE PLATE IS AVAILABLE TO FINE ADJUST GOOSENECK MAIN SPRING ASSY 65-R R162 HOUSING 65-R504 SCREW 65-R164 CONE NUT BLUE BROWN YELLOW BLACK RED WHITE 65-R R R129 JOG OPTION 65-R R R R R507 FRONT WIRE HOUSING ASSY

5 5 BACK END - ROBOTIC MIG TORCH AMP AIR COOLED TWECO # LINER 64-44xx CONNECTOR CONE MILLER LINCOLN ADDITIONAL POWER PIN CONNECTORS ARE AVAILABLE - CALL ATTC FOR AVAILABILITY SPRING GUARD CLAMPS (X2) HANDLE UNICABLE 65-R161-X-XXX Brown Green Yellow Grey TAB White Blue Red Pink 65-R (x2) (x2) (x2) (x2) Standard Back end with control cable Special Back end (-S) with no electrical connectors

6 6 WIRING DIAGRAM FRONT HOUSING. SAFETY CLUTCH MALE CONNECTOR REAR SWITCH HOUSING TO CLUTCH VOLTS - VOC (1) BROWN WHITE WHITE WHITE OUTPUT +24-VOC (2) BLACK BLACK 0-VOLTS-DC (COMMON) (3) BLUE BLUE YELLOW (VOLTAGE SENSE) WIRE IS BARED AND CRIMPED MAKING CONTACT WITH FERRULE 500 AMP UNICABLE BLACK BROWN 2 GREEN 3 YELLOW YELLOW BRAD HARRISON 8 PIN MALE CONNECTOR GRAY 5 JOG BUTTON PINK RED RED PINK 6 JOG BUTTON WHITE VIOLET BLUE BLUE 7 VIOLET RED VOC (INPUT) +24 VOC (OUTPUT) VOLTAGE SENSE JOG BUTTON 0 VOC (COMMON) JOG BUTTON WHITE 1 BROWN 2 GREEN 3 YELLOW 4 GRAY 5 PINK 6 BLUE 7 RED BRAD HARRISON 8 PIN MALE CONNECTOR 3 4

7 MAINTENANCE 7 NOZZLE AND CONTACT TIP SYSTEMS REMOVAL AND REPLACEMENT Pull slip-on nozzles off with a clockwise twisting motion. When installing nozzle, exposed insulator should nest inside shock washer to assure concentricity. Shock washers are positioned on the end of the gooseneck with the large insulated counterbore facing the nozzle. Replace nozzle retainer with deep counterbore toward the gooseneck. Tighten until retainer and shock washer are secure. IMPORTANT Shock washer must be in place before welding to maintain insulation of gooseneck. Be sure all parts are tightened will before welding. When using the heavy duty retaining head make sure it is tightened with a 11/16 wrench to prevent overheating of contact tip. To prevent scoring on heavy duty retaining head do not use pliers. Nozzle Contact Tip HD Contact Tip HD TPRD Diffuser Assy. 500A THANK YOU For selecting this American Torch Tip product. The Lightning Gun is for welding professionals who want durability and comfort while working in harsh welding environments. Lightning guns are available with Lightning, Tregaskiss, Bernard and Tweco consumables. This technical guide with instructions and illustrations is designed to make it easy to maintain your Lightning Gun. Please read and follow all the safety procedures. For technical support, please call the American Torch Tip Customer Service department at between 8:30 AM and 5:00 PM EST daily. American Torch Tip is committed to providing the best quality products and services. We are constantly working to improve our products and would appreciate hearing your suggestions. ATTC manufactures a wide line of welding equipment, parts and comsumables on a variety of platforms. Plasma MIG Laser Oxy-Fuel TIG Torches and Consumables Guns and Consumables Optics and Parts Apparatus and Cutting Tips Torches, Parts and Consumables

8 LIMITED WARRANTY Subject to the terms and conditions below American Torch Tip Co. (ATTC) warrants its products to the original end user for the periods listed below: PLASMA LIFETIME *PHD and PHDX Torch Bodies Hurricane Torch Series NOTE: Warranty Does Not Apply to Plasma Consumables OXY-FUEL THREE YEARS Complete Oxy-Fuel Kit Components Regulators/Flowmeters/Flowregulators Torches, Handles & Cutting Attachments NOTE: Warranty Does Not Apply to Cutting Tips & Welding Nozzles *Optics LASER *Buyer is solely responsible for proper packaging of any optic products shipped to ATTC. Optics must be in original packaging or of suitable quality. Optics must have RGA clearly marked or attached. NOTE: Warranty Does Not Apply to Laser Consumables MIG LIFETIME Lightning Handle and Trigger Switch Lightning MIG Guns All Other Gun Models NOTE: Warranty Does Not Apply to MIG Consumables TIG TIG Torches 180 DAYS Replacement TIG Torch Bodies and Cables NOTE: Warranty Does Not Apply to TIG Consumables Thermal Spray Guns THERMAL SPRAY NOTE: Warranty Does Not Apply to Thermal Spray Consumables This warranty shall not apply to any product that has been modified or used in a manner inconsistent with ATTC s installaton instructons and operatng guidelines. Within the warranty periods listed above and at ATTC s sole discreton, ATTC will repair or replace any warranted parts or components that fail due to such defects in material or workmanship. ATTC must be notfied within thirty (30) days of such defect or failure, at which tme ATTC will determine if a Return Goods Authorizaton (RGA) is justfied and issue an RGA number, authorizaton of a RGA number shall not be unreasonably withheld. ATTC will supply a RGA form, which must be included with the returned products for inspection by ATTC. Shipping and packing costs shall be the responsibility of the party returning the goods. Once received, ATTC shall inspect and determine if a warranty claim is justified and at ATTC s sole discreton authorize a repair or replacement. Once authorizaton has been granted ATTC shall provide instructons on the warranty claim procedures to be followed. Where authorized, repair or replacement consttutes the sole remedy for breach of warranty and expressly excludes claims for lost revenue, down tme and other consequental damages. The warranty is limited to the conditons stated above and excludes, to the fullest extent permited by law, all conditons, warrantes and representatons express or implied by statue, law or otherwise in relaton to the supply or delay in supplying the goods/services. There are no agreements, promises or understandings, either verbal or writen that are not fully expressed in this warranty. This warranty may be amended or altered only if agreed to in writing signed by ATTC. ATTC Limited Warranty PROUDLY MADE IN THE USA