qrc -2000 TM nozzle cleaning station English Français Español installation and Operation guide 1 SMAW GTAW Version No: AA.
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 www.tweco.com.
WARNING Read and understand this entire Manual and your employer’s safety practices before installing, operating, or servicing the equipment. While the information contained in this Manual represents the Manufacturer’s best judgment, the Manufacturer assumes no liability for its use. Nozzle Cleaning Station Installation and Operation Guide Instruction Manual Number SM-QRC-2000 Published by: Tweco® Products Inc. 2800 Airport Road Denton, TX 76208 (940) 566-2000 www.tweco.
nozzle cleaning station Table of Contents SECTION 1: SAFETY INSTRUCTIONS AND WARNINGS........................................... 1-3 1.01 Welding Hazards........................................................................................1-3 1.02 Principal Safety Standards.........................................................................1-5 1.03 Safety and Health.......................................................................................1-5 SECTION 2: INTRODUCTION AND DESCRIPTION.......
nozzle cleaning station 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.
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.
nozzle cleaning station 1.02 Principal Safety Standards 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”.
nozzle cleaning station SECTION 2: INTRODUCTION AND DESCRIPTION 2.01 How to Use this Manual 2.03 Introduction To ensure safe operation, read the entire manual, including the chapters on safety instructions and warnings. Throughout this manual, the words WARNING, CAUTION, and NOTE may appear. Pay particular attention to the information provided under these headings.
nozzle cleaning station SECTION 3: INSTALLATION AND OPERATION 3.01 Installation The Tweco® Robotics QRCTM-2000 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. 4.3 [108] 3.
nozzle cleaning station Note The QRC2000 nozzle cleaning station is factory preset at 3 (+) clicks. 3.03 Air Supply, Connections, and Lubrication Requirements The air supply for the QRCTM-2000 nozzle cleaning station should be filtered, unlubricated air. This unit requires 80100 PSI @ 8 CFM (5.5 – 6.8 BAR @ 225 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.
nozzle cleaning station 3.05 Electrical and Pneumatic Controls Access switch 2 (SW2) output jaws unclamped 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 10-24 button head screws and slide cover away from cleaning station being careful not to disconnect the interface connections from circuit board.
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.
nozzle cleaning station The other variable part in the QRCTM-2000 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 QRCTM-2000 Nozzle Cleaning Station. Clamp blocks A, C, D, and E are also supplied with the unit. • 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.
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
nozzle cleaning station 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. • 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.
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 5/32 tube x 5/32 tube elbow 1/4-18 npt x 1/4 tube elbow 1/4 tube x 1/4 tube elbow 1/4-18 npt x 1/4 tube adapter feed rate control 1/4 tube “y” connector 10-32 x 5/32 tube adapter 1/8-27 npt x 1/4 tube elbow (5 ea.) Figure 13 4.
nozzle cleaning station Section 5: Maintenance 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. 5.01 Maintenance Schedule The QRCTM-2000 will require a periodic maintenance schedule to ensure an optimum service life. The following maintenance checks are required.
nozzle cleaning station • 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. j4 connector j3 connector j5 connector j1 connector j2 connector circuit board Note Part numbers are stamped on clamp blocks. Please refer to Table 4 - QRCTM 2000 clamp block list for the outside diameter of the nozzle.
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.
nozzle cleaning station Section 6: Troubleshooting Problem LED signals not activating Reamer Blade/Air Motor stops during operation (see also Pneumatic functions not operating properly) Pneumatic functions not operating properly Cause 1. The unit is not receiving power. 2. The unit is not getting air. 3. Input voltage is incorrect. 1. 2. 3. 1. Cutter feed rate is too fast. 1. 2. Excessive spatter buildup. 2. 3. Incorrect air supply. 3. 1. Incorrect air supply. 1. 2.
nozzle cleaning station Section 7: Replacement Parts Figure 23 Table 5: QRCTM-2000 Replacement Parts Item No. Part No. 1 QRC-2103 QRC-2102A QRC-2102B QRC-2102C 2 QRC-2102D QRC-2102E QRC-2102F 3 See Table 1 4 QRC-2205 5 QRC-2300 6 QRC-PG2 7 QRC-2213 8 QRC-2204 9 QRC-2222 10 QRC-2225 11 QRC-440 12 QRC-441 13 QRC-417 14 QRC-2118 Stock No.
nozzle cleaning station Statement of Warranty LIMITED WARRANTY: THERMADYNE® warrants that its products will be free of defects in workmanship or material.
nozzle cleaning station Warranty SCHEDULE The warranty is effective below for the time stated in the Warranty Schedule beginning on the date that the authorized distributor delivers the products to the purchaser. THERMADYNE® reserves the right to request documented evidence of date of purchase. Engine Driven Welders Scout®, Raider®, Explorer™ Parts / Labor Original Main Power Stators and Inductors Original Main Power Rectifiers, Control P.C.
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