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Servo Torch for ARC Mate +C series (Option)

OPERATOR'S MANUAL

B-83074EN/05

© FANUC CORPORATION, 2010

 • Original Instructions

Thank you very much for purchasing FANUC Robot.

Before using the Robot, be sure to read the "FANUC Robot SAFETY HANDBOOK (B-80687EN)"
and understand the content.

• No part of this manual may be reproduced in any form.

• The appearance and specifications of this product are subject to change without notice.

The products in this manual are controlled based on Japan's “Foreign Exchange and
Foreign Trade Law". The export from Japan may be subject to an export license by the
government of Japan. Further, re-export to another country may be subject to the license
of the government of the country from where the product is re-exported. Furthermore, the
product may also be controlled by re-export regulations of the United States government.
Should you wish to export or re-export these products, please contact FANUC for advice.

In this manual, we endeavor to include all pertinent matters. There are, however, a very
large number of operations that must not or cannot be performed, and if the manual
contained them all, it would be enormous in volume. It is, therefore, requested to assume
that any operations that are not explicitly described as being possible are "not possible".
B-83074EN/05 SAFETY PRECAUTIONS

SAFETY PRECAUTIONS
This chapter must be read before using the robot.

For detailed functions of the robot operation, read the relevant operator's manual to understand fully its
specification.

For the safety of the operator and the system, follow all safety precautions when operating a robot and its
peripheral equipment installed in a work cell.
For safe use of FANUC robots, you must read and follow the instructions in “FANUC Robot SAFETY
HANDBOOK (B-80687EN)”.

1 DEFINITION OF USER
The personnel can be classified as follows.

Operator:
• Turns the robot controller power on/off
• Starts the robot program from operator panel

Programmer or Teaching operator:

• Operates the robot
• Teaches the robot inside the safety fence

Maintenance technician:
• Operates the robot
• Teaches the robot inside the safety fence
• Performs maintenance (repair, adjustment, replacement)

- Operator is not allowed to work in the safety fence.

- Programmer/Teaching operator and maintenance technician is allowed to work in the safety fence.
Works carried out in the safety fence include transportation, installation, teaching, adjustment, and
maintenance.
- To work inside the safety fence, the person must be trained on proper robot operation.

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SAFETY PRECAUTIONS B-83074EN/05

Table 1 (a) lists the work outside the safety fence. In this table, the symbol “{” means the work allowed
to be carried out by the worker.

Table 1 (a) List of work outside the fence

Programmer or Maintenance
Operator
Teaching operator technician
Turn power ON/OFF to Robot controller { { {
Select operating mode (AUTO, T1, T2) { {
Select remote/local mode { {
Select robot program with teach pendant { {
Select robot program with external device { {
Start robot program with operator’s panel { { {
Start robot program with teach pendant { {
Reset alarm with operator’s panel { {
Reset alarm with teach pendant { {
Set data on teach pendant { {
Teaching with teach pendant { {
Emergency stop with operator’s panel { { {
Emergency stop with teach pendant { { {
Operator’s panel maintenance {
Teach pendant maintenance {

In the robot operating, programming and maintenance, the operator, programmer/teaching operator and
maintenance technician take care of their safety using at least the following safety protectors.

• Use clothes, uniform, overall adequate for the work

• Safety shoes
• Helmet

2 DEFINITION OF SAFETY NOTATIONS

To ensure the safety of users and prevent damage to the machine, this manual indicates each precaution
on safety with "WARNING" or "CAUTION" according to its severity. Supplementary information is
indicated by "NOTE". Read the contents of each "WARNING", "CAUTION" and "NOTE" before
using the robot.

Symbol Definitions
Used if hazard resulting in the death or serious injury of the user will be expected to
WARNING occur if he or she fails to follow the approved procedure.
Used if a hazard resulting in the minor or moderate injury of the user, or equipment
CAUTION damage may be expected to occur if he or she fails to follow the approved
procedure.
Used if a supplementary explanation not related to any of WARNING and CAUTION
NOTE is to be indicated.

• Check this manual thoroughly, and keep it handy for the future reference.

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B-83074EN/05 TABLE OF CONTENTS

TABLE OF CONTENTS
SAFETY PRECAUTIONS............................................................................s-1

1 CONFIGURATION .................................................................................. 1
1.1 BASIC SPECIFICATION ............................................................................... 1
1.2 SYSTEM STRUCTURE ................................................................................. 5
1.3 STRUCTURE OF THE SERVO TORCH ....................................................... 8
1.4 SENSE LEAD CABLE ................................................................................... 9
1.5 AIR BLOW OPTION .................................................................................... 10
2 INSTALLATION .................................................................................... 11
2.1 ATTACHING ROLLER................................................................................. 11
2.2 CABLE CONNECTION................................................................................ 13
3 SOFTWARE SETUP ............................................................................. 15
3.1 SETUP FOR SERVO TORCH ..................................................................... 15
3.1.1 Setup Servo Torch Axis .........................................................................................15
3.1.2 Setup in Weld Equipment Setup Screen.................................................................17
3.1.3 Servo Torch Setup Screen ......................................................................................18
3.2 SERVO TORCH FUNCTION ....................................................................... 19
3.2.1 Teaching of Arc Welding Instructions ...................................................................19
3.2.2 Manual Wire Inching..............................................................................................19
3.2.3 Air Purge Function .................................................................................................20
3.2.4 Touch Retract Start Function .................................................................................20
[Link] Outline ............................................................................................................... 20
[Link] Setup touch retract start ..................................................................................... 22
[Link] Manual setup touch retract start......................................................................... 26
3.3 ATTENCTIONS AND LIMITATIONS FOR USE........................................... 28
4 CHECKS AND MAINTENANCE ........................................................... 29
4.1 DAILY CHECKS .......................................................................................... 29
4.2 PERIODIC CHECK AND MAINTENANCE .................................................. 31
4.3 MAINTENANCE TOOLS ............................................................................. 32
5 PERIODIC MAINTENANCE .................................................................. 33
6 TROUBLESHOOTING .......................................................................... 35
6.1 TROUBLESHOOTING................................................................................. 35
7 ADJUSTMENT ...................................................................................... 37
7.1 MASTERING ............................................................................................... 37
7.1.1 Mastering of the Main Robot Unit .........................................................................37
7.1.2 Mastering of the Servo Torch.................................................................................37
7.2 ADJUSTING ROLLER JAMMING FORCE .................................................. 37
8 REPLACING PARTS ............................................................................ 39
8.1 REPLACING THE TORCH .......................................................................... 39
8.2 REPLACING THE ROLLER......................................................................... 41
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TABLE OF CONTENTS B-83074EN/05

8.3 REPLACING THE MOTOR COVER............................................................ 41

8.4 REPLACING THE MOTOR (SERVO TORCH FOR ALUMINUM/TIG) ........ 43
8.5 REPLACING THE MOTOR (SERVO TORCH FOR MILD STEEL).............. 44
8.6 REPLACING THE FLEXIBLE CONDUIT AND LINER
(SERVO TORCH FOR ALUMINUM) ........................................................... 45
8.7 REPLACING THE FLEXIBLE CONDUIT AND LINER
(SERVO TORCH FOR MILD STEEL).......................................................... 49
8.8 REPLACING THE FLEXIBLE CONDUIT AND LINER (Servo torch for TIG)50
9 CABLE REPLACEMENT ...................................................................... 52
9.1 CABLE WIRING........................................................................................... 52
9.2 REPLACING CABLES................................................................................. 53
9.2.1 Replacing the Welding Power Cable......................................................................53
9.2.2 Replacing the Motor Cable.....................................................................................57

APPENDIX
A MAINTENANCE PARTS ....................................................................... 61
A.1 SERVO TORCH FOR ALUMINUM.............................................................. 63
A.2 Servo torch for mild steel ............................................................................. 67
A.3 SERVO TORCH FOR TIG ........................................................................... 71
B CIRCUIT DIAGRAM .............................................................................. 72
C PERIODIC MAINTENANCE TABLE ..................................................... 78
D STRENGTH OF BOLT AND BOLT TORQUE LIST.............................. 80

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B-83074EN/05 1. CONFIGURATION

1 CONFIGURATION
For the structure of the mechanical unit of each robot, refer to the following robot maintenance manuals:

ARC Mate 100iC

: FANUC Robot ARC Mate 100iC, M-10iA, ARC Mate 100iCe, M-10iAe OPERATOR’S MANUAL
(B–82754EN)
: FANUC Robot ARC Mate 100iC/12/7L/12S/8L, M-10iA/12/7L/12S/8L
OPERATOR’S ANUAL (B–83654EN)
ARC Mate 120iC
: FANUC Robot ARC Mate 120iC, M-20iA OPERATOR’S MANUAL (B–82874EN)
Welding power supply
: Controller ARC Welding Power Supply Option (LINCOLN/FANUC welding power supply)
OPERATOR’S MANUAL (B-83614EN-1)

1.1 BASIC SPECIFICATION

Specification and external dimension are shown below.

Table 1.1 (a) Specification (Servo torch for aluminum)

Wire size φ1.2mm
Wire feeding speed Max 35m/min
Welding currency Max 500A

Table 1.1 (b) Specification (Servo torch for mild steel)

Wire size φ0.9、φ1.0、φ1.2mm
Wire feeding speed Max 35m/min
Welding currency Max 500A

Table 1.1 (c) Specification (Servo torch for TIG)

Wire size φ1.2mm
Wire feeding speed Max 5m/min
Welding currency Max 400A

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1. CONFIGURATION B-83074EN/05

174.7
45.4 54.8 22.6 145.5
137.9

8.3
104.3
104.3

DIA.14
23.5
405.2

3.5

ABIROB W500 35DEG NECK

11.9
4

Fig. 1.1 (a) External dimension (Servo torch for aluminum)

Table 1.1 (d) Parameter for load setting

Item For Aluminum Unit
Payload 4.540 [kg]
X 6.692 [cm]
Y -0.098 [cm]
Z 12.207 [cm]
Ix 0.273 [kgf･cm･s^2]
Iy 0.345 [kgf･cm･s^2]
Iz 0.111 [kgf･cm･s^2]

Please refer to Chapter 4 of each mechanical unit operator’s manual about method of the load setting.

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B-83074EN/05 1. CONFIGURATION

104.5 45.4 45.4 54.8

20
4
5

42
46

DIA.14
102

114
22.5
478.5

DIA.56

ABIROB A360 35 DEG. LONG NECK

71

Fig, 1.1 (b) External dimension (Servo torch for mild steel)

Table 1.1 (e) Parameter for load setting

Item For Mild steel Unit
Payload 5.000 [kg]
X -4.000 [cm]
Y -0.021 [cm]
Z 13.000 [cm]
Ix 0.300 [kgf･cm･s^2]
Iy 0.375 [kgf･cm･s^2]
Iz 0.116 [kgf･cm･s^2]

Please refer to Chapter 4 of each mechanical unit operator’s manual about method of the load setting.

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1. CONFIGURATION B-83074EN/05

45.4 67.1 61.4 123.1

191.6
156.4
14°

9.3
DIA. 14
406.4

3.5

ABITIG WH400 WO

Fig, 1.1 (c) External dimension (Servo torch for TIG)

Table 1.1 (f) Parameter for load setting

Item For TIG Unit
Payload 4.540 [kg]
X 6.692 [cm]
Y -0.098 [cm]
Z 12.207 [cm]
Ix 0.273 [kgf･cm･s^2]
Iy 0.345 [kgf･cm･s^2]
Iz 0.111 [kgf･cm･s^2]

Please refer to Chapter 4 of each mechanical unit operator’s manual about method of the load setting.

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B-83074EN/05 1. CONFIGURATION

1.2 SYSTEM STRUCTURE

Fig. 1.2 (a) to (c) show the servo torch structure.

(注意)
(Caution)

スリーブユニット
Sleeve unit
A05B-1220-J382
A05B-1220-J382

Robot mechanical unit

ARC Mate 100iC
Mechanical unit of servo torch ロボット機構部
ARCMate
ARC Mate 100iC/6L/7L/12
100iC
A05B-1220-J301 (standard) ARC
ARCMate
Mate100iC/6L
120iC/10L/12L
A05B-1220-J303
サーボトーチ機構部 (CE) ARC Mate 100iC/12
A05B-1220-J301 (標準仕様) ARC Mate 100iC/7L
A05B-1220-J303 (CE仕様) ARC Mate 120iC/10L
Roller assembly ARC Mate 120iC/12L
φ0.9 Roller for steel wire : A05B-1215-J373
ローラ組立
φ1.2O0.9 アルミワイヤ用ローラ
Roller : A05B-1215-J373
for steel wire : A05B-1215-J375
O1.2 アルミワイヤ用ローラ : A05B-1215-J375
Servo torch wrist cable
サーボトーチ手首ケーブル
A05B-1220-J335 (ARC Mate 100iC, ARC Mate 100iC/12)
A05B-1220-J335 (ARC Mate 100iC, ARC Mate 100iC/12)
A05B-1220-J336
A05B-1220-J336(ARC Mate
(ARC Mate100iC/6L/7L)
100iC/6L, /7L)
A05B-1220-J338
A05B-1220-J338(ARC Mate
(ARC Mate120iC/10L/12L)
120iC/10L, /12L)
φ1.2 water cooling aluminum torch
O1.2 水冷アルミ用トーチ
A05B-1220-J351
A05B-1220-J351
ブラケット組立
Bracket assembly
A05B-1220-J321
A05B-1220-J321

(注意)
(Caution)

Sleeve unit
スリーブユニット
A05B-1220-J382
A05B-1220-J382

Mechanical unit of servo torch Robot mechanical unit

サーボトーチ機構部 ロボット機構部
A05B-1220-J301 (standard) ARC Mate120iC
ARC Mate 120iC
A05B-1220-J301 (標準仕様)
A05B-1220-J303 (CE) (CE仕様)
A05B-1220-J303

ローラ組立
Roller assembly
O0.9 アルミワイヤ用ローラ : A05B-1215-J373
φ0.9 Roller
O1.2for steel wire : A05B-1215-J373
アルミワイヤ用ローラ : A05B-1215-J375
φ1.2 Roller for steel wire : A05B-1215-J375

サーボトーチ手首ケーブル
Servo torch wrist cable (ARC Mate 120iC)
A05B-1220-J337
A05B-1220-J337 (ARC Mate 120iC)
φ1.2 water cooling aluminum torch
O1.2 水冷アルミ用トーチ
A05B-1220-J351A05B-1220-J351
Bracket assembly
ブラケット組立
A05B-1220-J322
A05B-1220-J322

Fig. 1.2 (a) system structure (Servo torch for aluminum)

CAUTION
Be sure to hang the flexible conduit. Make bend radius of back of wire feeder or
around the hanging tool more than 400mm, maximize the bend radius of other
parts, so that you can feed wire smoothly. Make length of flexible conduit less than
760mm.
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1. CONFIGURATION B-83074EN/05

(注意)
(Caution)

Mechanical unit of servo torch

A05B-1220-J302 (standard)
A05B-1220-J304 (CE)

サーボトーチ機構部 Robot mechanical unit

ロボット機構部
Roller assembly
A05B-1220-J302 (標準仕様) ARC
ARC Mate 100iC
Mate 100iC
φ0.9 Roller for steel wire
A05B-1220-J304 : A05B-1220-J363
(CE仕様) ARC Mate
Mate 100iC/6L
ARC 100iC/6L/7L/12
φ1.0 Roller for steel wire : A05B-1220-J364 ARC Mate 100iC/7L
ローラ組立 ARC
ARC Mate 120iC/10L/12L
Mate 100iC/12
φ1.2 Roller
φ0.9for steel wire : A05B-1220-J365
鉄ワイヤ用ローラ : A05B-1215-J363 ARC Mate 120iC/10L
φ1.0 鉄ワイヤ用ローラ : A05B-1215-J364 ARC Mate 120iC/12L
φ1.2 鉄ワイヤ用ローラ : A05B-1215-J365
Servo torch wrist cable
サーボトーチ手首ケーブル
A05B-1220-J365 (ARC Mate 100iC, ARC Mate 100iC/12)
A05B-1220-J365 (ARC Mate 100iC, ARC Mate 100iC/12)
A05B-1220-J366 (ARC (ARC
A05B-1220-J366 MateMate
100iC/6L/7L)
100iC/6L, 7L)
A05B-1220-J368 (ARC (ARC
A05B-1220-J368 MateMate
120iC/10L/12L)
120iC/10L, 12L)

φ1.2 air cooling steel torch

O1.2空冷鉄トーチ
A05B-1220-J352Bracket assembly
A05B-1220-J352
ブラケット組立
A05B-1220-J323
A05B-1220-J323

(Caution)
(注意)

Mechanical unit of servo torch

A05B-1220-J302 (standard)
A05B-1220-J304 (CE)
サーボトーチ機構部 Robot mechanical unit
ロボット機構部
A05B-1220-J302 (標準仕様)
Roller assembly ARC Mate120iC
ARC Mate 120iC
A05B-1220-J304 (CE仕様)
φ0.9 Roller for steel wire : A05B-1220-J363
ローラ組立
φ1.0 Roller for steel wire : A05B-1220-J364
φ0.9 鉄ワイヤ用ローラ : A05B-1215-J363
φ1.2 Roller for鉄ワイヤ用ローラ
φ1.0 steel wire : A05B-1220-J365
: A05B-1215-J364
φ1.2 鉄ワイヤ用ローラ : A05B-1215-J365
Servo torch wrist cable
サーボトーチ手首ケーブル
A05B-1220-J367
A05B-1220-J367 (ARC120iC)
(ARC Mate Mate 120iC)

φ1.2 air cooling steel torch

O1.2空冷鉄トーチ
A05B-1220-J352
A05B-1220-J352

ブラケット組立
Bracket assembly
A05B-1220-J323
A05B-1220-J323

Fig. 1.2 (b) system structure (Servo torch for mild steel)

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B-83074EN/05 1. CONFIGURATION

CAUTION
Be sure to hang the flexible conduit.
If it was not hanged, excessive load is applied onto the metal plate of J3 casing
backside and it might be broken.
Make bend radius of back of wire feeder or around the hanging tool more than
400mm, maximize the bend radius of other parts, so that you can feed wire
smoothly. Make length of flexible conduit less than 760mm.

NOTE
When servo torch is specified, allowable payload of robot is below.
ARC Mate 100iC/12 , ARC Mate 120iC/12L : 12kg
ARC Mate 100iC, ARC Mate 100iC/10S, ARC Mate 120iC/10L : 10kg
ARC Mate 100iC/7L : 7kg
ARC Mate 100iC/6L : 6kg
ARC Mate 120iC : 20kg
Do not change the payload of robot which has servo torch because it may cause
breakage.
(It is impossible to change allowable payload depend on the shipment time.)

Torch cable support

トーチケーブルサポート
A05B-1210-J615
A05B-1210-J615

ロボット機構部
Robot mechanical unit
ARC Mate
ARC Mate100iC
100iC
ARC Mate
ARC Mate100iC/12
100iC/12

TIG reconstruction
TIG改造
サーボトーチ機構部
Servo torch mechanical unit A05B-1221-J101
A05B-1221-J101
A05B-1220-J305
A05B-1220-J305

ブラケット組立
Bracket assembly
空冷トーチ
Air A05B-1291-H391
cooling torch : A05B-1291-H391 A05B-1220-J324
A05B-1220-J324
水冷トーチ
Water coolingA05B-1291-H392
torch : A05B-1291-H392

Fig. 1.2 (c) system structure (Servo torch for TIG)

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1. CONFIGURATION B-83074EN/05

1.3 STRUCTURE OF THE SERVO TORCH

Fig. 1.3 (a) shows the drive mechanism of the servo torch. The drive mechanism of the servo torch is such
that the rotation of the AC servo motor is reduced using a gear to turn the wire feed rollers.

NOTE
You can setup Servo Torch axes in MAINTENANCE screen at controlled start
status. Servo Torch axes are set as the axes of motion group 0.

ワイヤ送給ローラ
Wire feed roller

ローラ
Roller
ギヤ
Gear

AC　サーボモータ
AC servo motor

Fig. 1.3 (a) Servo torch drive mechanism

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B-83074EN/05 1. CONFIGURATION

1.4 SENSE LEAD CABLE

Sense lead cable of the welding power supply is supplied to detect welding part voltage correctly.
For Power Wave R350, Power Wave R500, to use STT or Advanced module in welding, installing plus
side and minus side are required.

Sense lead

Welding power
supply
Welding power
supply

Arc welding system Arc welding system

without STT or Advanced module with STT or Advanced module

Fig. 1.4 (a) Installation of the sense lead cable

Below shows specifications of sense lead cable for servo torch .

Between welding power supply and robot mechanical unit

x A05B-1291-H582

For mechanical unit

x A05B-1220-J341 for ARC Mate 100iC series
x A05B-1220-J344 for ARC Mate 120iC series

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1. CONFIGURATION B-83074EN/05

1.5 AIR BLOW OPTION

To clean the spatters inside of the torch nozzle of servo torch, air blow option (A05B-1220-J390) is
prepared. Fig. 1.5 (a) shows air blow option schematic. Air and gas are supplied from the J1 base backside.
Refer to Section 2.2 for J1 base back side interface. To use this option, mechanical unit cable with RO X 2
is required.

AIR or GAS A
(←)

電磁弁2
Solenoid valve 2
AIR(←)

電磁弁1
Solenoid valve 1
AIR(→)
GAS(→)

GAS AIR EE
View
矢視A A
Fig. 1.5 (a) Air blow option schematic

Fig. 1.5 (b) shows circuit diagram.

AIR or GAS (→)

2(A) Solenoid valve 2

EE
1 RO1
2 XBK
3(R) 1(P)
3 0V
4 RO2
AIR (→)

5 24V
GAS (→)

2(A) Solenoid valve 1

3(R) 1(P)

Fig. 1.5 (b) Air blow option circuit diagram.

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B-83074EN/05 2. INSTALLATION

2 INSTALLATION
When servo torch is shipped, you must attach feed roller and jamming roller. This chapter explains about
the procedure.

2.1 ATTACHING ROLLER

(1) Replacing the feed rollers

1) Loosen the knob, open the cover, raise the adjusting bolts, then release the roller lever (2 places).
2) Remove the knurled nut while pressing the feed rollers.
3) Pull out the feed roller from the shaft.
4) Remove the feed roller on the opposite side in the same way.
5) Assemble new feed rollers by reversing the procedure above. Install feed rollers so that the spring
pin stuck into the shaft sits in the groove on the bottom surface of each feed roller.

(2) Replacing the jamming roller

1) Loosen the knob, open the cover, raise the adjusting bolts, then release the roller lever (2 places).
2) Pull out the jamming roller from the roller lever (see the top of Fig. 2.1 (a)).
3) Pull out the pin stuck at the center of the jamming roller. and pull out the upper and lower bushings
from the jamming roller,
4) Remove the opposite side in the same way.
5) For its assembly, please apply the steps above in reversed sequence.

Feed roller
送給ローラ

Jamming roller
加圧ローラ

Cover
カバー
A290-7220-X707
A290-7220-X707

Roller holder
ローラホルダ
A290-7220-X722
A290-7220-X722

Block
ブロック Adjust
調整ボルト bolt
A290-7215-X749
A290-7215-X749 A290-7220-X727
A290-7220-X727

Washer
ワッシャ
A290-7220-X728
A290-7220-X728
Adjust
調整ノブ knob
A290-7220-X725
A290-7220-X725 Spring
スプリング
ノブ A97L-0118-0714#TH10X20
A97L-0118-0714#TH10X20
Knob
A97L-0218-0766#041014
A97L-0218-0766#041014
Nut
ナット
A290-7215-X722(標準仕様)
A290-7215-X722 (standard)
A290-7215-Z722(CE仕様)　(*)
A290-7215-Z722 (CE) (*)
Roller
ローラホルダholder
Feed roller A290-7220-X722
A290-7220-X722
A290-7210-X763 Jamming roller
Bush
ブッシュ (black)
(黒)
(A05B-1215-J363
送給ローラ 加圧ローラ
A05B-1215-J363 (φ0.9 mild steel)
A290-7215-X750
A290-7215-X750 A05B-1215-J363 (φ0.9
(φ0.9 mild steel) is specified.) A05B-1220-J348 (φ0.9 mild鉄)
steel double nut spec.)
A290-7210-X764
A290-7210-X763 A05B-1220-J348
A05B-1215-J364 (φ0.9
(φ1.0 mild鉄 ダブルナット仕様)
steel)
(A05B-1215-J364
(A05B-1215-J363 (φ0.9 鉄) 指定時) A05B-1215-J364 (φ1.0
A05B-1220-J349 (φ1.0 mild鉄)
steel double nut spec.)
(φ1.0 mild steel) is specified.)
A290-7210-X764 A05B-1220-J349 (φ1.0 鉄 ダブルナット仕様)
Bolt M3 x 8 (2) (2)
ボルト　M3X8 A05B-1215-J365 (φ1.2 mild
A05B-1215-J365 (φ1.2 鉄)steel)
A290-7210-X765
(A05B-1215-J364 (φ1.0 鉄) 指定時) Tightening torque 0.6Nm
締付けトルク　0.6Nm A05B-1220-J350 (φ1.2 mild鉄steel double nut spec.)
A290-7210-X765
(A05B-1215-J365
A05B-1220-J350 (φ1.2 ダブルナット仕様)
ロックタイト243を塗布すること
Apply LOCTITE 243. A05B-1215-J375 (φ1.2
A05B-1215-J375 aluminum)
(φ1.2 アルミ)
(A05B-1215-J365
(φ1.2 mild steel) is (φ1.2 鉄) 指定時)
specified) A05B-1220-J347 (φ1.2 aluminum double nut spec.)
Bush
ブッシュ (white)
(白) A05B-1220-J347 (φ1.2 アルミ ダブルナット仕様)
A290-7215-X765
A290-7215-X765
(A05B-1215-J375 A290-7215-X747 Pin
ピン
(A05B-1215-J375
(φ1.2 aluminum) is(φ1.2 アルミ) 指定時)
specified) JB-PH-H7A-6X20S45C
JB-PH-H7A-6X20S45C

Roller bush Bush

ローラブッシュ ブッシュ
A290-7220-Z744 A290-7220-X746
A290-7220-Z744 A290-7220-X746
Pin
ピン
A290-7220-X723
A290-7220-X723
CCリング
ring
A6-CJR-5
A6-CJR-5

Replacing feed rollers

送給ローラの交換 Replacing jamming rollers
加圧ローラの交換

(*)(*)
When CE specification is specified, a special fixture (Spec. : A290-7220-X981 or A290-7220-X982) is required.
CE仕様指定時はナット外し治具(A290-7220-X981またはA290-7220-X982)が必要になります。

Fig. 2.1 (a) Attaching roller

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2. INSTALLATION B-83074EN/05

When CE specification is specified, protector is attached around the feed roller.

Protector

Fig. 2.1 (b) Protector (When CE specification is specified)

Fig.2.1 (c) shows method of using fixture (Spec: A290-7220-X981) to remove nut. It is necessary when
CE specification is specified.

Fixture to remove nut

(Spec : A290-7220-X981)

Fig. 2.1 (c) Fixture to remove nut (When CE specification is specified)

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B-83074EN/05 2. INSTALLATION

2.2 CABLE CONNECTION

Connect servo torch cable to J1 base of robot referring to Fig.2.2 (a) to (c).

CAUTION
When changing wire feeder made by LINCOLN by servo torch, do not use wire
feeder control cable (between connector panel of robot main body and welding
power supply). Be sure to use servo torch connection cable (between connector
panel of robot main body and robot controller.
If using wire feeder cable (between connector panel of robot main body and
welding power supply) and turning on the power, it will cause breakdown of
feeder head main board inside the welding power supply.

Servo torch cable

Detail A
Fig. 2.2 (a) Cable connection

Welding
Weldingpower
powercable (NOTE
(NOTE ) 1)
EE
EEinterface
interface(RI/RO x 1)
(RI/RO*1)
Servo torch cable
Servo torch cable

Welding power
Welding cable (NOTE)
power (NOTE 1)

(Air outlet (Black))

Welding gas
Welding gas (Blue)
(Air inlet)

J1 base side J4 connector plate side

Fig. 2.2 (b) ARC Mate 100iC option cable interface
(A05B-1221-H202, H203, H206, H232, H233, H236, A05B-1224-H202, H203, H206, H232, H233, H236 are specified)

- 13 -
2. INSTALLATION B-83074EN/05

NOTE
1 These interfaces are attached only when A05B-1221-H203, H206, H233, H236,
A05B-1224-H203, H206, H233, H236 are specified.
2 Tolerance electrical current of the welding power cable is 5A/mm2.
Rated current of welding cable of A05B-1221-H203, H233 and A05B-1224-H203,
H233 is 190A. (38mm2 1 pcs)
Rated current of welding cable of A05B-1221-H206, H236 and A05B-1224-H206,
H236 is 300A. (60mm2 2 pcs)

Welding power Servo torchcable

Servo torch cable
Welding power
cable (NOTE 1) Servotorch
Servo torch cable
cable (Airoutlet)
(Air outlet) (Black)
(Black)
(NOTE)
Weldinggas
Welding gas(Blue)
(Blue)
(Air
(Airinlet)
inlet)
End
EE effector
interface
interface
(RI/RO x 1)
Weldinggas
Welding gas (RI/RO*1)

Weldingpower
Welding power
(NOTE)
cable (NOTE 1)

J1 base side J4 connector plate side

Fig. 2.2 (c) ARC Mate 120iC option cable interface
(A05B-1222-H202, H203, H206, H232, H233, H236, A05B-1225-H232, H233, H236 are specified)

NOTE
1 These interfaces are attached only when A05B-1222-H203, H206, H233, H236,
A05B-1225-H233, H236 are specified.
2 Tolerance electrical current of the welding power cable is 5A/mm2.
Rated current of welding cable of A05B-1222-H203, H233 and A05B-1225-H233
is 190A. (38mm2 1 pcs)
Rated current of welding cable of A05B-1222-H206, H236 and A05B-1225-H236
is 300A. (60mm2 2 pcs)

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B-83074EN/05 3. SOFTWARE SETUP

3 SOFTWARE SETUP
The Servo Torch is a mechanism which feeds welding wire by a servo motor. Servo Torch is controlled
by Servo Torch control Software (Servo Torch Control function) on ArcTool software. Servo Torch
Control function is supported in the Lincoln weld equipment configuration only.
Wire feeding by a servo motor always stabilize actual wire feed speed during welding and avoid influence
of disturbance such as a bend of conduit tube by robot motion. This also enables high accuracy wire
feeding.
In case of aluminum welding, it is possible to stabilize the welding easily by using a heat wave function.
About the heat wave function, please refer to the following manual according to your system.

R-30iB CONTROLLER : Chapter 10 in “R-30iB/R-30iB Mate/R-30iB Plus CONTROLLER Arc

Welding Function OPERATOR’S MANUAL (B-83284EN-3)”
R-30iA CONTROLLER : Section 13.20 in “R-30iA CONTROLLER ARC TOOL OPERATOR’S
MANUAL (B-83124EN-3)”
R-30iA Mate CONTROLLER : Section 13.18 in “R-30iA Mate CONTROLLER LR ARC TOOL
OPERATOR’S MANUAL (B-83134EN-2)”

Before using Servo Torch, “3.1 SETUP FOR SERVO TORCH” should be performed.

3.1 SETUP FOR SERVO TORCH

Following setups are required in order to use Servo Torch.
- Setup Servo Torch axis
- Setup in weld equipment setup screen
- Setup in Servo Torch setup screen

This section describes the details of these setups.

3.1.1 Setup Servo Torch Axis

You can setup Servo Torch axis in MAINTENANCE screen after controlled start. Servo Torch axis is set
as the axis of motion group 0 (axis for no motion group).

Procedure 3-1 Setup servo torch axis

Step
1 Turn on the controller with the [PREV] and the [NEXT] key pressed. Then select [3 Controlled
start].
2 Press the [MENU] key and select [MAINTENANCE]. The following screen will be displayed.

ROBOT MAINTENANCE
1/10
Setup Robot System Variables

Group Robot Library/Option Ext Axes

1 M-10iA(B401 B402) 0
0 ServoTorch for Steel 0

[TYPE] ORD NO AUTO MANUAL

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3. SOFTWARE SETUP B-83074EN/05

3 Move the cursor to [ServoTorch for Steel] (or [ServoTorch for Alumi] in aluminum welding system)
and press F4 [MANUAL]. Following screen is displayed. Select [1: Normal].

------ Setup Servo Torch axis ------

FSSB AXIS AMP
ServoTorch 1 **** **** ****
ServoTorch 2 **** **** ****
ServoTorch 3 **** **** ****
ServoTorch 4 **** **** ****

Select Setup type

( 0: Exit 1: Normal 2: ISDT Direct )

Setup type ? 1

4 Input the number of Servo Torch axes. If only one ServoTorch is used, please enter 1. If two or more
Servo Torches are used, please enter the number. The maximum number of Servo Torch axes is 4.

Enter number of axes (1 – 4)?:

5 Input the FSSB number for Servo Torch axis 1. It is necessary to input the appropriate FSSB number
for Servo Torch axis corresponding to your hardware configuration. For more detail, please refer to
the following manual according to your system.
R-30iB CONTROLLER : APPENDIX B.8 in “R-30iB/R-30iB Mate CONTROLLER
OPERATOR’S MANUAL (Basic Operation) (B-83284EN)”
R-30iA CONTROLLER : APPENDIX C.8 in “R-30iA CONTROLLER ARC TOOL
OPERATOR’S MANUAL (B-83124EN-3)”
R-30iA Mate CONTROLLER : APPENDIX B.7 in “R-30iA Mate CONTROLLER LR ARC
TOOL OPERATOR’S MANUAL (B-83134EN-2)”

ServoTorch 1:
Enter FSSB number (1 – 3 or 5)?:

When the FSSB number for Servo Torch axis is 2, it is necessary to input the total number of axes
used by FSSB 1.

Total number of axes on FSSB 1 ?:

(Current value = 6)

6 Input the hardware axis number.

ServoTorch 1:
Enter hardware axis (1 – 32)?:

7 Input the amplifier number.

ServoTorch 1:
Enter amplifier number ?:

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B-83074EN/05 3. SOFTWARE SETUP
8 If the number of Servo Torch axes is set to 2 or more at step 4, questions of Step 5 - 7 are repeated
for each Servo Torch. Please repeat the setup for each Servo Torch.
9 After a few seconds, the screen is returned to ROBOT MAINTENANCE screen. Check that the
value of “Ext Axes” for [ServoTorch for Steel] (or [ServoTorch for Alumi] in aluminum welding
system) matches with the number of Servo Torch axes (The following screen is the case that the
number of Servo Torch is 1). According to this step, setting of Servo Torch axis is completed. Press
FCTN key and select the [START (COLD)].
ROBOT MAINTENANCE
1/10
Setup Robot System Variables

Group Robot Library/Option Ext Axes

1 M-10iA(B401 B402) 0
0 ServoTorch for steel 1

[TYPE] ORD NO AUTO MANUAL

3.1.2 Setup in Weld Equipment Setup Screen

Wire type can be set in Weld equipment setup screen. In addition, Servo Torch setup screen is entered
from this screen. Setting items and descriptions relates to Servo Torch are as following.

Table 3.1.2 (a) Setting items and descriptions relates to Servo Torch in Weld equipment setup screen
Item Description
Wire size Specifies diameter of welding wire. Cycle power is required to enable this changing.
Wire material Specifies material of welding wire. Cycle power is required to enable this changing.
Servo Torch Servo Torch setup screen is entered by pressing the [ENTER] key with the cursor located at
'DETAIL' of this item.

NOTE
Please set correct wire type. Otherwise correct wire feed speed is not issued at
welding and welding is not performed correctly.

Procedure 3-2 Setup in weld equipment setup screen

Step
1 Press the [MENU] key and select [SETUP].
2 Press F1 [TYPE] and select [Weld Equip]. The following screen will be displayed.

SETUP Weld Equip

1/10
Welder: Lincoln Electric PowerWave+Enet

Feeder: Servo Torch

1 Wire size: 1.2 mm

2 Wire material: Steel
3 WIRE+ WIRE− speed: 80 cm/min
4 High WIRE+ speed: 500cm/min
5 Feed forward/backward: ENABLED
6 Servo Torch (ENABLED ): <*DETAIL*>

Timing
7 Arc start error time: 1.40 sec
8 Arc detect time: 0.005 sec
9 Arc loss error time: 0.25 sec
10 Gas detect time: 0.05 sec

[ TYPE ] HELP

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3. SOFTWARE SETUP B-83074EN/05

3 Move the cursor to the item of [Wire size] or [Wire material]. Press F4 [CHOICE] and select desired
items from displayed menu. When those settings are changed, please cycle power.
4 Move the cursor to [DETAIL] of the line of [Servo Torch] and press the [ENTER] key. Servo Torch
setup screen is displayed. The next subsection explains items in Servo Torch setup screen.

3.1.3 Servo Torch Setup Screen

This screen is entered from Weld equipment setup screen.
Setting items and descriptions in this screen are as following.

Table 3.1.3 (a) Setting items and descriptions in servo torch setup screen
Item Description
ServoTorch function Enable/Disable Servo Torch control function. Cycle power is required to enable this
changing.
ServoTorch axis index Specifies the Servo Torch axis index. Servo Torch axes are set as the axes of Group
0. The axis index to be specified is the index number of the axis in Group 0. If the
index is set to 0, Servo Torch control function is disabled. Cycle power is required to
enable this changing.
Wire inching mode Specifies wire inching mode (NORMAL or CONSTANT).
Inch length (mm) Specifies inching length in constant inching mode.
Touch Retract Start This is enabled by default (This is defined as $SVT_CONFIG[Servo Torch axis
index].$TCH_RET_ENA in system variable screen). This function is a function to
reduce sputter at the arc start by generating an arc while retracting a wire after the
wire touches to the work. For more detail, please refer to the Subsection 3.2.4.
Sense Lead setting This must be set according to the sense lead connection and system configuration. If
this setting is not correct, welding can not be performed correctly. This setting item is
displayed in this screen at the V7.70 software or later. If this setting item is not
displayed in your system, please change directly in system variable screen. This
setting is defined by $AWELEWC[weld equipment number].$AO1_SEL. Cycle power
of robot controller / weld equipment is required to enable this changing.

In case of normal sense lead connection and system configuration, please refer to the
following descriptions.
• If your system does not use Servo Torch, it is not necessary to change this setting
(the initial value is 0).
• When the weld equipment is Lincoln PowerWave R350 or PowerWave R500, it is
not necessary to change this setting from the default value.
• When the weld equipment is Lincoln PowerWave 455M/STT, please set this to 3.
• When the weld equipment is Lincoln PowerWave other than above-mentioned (ex:
PowerWave i400), please set this to 2.
Air purge function Enable/Disable air purge function.
Air purge signal Specifies the kind of signal to control the solenoid valve for air purge. There is no need
to change this setting for usual case. Please change this setting only when the wiring
of the signal which controls the solenoid valve for air purge is different from standard
specification.
Default setting : Weld Eq.1 is RO[2], Weld Eq.2 is RO[10]
Post flow time (sec) Specifies time between stopping Servo Torch and stopping air purge.

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B-83074EN/05 3. SOFTWARE SETUP

Procedure 3-3 Setup in servo torch setup screen

Step
1 Press the [MENU] key and select [SETUP].
2 Press F1 [TYPE] and select [Weld Equip] from the displayed menu.
3 Move the cursor to [DETAIL] in the line of [Servo Torch] and press the [ENTER] key. The
following screen will be displayed.
SETUP Weld Equip
1/9
Servo Torch setup
1 ServoTorch function: DISABLE
2 ServoTorch axis index: 0
3 Wire inching mode: NORMAL
4 inch length: 15.000mm
5 Touch Retract Start: ENABLE
6 Sense Lead setting: 0

Air purge setup

7 Air purge function: DISABLE
8 Air purge signal: RO[ 2]
9 Post flow time: 0.50sec

[ TYPE ] HELP ENABLE DISABLE

4 Press F4 [ENABLE] after moving the cursor to [ServoTorch function]. And, input the appropriate
Servo Torch axis number after moving the cursor to [ServoTorch axis index] (Normally, Servo
Torch axis index number is 1 in the one Servo Torch configuration. In the two Servo Torch
configuration, Servo Torch axis index 1 is for weld equipment 1 and Servo Torch axis index 2 is for
weld equipment 2).
5 Input the appropriate number according to your configuration after moving the cursor to [Sense Lead
setting].
6 Cycle power the robot controller and weld equipment (Setting in step 4 and 5 enables after cycle
power).
7 If necessary, please execute the other settings in this screen. When the [PREV] key is pressed,
displaying is return to Weld equipment setup screen from Servo Torch setup screen.

3.2 SERVO TORCH FUNCTION

3.2.1 Teaching of Arc Welding Instructions

Weld Start / End instructions are used as well as the not Servo Torch configuration.

3.2.2 Manual Wire Inching

Following two wire inching modes are prepared for Servo Torch.
- Normal inching
Please hold the deadman switch and enable the teach pendant. And please switch to T1 or T2 mode.
In that state, WIRE+ key or WIRE- key with holding SHIFT key on a teach pendant are used for
feeding/retracting wire as well as an ordinary wire feeder. Wire feed speed is automatically changed
to high speed when the feeding wire operation is executed over 2 sec.
- Constant inching
Constant inching can be also executed according to the procedure of above Normal inching.
However, inching speed is not changed to high speed. When wire inching is continued and wire is
inched by specified length, wire inching is stopped automatically. The length to stop inching is
specified in Servo Torch setup screen. If the keys are released before wire is inched by specified
length, wire inching is stopped immediately.
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3. SOFTWARE SETUP B-83074EN/05

NOTE
x Wire inching can be executed without SHIFT key in V7.50 software or later.
However, inching speed is not changed to high speed with no SHIFT key
inching.
x Remote wire inching can be performed only when the Servo Torch motor is
activated as well as the manual wire inching.

3.2.3 Air Purge Function

Air purge function removes dust in Servo Torch wire feed mechanism by blowing high-pressured air. If
the air purge option is attached to Servo Torch mechanism, air purge function enables following two
operation.
- When the Servo Torch axis start moving, air purge starts.
- After the Servo Torch axis stops and the specified time (post flow time) passes, air purge stops.

Air purge is executed not only at welding but also at inching.

If Power Off stop is performed during air purge, post flow is not executed and air purge is stopped
immediately.
Air purge can be executed manually in I/O screen by switching the status of the signal which is assigned
as the air purge control signal.
When a RO or a DO is assigned as the air purge signal, a comment of “SVTorch air purge” is added for
the signal in I/O screen.

Procedure 3-4 Manual execution of air purge

Condition
- The air purge option is attached to Servo Torch mechanism.
- Servo Torch control function is enabled.
- Air purge function is enabled.

Step
1 Press the [MENU] key and select [I/O].
2 Press F1 [TYPE] and select the screen corresponding to the type of the air purge control signal. This
procedure explains the case that RO[2] is set as the air purge control signal (default setting). In this
case, select the [Robot].
3 If the displayed screen is an input signal screen, press F3 [IN/OUT] to switch the screen into an
output signal screen.
4 Move the cursor to the RO[2] and press F4[ON] or F5[OFF] to switch the status of the signal. If the
status of the signal is ON, air purge is executed. If the status of the signal is OFF, air purge is
stopped.

3.2.4 Touch Retract Start Function

[Link] Outline
Please refer to following figures about the outline of the touch retract start.
If the software is before 7DA7 (V7.70) series and improved touch retract start option (A05B-xxxx-J583)
is not ordered, sequences of wire preheat and arc heat input (described in 3 and 6 in following figure) can
not be executed. Even if the software is before 7DA7 (V7.70) series, improved touch retract start option
enables those sequences. And, those are enable if the software is 7DC1 (V8.10) or later.

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B-83074EN/05 3. SOFTWARE SETUP

Forward feeding starts Forward feeding stops

by weld start instruction after detecting the touch Wire Preheat starts Backward feeding starts

1 2 3 4

Wire detaches from work Shift to production welding

and Arc generates Arc Heat Input starts

5 6 7

Arc molten pool

Fig. [Link](a) Outline of touch retract start motion

Arc generates

40V

30V

20V

10V
400A
Wire Preheat Arc Heat Input Current
300A Wire Preheat Retract Current
Start Current
200A

100A

Wire Preheat Duration Arc Heat Input Duration

Touch Retract Start Sequence Production welding

Fig. [Link](b) Sample waveform of voltage/current during touch retract start

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3. SOFTWARE SETUP B-83074EN/05

[Link] Setup touch retract start

Setting items and descriptions concerning to touch retract start are as following.

Table [Link] (a) Setting items and descriptions for Touch Retract Start
Item Description
TchRetract Sch First, please confirm that the setting of [Wire size] (this item exits in SETUP Weld
(Touch Retract Mode) Equip screen) is set correctly. Setting result of this item changes corresponding to the
[Wire size].

This item has selection menus that are shown below. Please select the touch retract
mode corresponding to welding wire material and welding process (CV, Pulse, etc.)
that are used in your system. When this setting is done, all settings of touch retract
start (wire preheat setting, arc heat input setting) are automatically set to the
recommended value. Therefore, touch retract start setting is normally finished by this
selection. It is possible to adjust each setting items if you are not satisfied with the
performance of arc start by the recommended setting of touch retract start. Please note
that the current settings are reset to recommended value when the touch retract mode
is changed.

z NO heating (This is named [Initialize] in the 7DA7/14 or before)

Touch retract start is executed with no wire preheat and no arc heat input. This
mode ignores the wire preheat setting and arc heat input setting.

z Steel -Pulse (This is named [Pulse] in the 7DA7/18 or before)

Recommended values for pulse welding with steel wire are automatically set.

z Steel -Pulse(heat+) (This is named [Pulse(heat+)] in the 7DA7/18 or before)

Recommended values for pulse welding with steel wire are automatically set. And
this mode increases the weld penetration around the weld start position. However,
please note this mode has a tendency that the top of welding bead becomes big
because the arc heat input duration is long.

z Steel -STT (This is named [STT welding] in the 7DA7/18 or before)

Recommended values for STT welding with steel wire are automatically set.

z Steel -CV (This mode is not supported in the 7DA7 series or before)
Recommended values for CV welding with steel wire are automatically set.

z Aluminum -CV,Pulse (This is named [Aluminum] in the 7DA7/18 or before)

Recommended values for any welding with aluminum wire are automatically set.

z Stainless -CV,Pulse (This mode is supported in 7DA7/19 or later)

Recommended values for any welding with stainless wire are automatically set.

z For general use (This mode is supported in 7DA7/19 or later)

Please select this mode when the system executes the welding excluding
above-mentioned touch retract modes. Recommended values for this mode are not
prepared. So it is necessary to set all settings of touch retract start manually.
Wire Preheat This item specifies the 1st current command during wire preheat (Refer to Fig.
Start Current [Link](b)). If this item is not displayed in your software version, please set the value of
(Amps) $SVT_TRS[servo torch axis index].$TRS_CURR1 (unit : [Amps]) in system variables
screen. In the case of aluminum welding, the tip of wire easily melts and wirestick
occurs if a lot of wire preheat is executed. If it occurs, there is an adverse effect to the
touch retract motion. So it is necessary to set this to low. In the aluminum welding, this
is normally set to 10A - 40A. In the excluding the aluminum welding, this is normally set
to 40A. In addition, it is impossible to specify the wire preheat start duration (The
duration is always constant).

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B-83074EN/05 3. SOFTWARE SETUP

Item Description
Wire Preheat This item specifies the 2nd current command during wire preheat (Refer to Fig.
Retract Current [Link](b)). There is an effect of promoting the tip of wire melt. If the tip of wire is not
(Amps) easily melts, metal transfer is not executed smoothly. As the result, spatter generates
by thrusting the wire into the work. In the aluminum welding, this is normally set to 20A
- 60A. In the excluding the aluminum welding, this is normally set to 60A - 200A.
Wire Preheat Time This item specifies the 2nd current duration during wire preheat. This is normally set to
0.01sec – 0.1sec.
Wire Preheat WFS When the tip of wire detaches from the work, arc generates. This item specifies the
(Wire retract speed after wire retract speed after the wire preheat ends. Unit is the same to wire speed units that
the wire preheat) system uses (this is defined at [Wire speed units] in controlled start screen). If this is
too slow, spatter generates because the tip of molten wire touches to the work. If this is
too fast, there is a possibility that the generated arc lost or wirestick at contact tip.
Please set this speed as slow as possible in a range where the spatter is not
generated. This is normally set to -100cm/min - -350cm/min.
Arc Heat Current This item specifies the current command during arc heat input. There is an effect that
(Amps) the surface of work melts by the arc heat input. It is possible to reduce the spatter
because the tip of molten wire is adsorbed to the surface of molten work. Please note
that it is necessary to adjust the [Arc heat WFS] (Wire Feed Speed during arc heat
input) if this current is changed (Please refer to the following item of [Arc heat WFS]).
This is normally set to 60A - 300A.
Arc Heat Time This item specifies the duration of arc heat input. Arc Heat duration can not be
adjusted to [Arc detect time] (this is defined in SETUP Weld Equip screen) or less. This
is normally set to 0.005sec - 0.150sec.
Arc Heat WFS This item specifies the wire feed speed during arc heat input. Unit is the same to wire
(Wire feed speed during speed units that system uses (this is defined at [Wire speed units] in controlled start
arc heat input) screen).
It is necessary to setup arc heat input parameters (Amps, Time, this item) synthetically.
When this speed is too slow compared with a certain arc heat input current, there is a
possibility that the generated arc lost or wirestick at contact tip because of the wire
burnback. Even if those problems are not generated, the bead shape around weld start
position tends to become worse because the arc heat input sequence shifts to the
production welding in the state of long arc length. When this speed is too fast
compared with certain arc heat input current, there is a possibility that the generated
arc lost or spatter generates because the wire thrusts into the work during arc heat
input. It is necessary to adjust this speed for the maximum effect of arc heat input. That
means, the tip of wire keeps the position as near as possible to the work in a range
where the spatter is not generated. This is normally set to 200cm/min - 1000cm/min.
Please note that the adjustment of this speed may ineffectual when the arc heat time is
very short (for example, 0.005sec). Because the execution time of wire feed speed is
also very short. In that case, it is necessary to adjust those parameters synthetically.

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3. SOFTWARE SETUP B-83074EN/05

Before executing the following procedure 3-5 and 3-6, please confirm the top item name that is displayed at
DATA menu (press F1[TYPE] key after pressing DATA key). If it is [Weld Sched], please execute the
procedure 3-5. If it is [Weld Procedure], please execute the procedure 3-6.

Procedure 3-5 SETUP Touch Retract Start (in the case of [Weld Sched])
Condition
x Initial setting of Servo Torch is already finished (Refer to Section 3.1)
x Improved Touch Retract Start option (A05B-XXXX-J583) is ordered if the software is 7DA7 series
or before
x The firmware of Lincoln welder receives this function (welder has the welding mode 220)
x The communication between robot controller and Lincoln welder has been established

Step
1 Press the [MENU] key and select [SETUP].
2 Press F1 [TYPE] key and select [Weld Equip]. SETUP Weld Equip screen will be displayed.
3 Move the cursor to [Servo Torch] and press the [ENTER] key. SETUP Servo Torch screen will be
displayed.
4 Move the cursor to [Touch Retract Start] and press F3[DETAIL]. Following screen will be
displayed.

SETUP Weld Equip

1/8
SETUP Touch Retract Start
1 Touch Retract Mode: Steel-Pulse

Wire Preheat
2 Start current: 40.0 Amps
3 Retract current: 200.0 Amps
4 Duration: 85 msec
5 Wire retract speed: -200.0 cm/min

Arc Heat Input

6 Current: 300.0 Amps
7 Duration(Arc det time): 0.005 sec
8 Wire Feed Speed: 370.0 cm/min

[ TYPE ] CHOICE

5 When the [Touch Retract Mode] is set, all settings are automatically set to the recommended value
corresponding to the specified mode. So it is not necessary to set each touch retract settings. If you
are not satisfied with the performance of recommended value or desired touch retract mode is not
exists (in the case of [For general use] is selected), please adjust manually each touch retract settings.
About the manual setting, please refer to the next subsection.

Procedure 3-6 SETUP Touch Retract Start (in the case of [Weld Procedure])
Condition
x Initial setting of Servo Torch is already finished (Refer to Section 3.1)
x Improved Touch Retract Start option (A05B-XXXX-J583) is ordered if the software is 7DA7 series
or before
x The firmware of Lincoln welder receives this function (welder has the welding mode 220)
x The communication between robot controller and Lincoln welder has been established

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B-83074EN/05 3. SOFTWARE SETUP

Step
1 Press F1 [TYPE] key after pressing DATA key. Select [Weld Procedure] from the displayed menu.
DATA Weld Procedure screen is displayed.
2 Move the cursor to [Procedure] that you would like to use and press [ENTER] key. Following screen
is displayed. It is possible to setup enable/disable of touch retract start in each weld procedures. By
the way, the setup enable/disable of touch retract start is also exists in SETUP Servo Torch screen
(refer to step 1-3 in procedure 3-5), it defines enable/disable of touch retract start in the servo torch
axis. If it disabled, touch retract start is disabled in all weld procedures that uses the servo torch axis
(In the DATA Weld Procedure screen, the setting item of [Touch Retract] is not displayed).

DATA Weld Procedure 1

1/14
- Procedure 1[ ]
Weld equipment: 1
Manufacturer: Lincoln Electric
Model: PowerWave+Enet
File name: AWE1WP01
Schedules: 3

Touch Retract: ENABLED

Runin: DISABLED
Burnback: ENABLED
Wirestick resets: 3 ENABLED
Ramping: DISABLED

Gas purge: 0.35 sec

Gas preflow: 0.00 sec
Gas postflow: 0.00 sec
Arc End pre-time: 0 msec
Strike wire feed speed: 125cm/min

[ TYPE ] DETAIL [CMND] [VIEW] HELP

3 Confirm that the [Touch Retract] is enabled. If it is disabled, please enable it.
4 Move the cursor to [Schedules] and press the [ENTER] key. Following screen is displayed.

DATA Weld Procedure 1

3/13
+ Procedure 1[ ]
+ Mode 21[CV ]
- Schedules

TchRetract Sch setup: For general use

TchRetract Sch # Amps Time WFS

Wire Preheat Start 40.0 ---- ---
Wire Preheat 60.0 0.010 -200.0
Arc heat 60.0 0.005 225.0

Schedule Amps Volts Speed Time

Sch 1 200.0 20.0 20.0 0.00
Sch 2 200.0 20.0 20.0 0.00
Sch 3 200.0 20.0 20.0 0.00

[ TYPE ] DETAIL [CMND] [VIEW] HELP

5 When the [TchRetract Sch setup] is set, all settings are automatically set to the recommended value
corresponding to the specified touch retract mode. So it is not necessary to set each touch retract
settings. If you are not satisfied with the performance of recommended value or desired [TchRetract
Sch setup] is not exists (in the case of [For general use] is selected), please adjust manually each
settings. About the manual setting, please refer to the next subsection.

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3. SOFTWARE SETUP B-83074EN/05

[Link] Manual setup touch retract start

Please refer to the following procedure about the manual setup of touch retract start.

Procedure 3-7 Manual SETUP Touch Retract Start

Condition
x Though you set the touch retract mode and confirm the performance of touch retract with
recommended parameters, you are not satisfied with it. Or, desired touch retract mode is not exists
(in the case of [For general use] is selected). In those cases, please execute this procedure.
x Beforehand, please define the production weld schedule (It is not necessary to consider the spatter at
the beginning of arc start). Please define the production weld schedule for desired weld penetration,
desired beat shape, etc.
x Beforehand, please define the weld end schedule (craterfill and burnback). The tip of wire condition
influences the phenomenon of arc generation by the touch retract start. Therefore, it is necessary to
define the weld end schedule beforehand to stabilize the tip of wire condition at previous welding.
The ideal condition is that the tip of wire is not a large globular more than the wire diameter.

Step
1 This step checks whether the spatter is reduced or not when the amount of wire preheat is
increased or decreased.
If your system is aluminum welding, it is not necessary to execute this step (the reason is explained
at the item of [Wire Preheat Start Current] and [Wire Preheat Retract Current] in Table [Link] (a)).
First, please confirm the value of wire preheat duration. If the value is 10msec - 20msec, please
change it to 30msec - 50msec. If this value is originally over 30msec, it is not necessary to change.
After that, please confirm whether the spatter is reduced or not with changing the wire preheat retract
current. In this confirmation, amount of this increment or decrement is about 20Amps. Normally, the
confirmation range is from 60Amps to 200Amps. If the spatter is reduced, please find the best value
of wire preheat retract current. Besides, there is no problem to shorten the wire preheat duration as
long as the spatter is not generated. If the spatter generates yet, please proceed to step 2.

2 This step checks whether the spatter is reduced or not when the wire retract speed is increased
or decreased.
Please confirm whether the spatter is reduced or not with changing the wire retract speed. In this
confirmation, amount of this increment or decrement is about 10cm/min. If this is too slow, spatter
generates because the tip of molten wire touches to the work. If this is too fast, there is a possibility
that the generated arc lost or wirestick at contact tip. Please set this speed as slow as possible in a
range where the spatter is not generated. Normally, the confirmation range is from -100cm/min to
-350cm/min. If the spatter is reduced, please find the best value of wire retract speed. If the spatter
generates yet, please proceed to step 3.

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B-83074EN/05 3. SOFTWARE SETUP
3 This step checks whether the spatter is reduced or not when the wire feed speed during arc
heat input is increased or decreased.
This step adjusts the appropriate value of wire feed speed during arc heat input with keeping the
recommended current that is defined by selecting touch retract mode. The appropriate value of wire
feed speed exists responding to the arc heat input current. When the wire feed speed is too slow
compared with certain arc heat input current, there is a possibility that the generated arc lost or
wirestick at contact tip because of the wire burnback. Even if those problems are not generated, the
bead shape around arc start position tends to become worse because the arc heat input sequence
shifts to the production welding in the state of long arc length. When the wire feed speed is too fast
compared with certain arc heat input current, there is a possibility that the generated arc lost or
spatter generates because the wire thrusts into the work during arc heat input. It is necessary to adjust
the wire feed speed during arc heat input for the maximum effect of arc heat input. That means, the
tip of wire keeps the position as near as possible to the work in a range where the spatter is not
generated. Normally, the confirmation range is from 200cm/min to 1000cm/min. Please note that the
adjustment of the wire feed speed may ineffectual when the arc heat input duration is very short (For
example, 0.005sec). Because the execution time of wire feed speed is also very short. In that case, it
is necessary to adjust those parameters synthetically. If the spatter is reduced, please find the best
value of wire feed speed. If the spatter generates yet, please proceed to step 4.

4 This step checks whether the spatter is reduced or not when the amount of arc heat input
current is increased or decreased.
Please change the value of arc heat input current in the range of about ±50Amps from the
recommended value. When the value of arc heat input current is changed, it is necessary to adjust the
value of wire feed speed during arc heat input again (Please refer to step 3). If the spatter is reduced,
please find the best value of arc heat input current / wire feed speed during arc heat input. If the
spatter generates yet, please proceed to step 5.

5 This step checks whether the spatter generates or not after the touch retract sequence.
There is a possibility that the spatter generates after touch retract sequence even if no spatter
generates during touch retract sequence. In this case, the robot begins the motion before the arc
steadies. Please add the WAIT instruction (0.01sec - 0.1sec) at just behind the weld start instruction,
and confirm whether the spatter is reduced or not. On the other hand, there is other method that uses
runin schedule. If runin is enabled, runin sequence is executed after the touch retract sequence. After
that, welding shifts to the production welding. It is possible to adjust the arc state arbitrarily after the
touch retract sequence because runin schedule can be set to a special schedule independent of a
production weld schedule. And, it is possible to increase/decrease the welding commands from runin
schedule to production welding schedule smoothly by ramping function.
About the runin, please refer to the following manual according to your system.
R-30iB CONTROLLER: Subsection 3.5.5 in “R-30iB/R-30iB Mate/R-30iB Plus CONTROLLER
Arc Welding Function OPERATOR’S MANUAL (B-83284EN-3)”
R-30iA CONTROLLER: Subsection 12.1.7 in “R-30iA CONTROLLER ARC TOOL
OPERATOR’S MANUAL (B-83124EN-3)”
R-30iA Mate CONTROLLER: Subsection 12.1.7 in “R-30iA Mate CONTROLLER LR ARC
TOOL OPERATOR’S MANUAL (B-83134EN-2)”

About the ramping function, please refer to the following manual according to your system.
R-30iB CONTROLLER: Chapter 9 in “R-30iB/R-30iB Mate/R-30iB Plus CONTROLLER Arc
Welding Function OPERATOR’S MANUAL (B-83284EN-3)”
R-30iA CONTROLLER: Section 13.13 in “R-30iA CONTROLLER ARC TOOL OPERATOR’S
MANUAL (B-83124EN-3)”
R-30iA Mate CONTROLLER: Section 13.13 in “R-30iA Mate CONTROLLER LR ARC TOOL
OPERATOR’S MANUAL (B-83134EN-2)”

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3. SOFTWARE SETUP B-83074EN/05

3.3 ATTENCTIONS AND LIMITATIONS FOR USE

- Wire type
This function supports following types of welding wire.

Wire material:
Steel, Steel (flux cored), Aluminum

Wire diameter:
0.6mm(steel), 0.9mm(steel), 1.0mm(steel), 1.2mm(steel, steel(flux cored), aluminum), 1.6mm(steel,
aluminum)

- Recovery from alarms of 'Pulse mismatch', 'BZAL' and 'RCAL' (SRVO-038, 062, 063)
To recover from these alarm, for Servo Torch axes(Group:0), set sysvars of $IS_MCR.$SPC_RESET
to TRUE and cycle power.

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B-83074EN/05 4. CHECKS AND MAINTENANCE

4 CHECKS AND MAINTENANCE

By performing preventive maintenance, the Servo Torch performance can be maintained. The preventive
maintenance items and maintenance tools of servo torch are described below. For the preventive
maintenance of the main unit of each servo torch model, refer to the following operator’s manual:

ARC Mate 100iC

: FANUC Robot ARC Mate 100iC, M-10iA, ARC Mate 100iCe, M-10iAe OPERATOR’S MANUAL
(B-82754EN)
: FANUC Robot ARC Mate 100iC/12/7L/12S/8L,M-10iA/12/7L/12S/8L OPERATOR’S MANUAL
(B-83654EN)
ARC Mate 120iC
: FANUC Robot ARC Mate 120iC, M-20iA OPERATOR’S MANUAL (B–82874EN)
Welding power supply
: R-30iB/R-30iB Mate Controller ARC Welding Power Supply Option
(LINCOLN/FANUC Welding Power Supply) OPERATOR’S MANUAL (B-83614EN-1)

4.1 DAILY CHECKS

Clean each part, and visually check component parts for damage before daily system operation. Check the
following items as the occasion demands.

NOTE
At the time of welding, be careful not to directly touch the high–temperature
sections such as the nozzle, tip, and torch. Before replacing a component near the
torch, turn off the power and confirm that the torch is cooled down.

Item Check items Check points and management

1 Cable abnormality See Chapter 8.
2 Vibration, abnormal sound, and Check if each axis is moving smoothly.
motor heat–up
3 Secure and precise operation of Check if commands from the robot and peripheral equipment ensure
peripheral equipment secure and precise operation.
4 Tip Replace the tip if its hole is enlarged or abnormal.
5 Nozzle Replace the nozzle if it is deformed.
6 Liner Check if powder is attached to the liner. If it is attached, clean the liner.
(See Section 7.3.)
Replace the liner if its inlet hole is enlarged. (See Section 7.1.)
7 Wire feed section Open the cover of the wire feed section, then check if the wire is set
correctly in the roller groove. Check also for dust. Remove dust if any.
8 Inlet guide liner Confirm whether a blue resin part of the inlet guide liner is worn, and a
(Servo torch for aluminum) wire is not about to short-circuit to a brass inlet guide. (See Fig. 4.1 (b).)
9 Neck liner Check if powder is attached to the neck liner. If it is attached, clean the
neck liner.
10 Torch power supply section Check if the screws used to secure the crimp terminal are loose.
11 Torch assist gas supply section Check if the piping for torch assist gas is attached to the joint correctly.
12 Torch cable connection section Check if the screw of the torch cable connection section is loose.
13 Jamming roller Check if jamming rollers are loosen.
14 Water cooling hose Check if water leak from water hose.
15 Cleaning and checking each part Clean each part (remove chips, etc.) and check component parts for
cracks and flaws.

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4. CHECKS AND MAINTENANCE B-83074EN/05

tip

nozzle

Inner tube

Fig. 4.1 (a) Daily checks

Note about aluminum welding

When the aluminum welding compares it with mild steel welding, there is the following characteristic.
x A melting point is low, in the case of a sheet, penetration is easy to occur.
x Specific heat, a thermal conductivity, fusion latent heat are big, and melting of the welding start
department is insufficient. (It is necessary to supply much heat rapidly for welding.)
x Coefficient of thermal expansion is big, and transformation and residual stress are easy to occur in
the weld.

Thus, it is necessary to warn the following points about the aluminum welding.
x Do not use rubber hose for shield gas piping (hose) to prevent moisture absorption.
x As for the execution environmental humidity, 80% please.
When the humidity exceeds 80%, blowholes (an aluminum welding defect) suddenly increase.
x For the dew point management of the shielding gas, purge it before welding for 20 minutes, and
please do below the dew point -45 degrees.
x Adjust the arc length appropriate, do not make it too long or too short.
x Make welding posture downward or direction long. Do not make it sideways-facing or an upswing.
x Make sealing up safekeeping by all means in order that a wire and the basic material prevent
influence such as the moisture.
x Validate retract function and use heat wave function to raise welding stability margin. (Refer to
Chapter 3.)

Fig. 4.1 (b) Inlet guide liner

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B-83074EN/05 4. CHECKS AND MAINTENANCE

4.2 PERIODIC CHECK AND MAINTENANCE

Check the following items at the intervals recommended below based on the total operating time or the
accumulated operating time, whichever comes first.

Check and maintenance

intervals
(Operation time, Check and Periodic
Check points, management and
Operation accumulated maintenance maintenance
maintenance methods
time) items table No.
1 3 6 1 3
month months months year years
320h 960h 1920h 3840h 11520h

○ Roller situation Confirm whether there is abnormal abrasion. If 1

trash is attached around, remove it.
○ Inlet guide liner Replace inlet guide liner. 2
replacement
(Servo torch for
aluminum)
○ ○ Loose connector Check if the motor connector and other 3
Only connectors are loose.
1st
check
○ ○ Loose bolt Check if the cover mounting bolt and external 4
Only mounting bolts are loose.
1st
check
○ ○ Clean spatters, Remove spatter, dust, and so forth from the 5
Only sawdust and dust mechanical section.
1st
check
○ ○ Cleaning and See Chapter 8. 6
Only replacement of
1st
check the liner
○ ○ Neck liner See Chapter 8. 7
Only replacement
1st
check
○ Roller See Section 2.1. 8
replacement
○ Flexible conduit See Section 8.5. 9
replacement
○ Torch cable See Chapter 9. 10
replacement
○ Replacement of See Chapter 5. 11
the grease

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4. CHECKS AND MAINTENANCE B-83074EN/05

4.3 MAINTENANCE TOOLS

The following tools and instruments are required for the maintenance procedures contained in this
manual.

(1) Measuring instruments

Instruments Condition Applications

Dial gauge 1/100 mm Measurement of positioning and backlash
Slide calipers 150 mm

(2) Tools
Cross–head screwdrivers : Large, medium, and small sizes
Straight-head screwdrivers : Large, medium, and small sizes
Nut drivers : wide across flats 2.5,3,4,5,6,8,10,12 for replacing each part
Hex key set : wide across flats 2.5,3,4,5,6,8,10,12 for replacing each part
Torque wrench
Adjustable wrenches : Medium and small sizes
Pliers
Cutting pliers
Cutting nippers
Offset box end wrench
Grease gun
Gear puller
Separator
Flashlight

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B-83074EN/05 5. PERIODIC MAINTENANCE

5 PERIODIC MAINTENANCE
Before greasing, be sure to turn off the controller power. Moreover, be sure to use the specified type of
grease.

According to below, replace the grease of the gearbox in cycle that is shorter among every three years and
11520 hours by using the following procedures. See table 5 for the grease name and the quantity for
gearbox.

1 Remove the seal bolt from grease outlet.

2 Feed the grease specified in Table 5 (a) through the grease nipple. Feed grease until new grease is
output after the old grease through the grease outlet. At this time, ensure that the amount of output
grease equals the amount of new fed grease so that the grease path is not fully filled.
3 Check that grease output through the grease outlet has stopped. Then seal the removed seal bolt with
sealing tape, and attach it to the grease inlet and outlet.

Table 5 (a) Grease name and amount to be replaced at regular intervals of three years (11520 hours)
Greasing points Amount of grease to be applied Gun tip pressure Specified grease

Kyodo Yushi
0.1MPa or less
Gearbox 50g VIGOGREASE RE0
(NOTE)
(Specification: A98L-0040-0174)

NOTE
When using a hand pump, apply grease approximately once per two seconds.

Grease outlet
Grease inlet Seal bolt M6X8
Seal bolt M6X8

Fig. 5 (a) Greasing point (Servo torch for aluminum)

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5. PERIODIC MAINTENANCE B-83074EN/05

Grease outlet
Seal bolt M6X8

Grease inlet
Screw with sealant
M6X8
Fig. 5 (b) Greasing point (Servo torch for mild steel)

Grease outlet
Screw with sealant
M6X8

Grease inlet
Seal bolt M6X8

Fig. 5 (c) Greasing point (Servo torch for TIG)

CAUTION
Failure to follow proper lubrication procedures may cause the suddenly increase
of the grease bath internal pressure and the damage to the seal, which could
lead to grease leakage and abnormal operation. When greasing, observe the
following cautions.
1 Before starting to grease, be sure to remove the seal bolt or screw with sealant
from the grease outlet.
2 Supply grease slowly, using a manual pump.
3 Whenever possible, avoid using an air pump, which is powered by the factory air
supply.
If the use of an air pump is unavoidable, supply grease with the pump at a
pressure lower than or equal to the gun tip pressure (see Table 5 (a)).
4 Use specified grease. Use of non-approved grease may damage the reducer or
lead to other problems.
5 To prevent the accident like slipping, fire, remove all the excess grease from the
floor and robot.

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B-83074EN/05 6. TROUBLESHOOTING

6 TROUBLESHOOTING
The cause of a failure in the mechanical unit may be difficult to localize, because failures can arise from
many interrelated factors. If you fail to take the correct measures, the failure may be aggravated. So, it is
necessary to analyze the symptoms of the failure precisely so that the true cause can be found.

6.1 TROUBLESHOOTING
Table 6.1 (a) indicates troubleshooting for the servo torch. If the cause of a failure cannot be identified or
action to be taken cannot be determined, contact your local FANUC representative.
For component replacement or adjustment for repair, see Chapter 7 and 8.

Table 6.1 (a) Troubleshooting

Symptom Cause Measure Remark
Wire feed trouble The roller jamming force is Adjust the roller jamming See Section 7.2.
not adjusted. force.
The roller groove is dirty. Clean the roller groove. See Section 8.2.
The roller groove is worn. Replace the roller. See Section 2.1.
An abnormal load is imposed Remove the load.
on the wire reel.
The wire conduit is twisted Correct the twist.
abnormally.
The roller diameter is Replace the roller with a roller See Section 2.1.
incorrect. whose diameter matches the
wire diameter.
Abnormal The external start signal is Make a check. Contact your local FANUC
termination of abnormal. representative.
reference position A parameter is specified Correct the parameter. Contact your local FANUC
return operation incorrectly. representative.
Incorrect Something hit the robot. Correct the taught point.
positioning The robot is not firmly fixed. Fix it.
Peripheral equipment has Fix it.
shifted.
Incorrect parameter setting Correct it. Contact your local FANUC
representative.
Broken cable Replace the cable. See Chapter 9.
Pulsecoder error Replace the motor. See Section 8.4 and 8.5.
Backlash in the mechanical If positioning pins are not
unit installed, install then
Vibration The robot is not firmly fixed. Fix it.
The floor is vibrating Re–examine the location of
(especially when the robot is installation.
installed on the second floor
or above).
Servo maladjustment Adjust the servo section. Contact your local FANUC
representative.
Broken cable Replace the cable. See Chapter 9.
Robot not grounded Ground the robot. Refer to “Maintenance
Manual for the Controller”.
Defective motor Replace the motor. See Section 8.4 and 8.5.
Defective axis printed–circuit Replace the axis Refer to “Maintenance
board printed–circuit board. Manual for the Controller”.

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6. TROUBLESHOOTING B-83074EN/05

Symptom Cause Measure Remark

Vibration Invalid time constant setting Change the time constant. Contact your local FANUC
representative.
Backlash in the mechanical
unit –– see the backlash or
wobbling part.
Backlash or Loose screw or pin Tighten it (and apply
wobbling LOCTITE to it if specified so)
Worn bearing Replace the bearing Contact your local FANUC
representative.
Broken casting or other part Replace the broken Contact your local FANUC
component. representative.
Abnormal heat Worn bearing Replace the bearing Contact your local FANUC
generation representative.
Non–specified grease used Replace the grease. See Chapter 5.
Invalid time constant setting Change the time constant Contact your local FANUC
setting. representative.
Grease leakage Deteriorated or broken Replace the O–ring, or oil Contact your local FANUC
O–ring, or oil seal seal representative.
Broken casting or other part Replace the broken Contact your local FANUC
component. representative.
Loose screw Tighten it.

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B-83074EN/05 7. ADJUSTMENT

7 ADJUSTMENT
The robot is shipped from the factory after each section of the mechanical unit is adjusted to the optimal
state. Therefore, you do not need to make any adjustments when robot is delivered.
However, after using robot for a long time or replacing components, make adjustments according to the
specifications in this chapter.

7.1 MASTERING
Mastering is an operation that matches the axis angle of each axis of the robot with the pulse count value
of the absolute pulse coder connected to each axis motor. Specifically, this operation finds a pulse count
value at the zero position. Perform mastering of the main robot unit and mastering of the servo torch
separately.

7.1.1 Mastering of the Main Robot Unit

Before mastering of the main robot unit, the servo torch must be detached.
For the method of mastering of the main robot unit, refer to the operator’s manual of the main robot unit.

7.1.2 Mastering of the Servo Torch

You do not have to perform mastering for servo torch.

7.2 ADJUSTING ROLLER JAMMING FORCE

With the servo torch, the force of the roller for nipping a wire is changed by adjusting the jamming force
of the spring with an adjustment knob. Based on Table 7.2 (a) and (b), adjust the spring. Read the scale
with respect to the right edge of the view port.

Table 7.2 (a) Value of scale and jamming force (Servo torch for aluminum/TIG)
Scale Jamming force (kgf)
1 5.6
2 9.5
3 13.3
4 17.1
5 21.0

Table 7.2 (b) Value of scale and jamming force (Servo torch for mild steel)
Scale Jamming force (kgf)
1 10.3
2 17.3
3 24.2
4 31.2
5 38.2

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7. ADJUSTMENT B-83074EN/05

Table 7.2 (c) Spring adjustment

Wire diameter Mark (from left edge)
0.8 3
0.9 3
1.0 3
1.2 3
1.6 3

Adjustment knob

A
This position represents mark 3.
DETAIL A

Fig.7.2 (a) Adjusting roller jamming force

When you pressurize jamming roller, First loosen looseness protection nut then pressurize jamming nut
by rotating jamming nut. If you rotate only looseness protection nut and rotate with jamming, screw
might be broken.

Spring

Decrease
pressure

Loosen Increase
pressure

Jamming nut
Tighten

Looseness protection nut

Fig.7.2 (b) Note when jam the roller

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B-83074EN/05 8. REPLACING PARTS

8 REPLACING PARTS
8.1 REPLACING THE TORCH
Replacement of Standard water–cooled torch (Torch for aluminum/mild steel)
1 Rotate root of torch counter clockwise by hand and remove torch from adapter.
2 Remove torch and clean the inner tube. When hole of entrance become large, replace neck liner.
Length of neck liner is adjusted usually. Order spec. is A14L-0166-0321#783XFS01.

Adapter
Neck liner
Torch

If this side is too long,

Servo torch for aluminum cut part which protrude from
outlet guide because
Adapter torch cannot be installed.

Neck liner Torch

Servo torch for mild steel

Fig. 8.1 (a) Replacing the torch (Servo torch for aluminum and mild steel)

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8. REPLACING PARTS B-83074EN/05

Replacement of TIG torch neck

1 Remove bolts M3X8 (2pcs).
2 Loosen the nut of nozzle and remove the nozzle.
3 Remove the screw and remove the earth line and earth ring.
4 Knock over the lever and pull out torch from main body.
5 Replace torch neck by new one.
6 Assemble it. For its assembly, please apply the steps above in reversed sequence.
7 Adjust the nozzle position using nozzle position adjust screw and nut.

Bolt
Bolt
M3X8
M3 (2)
x 8 (2)
Loosenthe
Loosen thenut
nut
Nozzle
Nozzle position
position
adjust
adjustscrew
screw
Nozzle
Nozzle
Earthring
Earth ring

Torch neck
Torch neck
Knockover
Knock overthe
thelever
lever
Removethe
Remove thescrew
screw
Earthline
Earth line
Fig. 8.1 (b) Replacing the torch (Servo torch for TIG)

Lock Release

Lever
(Appendix of torch

Fig. 8.1 (c) Lever for TIG torch

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B-83074EN/05 8. REPLACING PARTS

8.2 REPLACING THE ROLLER

Cleaning the feed rollers and jamming roller
1 Loosen the adjustment knob, then release the roller lever.
2 Clean off dust around the feed rollers and jamming roller.
3 Assemble the feed rollers and jamming roller by reversing the procedure above.

8.3 REPLACING THE MOTOR COVER

1 Remove the motor cover mounting M3 bolts (4pcs). In case of servo torch for TIG, remove plate
mounting bolts (2 pcs), too.
2 Remove the motor cover.
3 Replace old motor cover by new one. For its assembly, please apply the steps above in reversed
sequence.

ボルト
Bolt Cover
M3X8
M3 x8 カバー
A290-7220-X718
A290-7220-X718
(ARC Mate100
(ARC Mate 100iC, ARC
iC, ARC MateMate 100iC/6L/
100iC/6L/7L/12,
7L/12, ARC Mate 120iC/10L/12L)
ARC Mate120iC/10L/12L)
A290-7220-X738
A290-7220-X738
(ARC Mate
(ARC Mate120iC)
120iC)

Fig. 8.3 (a) Replacing motor cover (Servo torch for aluminum)

Cover
カバー
A290-7220-X788
A290-7220-X788

ボルト
Bolt
M3X6
M3 x6

Fig. 8.3 (b) Replacing motor cover (Servo torch for mild steel)

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8. REPLACING PARTS B-83074EN/05

Bolt
ボルト
M3 x 6(4)(4)
M3X6

Cover
カバー
A290-7220-Z718
A290-7220-Z718

Bolt ボルト
M3 xM3X6
6 (2)(2)

Cover
プレート
A290-7220-Z719
A290-7220-Z719

Fig. 8.3 (c) Replacing motor cover (Servo torch for TIG)

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B-83074EN/05 8. REPLACING PARTS

8.4 REPLACING THE MOTOR

(SERVO TORCH FOR ALUMINUM/TIG)
1 Move the robot to allow the motor to be pulled out in the upward direction, then turn off the power
to the robot controller and welding machine.
2 Remove the motor cover (according to Section 8.3).
3 Remove the cover holding the cable, then detach the cable connected to the motor.
4 Remove the M4X18 bolts (4 pcs) used to secure the motor, then remove the motor.
5 Loosen the M3 bolt at the top of the shaft by referring to Fig.8.4 (a), and remove the gears and
adapters.
Note) Do not forcibly remove the resin parts such as adapters. Otherwise, they would be damaged.
6 Attach a sort of the gear or adapter to the shaft of a new motor by reversing the procedure then
secure the gear to the shaft with an M3 (1 pc) bolt to which LOCTITE 243 is applied.
7 Confirm O ring is in it, and Install motor with M4 x 18 bolts (4 pcs).
8 Install cover etc. For its assembly, please apply the steps above in reversed sequence.
Bolt
A97L-0218-0606#M4X18 4 pcs)
Apply LOCTITE 263.
Tightening torque　2.0Nm
AC servo motor
A06B-0114-B204

Bush (4 pcs)
A290-7215-X745

Adapter
A290-7215-X721 Parallel key
JB-HKY-3X3X6B
Parallel pin (4 pcs) Apply LOCTITE 675.
JB-PH-H7B-3X6S45C

Parallel pin (4 pcs) Adapter

JB-PH-H7B-3X6S45C A290-7215-X742

Gear Collar
A290-7220-X711 A290-7215-X743

Bolt
M3X12
Apply LOCTITE 243.
Tightening torque　1.0Nm Washer
A290-7220-X745

O ring
JB-OR4D-G45

Fig. 8.4 (a) Replacing the motor (Servo torch for aluminum/TIG)
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8. REPLACING PARTS B-83074EN/05

8.5 REPLACING THE MOTOR

(SERVO TORCH FOR MILD STEEL)
1 Move the robot to allow the motor to be pulled out in the upward direction, then turn off the power
to the robot controller and welding machine.
2 Remove the motor cover (according to Section 8.3).
3 Remove the cover holding the cable, then detach the cable connected to the motor.
4 Remove the M3 x 14 bolts (4 pcs) used to secure the motor, then remove the motor. Be careful not to
damage the oil seal. If oil seal is broken, replace it by new one.
5 Loosen the M3 bolt at the top of the shaft by referring to Fig. 8.5, and remove the gears and
adapters.
Note) Do not forcibly remove the resin parts such as adapters. Otherwise, they would be damaged.
6 Attach a sort of the gear or adapter to the shaft of a new motor by reversing the procedure then
secure the gear to the shaft with an M3 (1 pc) bolt to which LOCTITE 243 is applied.
7 Confirm O ring is in it, and install motor with M3 x14 bolts (4 pcs).
8 Install cover etc. For its assembly, please apply the steps above in reversed sequence. At this time,
replace the gasket by new one.

Bolt
A6-BA-3X14 (4)
Bush Tightening torque 1.5Nm
A290-7220-Z745 Washer
A97L-0001-0823#M3L

AC servo motor
A06B-0117-B205#0049

Parallel pin
JB-PH-H7B-3X6X6B

Gasket
A290-7220-Z731 Adapter
A290-7220-Z703
Adapter
A290-7220-Z721 Parallel pin (4 pcs)
JB-PH-H7B-3X6S45C
Adapter
A290-7220-Z720
Parallel pin (4 pcs)
JB-PH-H7B-3X6S45C

Gear Washer
A290-7220-Z711 A290-7220-X745
Bolt
A6-BA-3X25
Oil seal Apply LOCTITE 243.
A98L-0040-0047#01902806 Tightening torque 1.0Nm

Fig. 8.5 (a) Replacing the motor (Servo torch for steel)

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B-83074EN/05 8. REPLACING PARTS

8.6 REPLACING THE FLEXIBLE CONDUIT AND LINER

(SERVO TORCH FOR ALUMINUM)
1 Remove the cover of servo torch and move the roller lever and release the fixation of wire.
2 Remove wire from flexible conduit and servo torch to reel stand side.
3 Remove the nut of connection part to servo torch with a monkey spanner. And remove flexible
conduit from servo torch. (See Fig. 8.6 (b).)
4 Remove the sleeve of the tip of conduit. (This procedure is when you replace sleeve.) (See Fig. 8.6
(c).)
5 Loosen adapter block mounting bolts and remove adapter block from servo torch. (See Fig. 8.6 (d).)
(This procedure is when you replace inlet guide liner.)
6 Remove inlet guide liner from adapter block. (This procedure is when you replace inlet guide liner.)
(See Fig. 8.6 (e).)
7 Remove the flexible conduit of reel stand. (See Fig. 8.6 (f).)
8 Remove connector from flexible conduit with a monkey spanner. Turn it in a course to unscrew it
(See Fig. 8.6 (f).)
9 Insert sleeve which is removed in procedure 2 to flexible conduit. (This procedure is only when you
replace sleeve.) (See Fig. 8.6 (c).)
10 Attach connector to flexible conduit of reel stand side. Install it with the point to tighten a nut. (See
Fig. 8.6 (f).)
11 Insert wire to flexible conduit.
12 Cut the inlet guide liner so that it does not interfere roller referring to Fig. 8.6 (g).
13 Insert new inlet guide liner to adapter block and attach adapter block to main body of servo torch.
14 Open the cover of servo torch and insert wire to it.
15 Attach flexible conduit of torch side to adapter block. Tighten Nut with regulated torque of 15Nm.
(See Fig. 8.6 (b))

Roller lever

Fig. 8.6 (a) Roller lever of servo torch

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8. REPLACING PARTS B-83074EN/05

Nut
(conduit side)
Nut
(inlet guide side)

Fig. 8.6 (b) Nut of servo torch side

Fig. 8.6 (c) Sleeve of flexible conduit

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B-83074EN/05 8. REPLACING PARTS

Adapter block mounting bolts

Apply LOCTITE 243.
Tightening torque 3Nm

Fig. 8.6 (d) Adapter block mounting bolts

Inlet guide

Adapter block

Fig. 8.6 (e) Liner

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8. REPLACING PARTS B-83074EN/05

Remove the connector

from the conduit
with a adjustable wrench

Connector

When atttaching and removing

the connector, put this part to
under by hands.

Fig. 8.6 (f) Connector of reel stand side

Fig. 8.6 (g) Cutting of liner

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B-83074EN/05 8. REPLACING PARTS

8.7 REPLACING THE FLEXIBLE CONDUIT AND LINER

(SERVO TORCH FOR MILD STEEL)
Replacing the flexible conduit
1 Remove the rubber cap of servo torch and loosen hexagon nut referring to Fig.8.7 (a),(b).
2 Remove the coupling of back of J3 casing referring to Fig.8.7 (c).
3 Replace old flexible conduit by new one. For its assembly, please apply the steps above in reversed
sequence.

Replacing liner
1 Remove the flexible conduit from one touch coupling of J3 casing back side referring to Fig.8.7 (c).
2 Pull out liner, replace it by new one. For its assembly, please apply the steps above in reversed
sequence.

Rubber cap

Fig. 8.7 (a) Replacing the flexible conduit and liner

Hexagon nut

Fig. 8.7 (b) Replacing flexible conduit and liner

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8. REPLACING PARTS B-83074EN/05

Liner
Flexible
conduit

Coupling

Fig. 8.7 (c) Replacing the flexible conduit

8.8 REPLACING THE FLEXIBLE CONDUIT AND LINER (Servo

torch for TIG)
Replacing flexible conduit
1 Remove the nut of servo torch side and connector of wire reel stand.
2 Replace the flexible conduit by new one and assemble it. For its assembly, please apply the steps
above in reversed sequence.

Nut

Connector

Fig. 8.8 (a) Replacing the flexible conduit

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B-83074EN/05 8. REPLACING PARTS

Replacing liner
1 Remove the hexagon bolt of Fig. 8.8 (b).
2 Remove the nut.
3 Remove parts which are below than nut from servo torch main body.
4 Replace liner by new one and assemble it. For its assembly, please apply the steps above in reversed
sequence.

Hexagon bolt
M3 x 8 (2)
Nut

Fig. 8.8 (b) Replacing the liner (1/2)

Liner

Fig. 8.8 (c) Replacing the liner (2/2)

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9. CABLE REPLACEMENT B-83074EN/05

9 CABLE REPLACEMENT
Replace the cablese at the intervals based on every 4 years or 15360 hours, whichever comes first. If a
cable is broken or damaged, replace it according to the procedure described in this chapter.

Cautions in handling the Pulsecoder cable

When transporting, installing, or maintaining the robot, do not detach the Pulsecoder cables carelessly.
The cables are provided with the marking tie shown below. If you detached any cable with the marking
tie, you need to perform mastering for the robot.
Do not detach any connector unless you replace a motor, Pulsecoder, gearbox or cable.

BATTERY BACKUP

DON'T

DISCONNECT

コネクタ取外不可

Fig. 9 (a) Wire mark

9.1 CABLE WIRING

Table 9.1 (a) is cable pattern diagram.

Table 9.1 (a) Cable pattern diagram

Stamp Cable pattern diagram Stamp Cable

No.

M7P
M7P

W/F 2 K163
K163 W/F 2

M7M
M7M

K181
POWER M7M
K183
POWER

M7M

CZ7 M7M K182

D-3
B
A

U,V,W,G

K184
M7M
CZ7
CODER
PULSE

PULSE
M7P K185
JF

TDK

CODER
M7P

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B-83074EN/05 9. CABLE REPLACEMENT

9.2 REPLACING CABLES

This section describes a procedure for replacing cables.
Contact FANUC about procedure for replacing mechanical unit cables of robot.

9.2.1 Replacing the Welding Power Cable

1 Move the robot to the posture all axes are 0º.
2 Turn off the controller power.
3 Remove 2 M4×10 bolts and remove conduit from wrist unit. (See Fig.9.2.1 (a).)
4 Remove the welding power cable. (See Fig.9.2.1 (f).)
5 Cut the cable tie of 2 locations which is back of J3 casing side. (See Fig.9.2.1 (c).)
6 Pull out cable to J3 casing side.
7 Remove connector of cable from plate (black color) of J3 casing side.
8 Replace old cable by new one. For its assembly, please apply the steps above in reversed sequence.
At this chance, be careful not to make tension or slack to the cable. Refer to Fig.9.2.1 (c) to (g) about
cable forming. We recommend using black cable ties which have high weatherability.

Bolt
Bolt
M4X10
M4 (2pcs)
x 10 (2 pcs)

Conduit
Conduit

Fig. 9.2.1 (a) Removing the conduit

Motor
Motor cover
cover

Bolt
Bolt
M3
M3X8x 8(4pcs)
(4 pcs)

Fig. 9.2.1 (b) Removing the motor cover

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9. CABLE REPLACEMENT B-83074EN/05

Fig. 9.2.1 (c) Cable tie of back of J3 casing

Clamp cables to yellow taped

ケーブルの黄色いテープを張っている
箇所にケーブルタイでこのように止めること
Places with a nylon band.

A 断面 A-A
Section A-A

Fig. 9.2.1 (d) Forming cables to bracket (Servo torch for aluminum) (1/5)

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B-83074EN/05 9. CABLE REPLACEMENT

Gas hose (black)

Welding cable
(torch cable side)
Cable tie

A A

B
White color
marking position

M7P Cable tie

M7M

Section A-A Section B-B

Fig. 9.2.1 (e) Forming cables to bracket (Servo torch for steel) (2/5)

M7P
A
M7M

Cable tie （black）

A
Section A-A
Fig. 9.2.1 (f) Forming cables to bracket (Servo torch for TIG) (3/5)

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9. CABLE REPLACEMENT B-83074EN/05

Fig. 9.2.1 (g) Forming cables to bracket (4/5)

Pass cable K163 through this gap

and connect to motor.
Fig. 9.2.1 (h) Forming cables to bracket (5/5)

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B-83074EN/05 9. CABLE REPLACEMENT

9.2.2 Replacing the Motor Cable

1 Move the robot to the posture all axes are 0º.
2 Turn off the controller power.
3 Remove 2 M4X10 bolts and remove conduit from wrist unit.
4 Remove the motor cover. (See Fig. 9.2.1 (b).)
5 Remove the side plate. (See Fig. 9.2.2 (a) to (c).)
6 Remove the motor connector.
7 Cut the Cable tie of 2 locations referring to Fig. 9.2.1 (d) and (e).
8 Cover the connector in cloth or vinyl. (to make it easy to pass hollow part of wrist)
9 Pass cables through bracket and hollow part of wrist unit and pull it out to J3 arm side.
10 Cut the nylon band which is back J3 casing side.
11 Pull out cable to J3 casing side.
12 Remove connector of cable from plate (black color) of J3 casing side.
13 Replace old cable by new one. For its assembly, please apply the steps above in reversed sequence.
At this chance, be careful not to make tension or slack to the cable. Push 15mm from the state that
does not get loose, and fix it. Refer to Fig. 9.2.1 (c) to (g) about cable forming.

Main body of servo torch

A05B-1220-J301

Button head cap screw

M6X14 (6pcs)
Apply LOCTITE 243
Tightening torque 6.0Nm

Side　plate
A290-7220-X716

Fig. 9.2.2 (a) Removing the main body of servo torch and plate (Servo torch for aluminum)

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9. CABLE REPLACEMENT B-83074EN/05

Main body of servo torch

A05B-1220-J302

Button bolt
M6X14 (6 pcs)
Apply LOCTITE 243.
Tightening torque 6.0Nm

Side plate
A290-7220-X783

Fig.9.2.2 (b) Removing the main body of servo torch and plate (Servo torch for mild steel)

Bolt M6X15 (2)

Apply LOCTITE 425
Tightening torque 1.0Nm

Button bolt
M6X14 (5)
Apply LOCTITE 243
Tightening torque 6.0Nm

Side plate
A290-7220-Z716

Fig.9.2.2 (c) Removing the main body of servo torch and plate (Servo torch for TIG)

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APPENDIX
B-83074EN/05 APPENDIX A. MAINTENANCE PARTS

A MAINTENANCE PARTS
NOTE
Contact your local FANUC representative about maintenance parts of robot main
body.

Gas regulator Solenoid valve kit for assist gas Sleeve unit

Wire reel stand Servo torch wrist cable

(floor mount type
or J2 Wire reel stand
base mount type) Wrist flexible conduit
Controller

Gas

Welding
power
supply
Water-cooled
circulation Fixture
unit

Fig. A (a) System constitution example (Servo torch for aluminum)

Gas regulator Solenoid valve kit for assist gas

Flexible conduit Servo torch wrist cable

Controller

Gas
Wire
Welding
power Wrist flexible conduit
supply

Fixture

Sense Sense lead

lead line line Wave
(Power 455M/STT,iC/H2,H3
(ROBOWELD only)
Power Wave R350, Power Wave R500)

Fig. A (b) System constitution example (Servo torch for mild steel)

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A. MAINTENANCE PARTS APPENDIX B-83074EN/05

J3 casing

Servo torch

Servo torch wrist cable (Standard)

(Servo torch part to back of J3 casing)

Fig. A (c) Cable mounting figure of servo torch wrist cable (In case of standard specification)

Figure is case of standard specification. Refer to operator’s manual of mechanical unit about cable
between J1 connector panel to J4 connector panel. In case of CE specification, servo cable is connected
from controller to servo torch. The cable is laid in the outside of robot.

Torch
Servo torch main body

Torch adapter

Bracket assembly
Fig. A (d) Mechanical unit of servo torch

Torch neck Neck liner

Tip holder

Tip

Gas nozzle

Gas nozzle

Fig. A (e) Parts of torch

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B-83074EN/05 APPENDIX A. MAINTENANCE PARTS

Flexible conduit (transparent tube of outside)

Liner (metal part of inner)

Fig.A (f) Flexible conduit and liner of servo torch for mild steel

A.1 SERVO TORCH FOR ALUMINUM

Table A.1 (a) Torch adapter assembly A05B-1220-J311 (Servo torch for aluminum)
Parts name Specifications Remarks
Torch adapter kit A14L-0166-2311 (NOTE)
Torch adapter insulator A14L-0166-2311#783X9656
Torch adapter cover A14L-0166-2311#783X9655

NOTE
Bar terminal connection type torch adapter is used for the unit made before Dec.
2013. Round terminal connection type torch adapter is used for the unit made
later than it. (See Fig. A(g))
When replacing the torch adapter made after Dec. 2013, replace the servo torch
wrist cable by round shape terminal, too.

Bar terminal Round terminal

(Made before Dec. 2013) (Made after Dec. 2013)

Fig. A.1 (a) Connection terminal of the torch adapter and the welding power cable

Table A.1 (b) Servo torch wrist cable A05B-1220-J335 (Standard ARC Mate 100iC, ARC Mate 100iC/12)
Parts name Specifications Remarks
Servo torch wrist cable Torch cable kit
A290-7220-V335 (NOTE)
(bar terminal connection type) (bar terminal connection type)
Servo torch wrist cable Torch cable kit
A290-7220-V345 (NOTE)
(round terminal connection type) (round terminal connection type)
Torch cable conduit
Hand cable assembly A97L-0118-0734#T36-0062
(It is included in A290-7220-V335, V345)
Wrist cable
Wrist cable K163 A660-4004-T972#L1R303
(It is included in A290-7220-V335, V345)

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A. MAINTENANCE PARTS APPENDIX B-83074EN/05

Table A.1 (c) Servo torch wrist cable A05B-1220-J336 (Standard ARC Mate 100iC/6L/7L)
Parts name Specifications Remarks
Servo torch wrist cable Torch cable kit
A290-7220-V336 (NOTE)
(bar terminal connection type) (bar terminal connection type)
Servo torch wrist cable
Torch cable kit
(round terminal connection A290-7220-V346 (NOTE)
(round terminal connection type)
type)
Torch cable conduit
Hand cable assembly A97L-0118-0734#T36-0084
(It is included in A290-7220-V336, V346)
Wrist cable
Wrist cable K163 A660-4004-T972#L1R543
(It is included in A290-7220-V336, V346)

Table A.1 (d) Servo torch wrist cable A05B-1220-J337 (Standard ARC Mate 120iC)
Parts name Specifications Remarks
Servo torch wrist cable Torch cable kit
A290-7220-V337 (NOTE)
(bar terminal connection type) (bar terminal connection type)
Servo torch wrist cable
Torch cable kit
(round terminal connection A290-7220-V347 (NOTE)
(round terminal connection type)
type)
Torch cable conduit
Hand cable assembly A97L-0118-0734#T36-0087
(It is included in A290-7220-V337, V347)
Wrist cable
Wrist cable K163 A660-4004-T972#L1R543
(It is included in A290-7220-V337, V347)

Table A.1 (e) Servo torch wrist cable A05B-1220-J338 (Standard ARC Mate 120iC/10L/12L)
Parts name Specifications Remarks
Servo torch wrist cable Torch cable kit
A290-7220-V338 (NOTE)
(bar terminal connection type) (bar terminal connection type)
Servo torch wrist cable
Torch cable kit
(round terminal connection A290-7220-V348 (NOTE)
(round terminal connection type)
type)
Torch cable conduit
Hand cable assembly A97L-0118-0734#T36-0101
(It is included in A290-7220-V338, V348)
Wrist cable
Wrist cable K163 A660-4004-T972#L1R703
(It is included in A290-7220-V338, V348)

NOTE
For the servo torch wrist cable, see Fig. A.1 (a), select the cable kit spec. which
matches the torch adapter connection terminal.

Table A.1 (f) Servo torch cable (CE)

Cable No. Specifications Function Applicable model
for aluminum
K181 A660-2007-T278
for alpha i amplifier
for aluminum
K182 A660-2007-T279
for beta i amplifier
J7 power line
for mild steel
K183 A660-2007-T280
for alpha i amplifier
for mild steel
K184 A660-2007-T281
for beta i amplifier
K185 A660-8017-T641 J7 signal line All models for CE

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B-83074EN/05 APPENDIX A. MAINTENANCE PARTS
Table A.1 (g) Roller for aluminum wire (Double nut Specifications) A05B-1220-J347
Parts name Specifications Remarks
φ1.2 Roller for aluminum wire A05B-1220-J347
(*) This specification is only for Japan.

Table A.1 (h) Roller for aluminum wire A05B-1215-J375

Parts name Specifications Remarks
φ1.2 Roller for aluminum wire A05B-1215-J375

Table A.1 (i) Servo torch mechanical section A05B-1220-J301, J303 (Servo torch for aluminum)
Parts name Specifications Remarks
Motor A06B-0114-B204 J7-axis βiS0. 4/5000 (without brake)
Bush A290-7215-X745 for mounting motor (4 pcs)
Adapter A290-7215-X742 for motor shaft (bakelite)
Parallel key JB-HKY-3X3X6B for motor shaft
For connection of motor shaft and
Parallel pin JB-PH-H7B-3X6S45C
adapter (8 pcs)
Collar A290-7215-X743 for motor shaft
Gear A290-7220-X711 for motor shaft
Washer A290-7220-X745 for motor shaft
O ring (fluorine) JB-OR4D-G45 for motor shaft
Bolt A97L-0218-0514#M3X12
Between motor and drive unit assembly
Adapter A290-7220-X743
(bakelite)
Adjust bolt A290-7220-X727 Jamming roller part
Kyodo Yushi VIGOGREASE RE0
Grease A98L-0040-0174#16KG
Refer to Chapter 5 for required quantity.

Table A.1 (j) Bracket assembly A05B-1220-J321 (Servo torch for aluminum)
Parts name Specifications Remarks
Motor cover A290-7220-X718
Insulator A290-7220-X747
Gasket A290-7220-X748
Parallel pin JB-PH-H7B-4X10S45C (3 pcs)
Parallel pin JB-PH-H7B-5X10S45C-Q (8 pcs)

Table A.1 (k) Bracket assembly A05B-1220-J322 (Servo torch for aluminum)
Parts name Specifications Remarks
Insulator A290-7220-X747

Table A.1 (l) Expendable supplies of water cooling aluminum torch A05B-1220-J351
Parts name Specifications Remarks
Torch neck kit (the whole) A14L-0166-2351
Torch neck A14L-0166-0311#782X0077
Tip holder A14L-0166-0311#142X0117
Gas diffuser A14L-0166-2351#943XJ003
Tip A14L-0166-0311#140X0313 φ1.0mm
Tip A14L-0166-0311#140X0442 φ1.2mm
Neck liner A14L-0166-0311#783XFA01
Gas nozzle A14L-0166-0311#145X0553
(*) Refer to Fig. A (e) about external figure of each part.

Be sure to apply grease of figure to O-ring of water cooling torch neck.

If grease is not applied, it may cause broken of O-ring. Use cotton swab of appendix to apply grease.
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A. MAINTENANCE PARTS APPENDIX B-83074EN/05

O-ring
O ring

Fig. A.1 (b) Applying grease to O-ring of attached of water cooling torch

Table A.1 (m) Solenoid valve kit for assist gas A05B-1220-J381
Parts name Specifications Remarks
Solenoid valve kit for
A14L-0166-2381
assist gas

Table A.1 (n) Gas hose for servo torch for aluminum A05B-1220-J384
Parts name Specifications Remarks
Gas hose for argon gas 10m A14L-0166-2384

Table A.1 (o) Gas regulator for servo torch for aluminum A05B-1220-J383
Parts name Specifications Remarks
Gas regulator for argon gas A14L-0166-2383

Table A.1 (p) Flexible conduit for servo torch for aluminum A05B-1220-J393, J395, J397, J398
Parts name Specifications Remarks
Adapter kit A14L-0166-2395#A-2LNIC-AK
Inner liner A14L-0166-2395#A-4L-H
Threaded connector A14L-0166-2395#A-16F-3
Servo torch
Flexible conduit
A14L-0166-2395#EC-3
ARC Mate 100iC for
aluminum /2.5m
Servo torch
Flexible conduit
A14L-0166-2393#EC-3
ARC Mate 100iC for
aluminum /5m

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B-83074EN/05 APPENDIX A. MAINTENANCE PARTS

Parts name Specifications Remarks

Servo torch
Flexible conduit
A14L-0166-2397#EC-3
ARC Mate 120iC for
aluminum /2.8m
Flexible conduit sleeve A14L-0166-2395#EC-3RG
Coupler A14L-0166-2392#WWTT-DP

A.2 Servo torch for mild steel

Table A.2 (a) Torch adapter assembly A05B-1220-J311 (servo torch for aluminum, servo torch for mild steel)
Parts name Specifications Remarks
Torch adapter kit A14L-0166-2311 (NOTE)
Torch adapter insulator A14L-0166-2311#783X9656
Torch adapter cover A14L-0166-2311#783X9655

NOTE
Bar terminal connection type torch adapter is used for robots which serial is
R13Z02460 (Made in Dec. 2013) or before. Round terminal connection type
torch adapter is used for robots which was made later than it. (See Fig. A.1 (a).)
You cannot order bar terminal connection type torch adapter. Be careful.

Table A.2 (b) Servo torch wrist cable A05B-1220-J365 (Standard ARC Mate 100iC, ARC Mate 100iC/12)
Parts name Specifications Remarks
Servo torch wrist cable Torch cable kit
A290-7220-V365 (NOTE)
(bar terminal connection type) (bar terminal connection type)
Servo torch wrist cable Torch cable kit
A290-7220-V375 (NOTE)
(round terminal connection type) (round terminal connection type)
Torch cable conduit
Hand cable assembly A97L-0118-0734#T36-0062
(It is included in A290-7220-V365, V375.)
Wrist cable (It is included in
Wrist cableK164 A660-4005-T072#L1R303
A290-7220-V365, V375)
Wrist cableK165 Welding power cable (It is included in
A660-8040-T037#L1R093 (NOTE
(bar terminal connection type) A290-7220-V365)
Wrist cableK173
Welding power cable (It is included in
(round terminal connection A660-8040-T041#L1R093 (NOTE)
A290-7220-V375)
type)

Table A.2 (c) Servo torch wrist cable A05B-1220-J366 (Standard ARC Mate 100iC/6L/7L)
Parts name Specifications Remarks
Servo torch wrist cable Torch cable kit
A290-7220-V366 (NOTE)
(bar terminal connection type) (bar terminal connection type)
Servo torch wrist cable Torch cable kit
A290-7220-V376 (NOTE)
(round terminal connection type) (round terminal connection type)
Torch cable conduit
Hand cable assembly A97L-0118-0734#T36-0084
(It is included in A290-7220-V366, V376)
Wrist cable
Wrist cable K164 A660-4005-T072#L1R543
(It is included in A290-7220-V366, V376)
Wrist cable K165 Welding power cable (It is included in
A660-8040-T037#L1R313 (NOTE)
(bar terminal connection type) A290-7220-V366)
Wrist cable K173
Welding power cable (It is included in
(round terminal connection A660-8040-T041#L1R313 (NOTE)
A290-7220-V376)
type)

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A. MAINTENANCE PARTS APPENDIX B-83074EN/05

Table A.2 (d) Servo torch wrist cable A05B-1220-J367 (Standard ARC Mate 120iC)
Parts name Specifications Remarks
Servo torch wrist cable Torch cable kit
A290-7220-V367 (NOTE)
(bar terminal connection type) (bar terminal connection type)
Servo torch wrist cable Torch cable kit
A290-7220-V377 (NOTE)
(round terminal connection type) (round terminal connection type)
Torch cable conduit
Hand cable assembly A97L-0118-0734#T36-0087
(It is included in A290-7220-V367, V377)
Wrist cable
Wrist cable K164 A660-4005-T072#L1R543
(It is included in A290-7220-V367, V377)
Wrist cable K165 Welding power cable (It is included in
A660-8040-T037#L1R313 (NOTE)
(bar terminal connection type) A290-7220-V367)
Wrist cable K173 Welding power cable (It is included in
A660-8040-T041#L1R313 (NOTE)
(round terminal connection type) A290-7220-V377)

Table A.2 (e) Servo torch wrist cable A05B-1220-J368 (Standard ARC Mate 120iC/10L, 12L)
Parts name Specifications Remarks
Servo torch wrist cable Torch cable kit
A290-7220-V368 (NOTE)
(bar terminal connection type) (bar terminal connection type)
Servo torch wrist cable
Torch cable kit
(round terminal connection A290-7220-V378 (NOTE)
(round terminal connection type)
type)
Torch cable conduit
Hand cable assembly A97L-0118-0734#T36-0101
(It is included in A290-7220-V368,V378)
Wrist cable
Wrist cable K164 A660-4005-T072#L1R703
(It is included in A290-7220-V368,V378)
Wrist cable K165
A660-8040-T037#L1R493 Welding power cable (It is included in
(bar terminal connection
(NOTE) A290-7220-V368)
type)
Wrist cable K173
A660-8040-T041#L1R493 Welding power cable (It is included in
(round terminal connection
(NOTE) A290-7220-V378)
type)

NOTE
For the servo torch wrist cable, select the cable kit spec. which match the torch
adapter connection terminal. Refer to Fig. A.1 (a).

Table A.2 (f) Roller for mild steel wire (Double nut Specifications) A05B-1220-J348
Parts name Specifications Remarks
φ0.9 Roller for mild steel wire A05B-1220-J348
(*) This specification is only for Japan.

Table A.2 (g) Roller for mild steel wire (Double nut Specifications) A05B-1220-J349
Parts name Specifications Remarks
φ1.0 Roller for mild steel wire A05B-1220-J349
(*) This specification is only for Japan.

Table A.2 (h) Roller for mild steel wire (Double nut Specifications) A05B-1220-J350
Parts name Specifications Remarks
φ1.2 Roller for mild steel wire A05B-1220-J350
(*) This specification is only for Japan.

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B-83074EN/05 APPENDIX A. MAINTENANCE PARTS
Table A.2 (i) Roller for mild steel wire A05B-1215-J363
Parts name Specifications Remarks
φ0.9 Roller for mild steel wire A05B-1215-J363

Table A.2 (j) Roller for mild steel wire A05B-1215-J365

Parts name Specifications Remarks
φ1.2 Roller for mild steel wire A05B-1215-J365

Table A.2 (k) Servo torch mechanical section A05B-1220-J302,J304 (Servo torch for mild steel)
Parts name Specifications Remarks
J7-axis0 βiS0. 2/6000 (without brake)
Motor A06B-0117-B205#0049
(Servo torch for aluminum)
Bush A290-7215-X745 for mounting of motor (4 pcs)
Gear A290-7220-Z711 for motor shaft
Adapter A290-7220-Z720 for motor shaft
Gasket A290-7220-Z731 for motor shaft
Bush A290-7220-Z745 for motor shaft
Key JB-HKY-3X3X6B for motor shaft
For connection of motor shaft and
Parallel pin JB-PH-H7B-3X6S45C
adapter (8 pcs)
Adjust bolt A290-7220-X727 Jamming roller part
Kyodo Yushi VIGOGREASE RE0
Grease A98L-0040-0174#16KG
Refer to Chapter 5 for required quantity.

Table A.2 (l) Bracket assembly A05B-1220-J323

Parts name Specifications Remarks
Insulator A290-7220-X786
Motor cover A290-7220-X788
Parallel pin JB-PH-H7B-4X10S45C (3 pcs)
Parallel pin JB-PH-H7B-5X10S45C-Q (8 pcs)

Table A.2 (m) air-cooling steel torch expendable supplies of A05B-1220-J352

Parts name Specifications Remarks
Torch neck kit (the whole) A14L-0166-2352
Torch neck A14L-0166-0321#213X0141
Tip holder A14L-0166-2352#142X0177
Tip A14L-0166-0301#140JP009 φ0.9mm (10 pcs set)
Tip A14L-0166-0301#140JP010 φ1.0mm (10 pcs set)
Tip A14L-0166-0301#140JP005 φ1.2mm (10 pcs set)
Neck liner A14L-0166-0321#783XFS01
Gas nozzle A14L-0166-2352#145X0615
(*) Refer to Fig. A (e) about external figure of each part.

Table A.2 (n) Flexible conduit for servo torch for mild steel A05B-1220-J374 (ARC Mate 120iC/10L, 12L)
Parts name Specifications Remarks
Conduit A14L-0166-2374#CONDUIT
Liner A14L-0166-2374#LINER
Block A14L-0166-2375#BLOCK
Inlet A14L-0166-2375#INLET
Joint A14L-0166-2375#JOINT

- 69 -
A. MAINTENANCE PARTS APPENDIX B-83074EN/05

Table A.2 (o) Flexible conduit for servo torch for mild steel A05B-1220-J375
(ARC Mate 100iC, ARC Mate 100iC/12)
Parts name Specifications Remarks
Conduit A14L-0166-2375#CONDUIT
Liner A14L-0166-2375#LINER
Block A14L-0166-2375#BLOCK
Inlet A14L-0166-2375#INLET
Joint A14L-0166-2375#JOINT

Table A.2 (p) Flexible conduit for servo torch for mild steel A05B-1220-J376 (ARC Mate 100iC/6L, 7L)
Parts name Specifications Remarks
Conduit A14L-0166-2376#CONDUIT
Liner A14L-0166-2376#LINER
Block A14L-0166-2375#BLOCK
Inlet A14L-0166-2375#INLET
Joint A14L-0166-2375#JOINT

Table A.2 (q) Flexible conduit for servo torch for mild steel A05B-1220-J377 (ARC Mate 120iC)
Parts name Specifications Remarks
Conduit A14L-0166-2377#CONDUIT
Liner A14L-0166-2377#LINER
Block A14L-0166-2375#BLOCK
Inlet A14L-0166-2375#INLET
Joint A14L-0166-2375#JOINT

A.2 (r) Flexible conduit for servo torch for mild steel A05B-1291-H411
Parts name Specifications Remarks
Flexible conduit 4.6m A14L-0166-0411

Table A.2 (s) Flexible conduit for servo torch for mild steel A05B-1291-H413
Parts name Specifications Remarks
Flexible conduit 3m A14L-0166-0413

Table A.2 (t) Flexible conduit for servo torch for mild steel A05B-1291-H414
Parts name Specifications Remarks
Flexible conduit 1.7m A14L-0166-0414

Table A.2 (u) Gas regulator A05B-1291-J101

Parts name Specifications Remarks
Standard (for gas cylinder) A14L-0166-1101

Table A.2 (v) Gas hose for servo torch for mild steel A05B-1291-J151,J152,J153,J154
Parts name Specifications Remarks
Gas hose 10m A97L-0218-0112#L10R03
Gas hose 15m A97L-0218-0112#L15R03
Gas hose 20m A97L-0218-0112#L20R03
Gas hose 25m A97L-0218-0112#L25R03

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B-83074EN/05 APPENDIX A. MAINTENANCE PARTS

A.3 SERVO TORCH FOR TIG

Table A.3 (a) Mechanical unit of servo torch A05B-1220-J305 (Servo torch for TIG)
Parts name Specifications Remarks
Motor A06B-0114-B204 J7-axis βiS0. 4/5000 (without brake)
Adapter A290-7215-X721 for motor
Adapter A290-7215-X742 for motor
Collar A290-7215-X743 for motor
Bush A290-7215-X745 for motor
Gear A290-7220-X711 for motor shaft
Adjust bolt A290-7220-X727 for motor shaft
Washer A290-7220-X745 for motor
Roller bush A290-7220-Z744 for roller
Bolt A97L-0218-0514#M3X12 for roller cover
Cover knob A97L-0218-0766#041014 Jamming roller part
Kyodo Yushi VIGOGREASE RE0
Grease A98L-0040-0174#16KG
Refer to Chapter 5 for required quantity.
Key JB-HKY-3X3X6B for motor
O ring JB-OR4D-G45 for motor
Pin JB-PH-H7B-3X6S45C for motor

Table A.3 (b) Bracket assembly A05B-1220-J324 (Servo torch for TIG)
Parts name Specifications Remarks
Gasket A290-7220-X748
Motor cover A290-7220-Z718
Parallel pin A290-7220-Z724 (4 pcs)
Parallel pin JB-PH-H7B-4X10S45C (3 pcs)
Parallel pin JB-PH-H7B-5X10S45C-Q (4 pcs)

Table A.3 (c) Torch A05B-1220-J354 (Servo torch for TIG)

Parts name Specifications Remarks
Torch A14L-0166-2354

- 71 -
 B
B. CIRCUIT DIAGRAM

CABLE K163(A660-4004-T972) J7 MOTOR (βiS0.4/5000)

J1 CONNECTOR PANEL CABLE K301(A66L-2006-T755) J3 CONNECTOR A66L-0001-0400#1 A63L-0001-0865#1
A66L-0001-0401#10 (0.5SQ*3P,0.2SQ*2P)φ8.5 A63L-0001-0864#CS M7 M MOLEX 55618-0401
(1.25SQ*10C)φ11.8 MS3108B20-27PY
WF 1 20-27P WF 2 20-27S 1 J7U1 4 J7G1
2 J7V1 3 J7W1
A J7U1 J FG J FG A J7U1
B J7V1 K G1 I I K G1 B J7V1
A63L-0001-0848#E10SL1 M7 P 10SL1(0.3SQ 3A)
C J7W1 L G1 N H 5V(J7) H 5V(J7) N L G1 C J7W1
A63L-0001-0850 4
D J7G1 M PRQJ7 G 0V(J7) G 0V(J7) M PRQJ7 D J7G1 8 5V(J7) 1
E XPRQJ7 F F E XPRQJ7 5 XPRQJ7
9 2
A66L-0001-0464#1 6 PRQJ7
10 0V(J7) 3 FG
(0.2SQ*4P)φ6.7 A66L-0001-0464#1 7
(0.2SQ*4P)φ6.7

- 72 -
CIRCUIT DIAGRAM

Servo Tocrh for ROBOWELD iC series

APPENDIX

Fig.B (a) Circuit diagram (Servo torch for aluminum/TIG)

B-83074EN/05
 B-83074EN/05

CABLE K164(A660-4005-T072) J7 MOTOR (βiSR0.2/6000)

J1 CONNECTOR PANEL CABLE K301(A66L-2006-T755) J3 CONNECTOR A66L-0001-0464#1 A63L-0001-0865#1
A66L-0001-0401#10 (0.2SQ*4P)φ6.7 A63L-0001-0864#CS M7 M MOLEX 55618-0401
(1.25SQ*10C)φ11.8 MS3108B20-27PY
WF 1 20-27P WF 2 20-27S 1 J7U1 4 J7G1
2 J7V1 3 J7W1
A J7U1 J FG J FG A J7U1
B J7V1 K G1 I I K G1 B J7V1
A63L-0001-0848#E10SL1 M7 P 10SL1(0.3SQ 3A)
C J7W1 L G1 N H 5V(J7) H 5V(J7) N L G1 C J7W1
A63L-0001-0850 4
D J7G1 M PRQJ7 G 0V(J7) G 0V(J7) M PRQJ7 D J7G1 8 5V(J7) 1
E XPRQJ7 F F E XPRQJ7 5 XPRQJ7
9 2
A66L-0001-0464#1 6 PRQJ7
10 0V(J7) 3 FG
(0.2SQ*4P)φ6.7 A66L-0001-0464#1 7
(0.2SQ*4P)φ6.7

- 73 -
APPENDIX

Servo Tocrh
Mild steel welding for ARC Mate iC series

Fig.B (b) Circuit diagram (Servo torch for mild steel)

B. CIRCUIT DIAGRAM
 B. CIRCUIT DIAGRAM

AUX AXIS AMPLIFIER

(ALPHA i AMPLIFIER) CABLE K181(A660-2007-T278)/A05B-1220-J303 J7 MOTOR
A63L-0001-0726#041KMMM A66L-0001-0400#1 A63L-0001-0865#1
POWER TYCO D-5200 4-A63L-0001-0727#CSN (0.5SQ*3P,0.2SQ*2P)φ8.5 A63L-0001-0864#CS M7 M MOLEX 55618-0401
A1 J7V1 B1 J7U1 1 J7U1 4 J7G1
A2 J7G1 B2 J7W1 2 J7V1 3 J7W1

A63L-0001-0848#E10SL1 M7 P 10SL1(0.3SQ 3A)

JF HONDA CABLE K185(A660-8017-T641)/A05B-1220-J303 A63L-0001-0850 4
A63L-0001-0399#20FP-CB 8 5V(J7) 1
11 01 5 XPRQJ7
9 2
12 6 PRQJ7
０Ｖ(J7) 02 10 0V(J7) 3 FG
A66L-0001-0464#1 7
13 03
(0.2SQ*4P)φ6.7
14 04
15 05 PRQJ7
16 ＦＧ 06 XPRQJ7
17 07
18 08

- 74 -
19 09 5V(J7)
20 10
APPENDIX

Servo Tocrh for CE

Aluminum welding for ARC Mate iC series
for Alpha i Amplifier

Fig.B (c) Circuit diagram (Servo torch for aluminum (CE) for alpha i amplifier)
B-83074EN/05
 B-83074EN/05

AUX AXIS AMPLIFIER

(BETA i AMPLIFIER) CABLE K182(A660-2007-T279)/A05B-1220-J303 J7 MOTOR
A63L-0001-0460#045KD A66L-0001-0400#1 A63L-0001-0865#1
POWER TYCO D-3500 4-A63L-0001-0456#ASL (0.5SQ*3P,0.2SQ*2P)O8.5 A63L-0001-0864#CS M7 M MOLEX 55618-0401
A1 J7V1 B1 J7U1 1 J7U1 4 J7G1
A2 J7G1 B2 J7W1 2 J7V1 3 J7W1

A63L-0001-0848#E10SL1 M7 P 10SL1(0.3SQ 3A)

JF HONDA CABLE K185(A660-8017-T641)/A05B-1220-J303 A63L-0001-0850 4
A63L-0001-0399#20FP-CB 8 5V(J7) 1
11 01 5 XPRQJ7
9 2
12 ０Ｖ(J7) 02 6 PRQJ7
10 0V(J7) 3 FG
A66L-0001-0464#1 7
13 03
(0.2SQ*4P)O6.7
14 04
15 05 PRQJ7
16 ＦＧ 06 XPRQJ7
17 07
18 08

- 75 -
19 09 5V(J7)
20 10
APPENDIX

Servo Tocrh for CE

Aluminum welding for ARC Mate iC series
for Beta i Amplifier

Fig.B (d) Circuit diagram (Servo torch for aluminum (CE) for beta i amplifier)
B. CIRCUIT DIAGRAM
 AUX AXIS AMPLIFIER
(ALPHA i AMPLIFIER) CABLE K183(A660-2007-T280)/A05B-1220-J304
J7 MOTOR
B. CIRCUIT DIAGRAM

A63L-0001-0726#041KMMM A66L-0001-0464#1 A63L-0001-0865#1

POWER TYCO D-5200 4-A63L-0001-0727#CSN (0.2SQ*4P)φ6.7 A63L-0001-0864#CS M7 M MOLEX 55618-0401
A1 J7V1 B1 J7U1 1 J7U1 4 J7G1
A2 J7G1 B2 J7W1 2 J7V1 3 J7W1

A63L-0001-0848#E10SL1 M7 P 10SL1(0.3SQ 3A)

JF HONDA CABLE K185(A660-8017-T641)/A05B-1220-J304 A63L-0001-0850 4
A63L-0001-0399#20FP-CB 8 5V(J7) 1
11 01 5 XPRQJ7
9 2
12 ０Ｖ(J7) 02 6 PRQJ7
10 0V(J7) 3 FG
A66L-0001-0464#1 7
13 03
(0.2SQ*4P)φ6.7
14 04
15 05 PRQJ7
16 ＦＧ 06 XPRQJ7
17 07
18 08
19 09 5V(J7)
20 10 Servo Tocrh for CE

- 76 -
Mild steel welding for ARC Mate iC series
for Alpha i Amplifier
APPENDIX

Fig.B (e) Circuit diagram (Servo torch for mild steel (CE) for alpha i amplifier)
B-83074EN/05
 B-83074EN/05

AUX AXIS AMPLIFIER

(BETA i AMPLIFIER) CABLE K184(A660-2007-T281)/A05B-1220-J304 J7 MOTOR
A63L-0001-0460#045KD A66L-0001-0464#1 A63L-0001-0865#1
POWER TYCO D-3500 4-A63L-0001-0456#ASL (0.2SQ*4P)φ6.7 A63L-0001-0864#CS M7 M MOLEX 55618-0401
A1 J7V1 B1 J7U1 1 J7U1 4 J7G1
A2 J7G1 B2 J7W1 2 J7V1 3 J7W1

A63L-0001-0848#E10SL1 M7 P 10SL1(0.3SQ 3A)

JF HONDA CABLE K185(A660-8017-T641)/A05B-1220-J304 A63L-0001-0850 4
A63L-0001-0399#20FP-CB 8 5V(J7) 1
11 01 5 XPRQJ7
9 2
12 6 PRQJ7
０Ｖ(J7) 02 10 0V(J7) 3 FG
A66L-0001-0464#1 7
13 03
(0.2SQ*4P)φ6.7
14 04
15 05 PRQJ7
16 ＦＧ 06 XPRQJ7
17 07
18 08
19 09 5V(J7)
20 10
Servo Tocrh for CE

- 77 -
Mild steel welding for ARC Mate iC series
APPENDIX

for Beta i Amplifier

Fig.B (f) Circuit diagram (Servo torch for mild steel (CE) for beta i amplifier)
B. CIRCUIT DIAGRAM
C. PERIODIC MAINTENANCE TABLE APPENDIX B-83074EN/05

C PERIODIC MAINTENANCE TABLE

Servo torch Periodic Maintenance Table

First 3 6 9 1 2
Check Grease
check months months months year years
time amount
320 920 1920 2880 3840 4800 5760 6720 7680 8640 9600 10560
Confirm the situation of
1 0.2H ― ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
roller
Replacing inlet guide liner
2 0.1H ― ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
(Servo torch for aluminum)
Check the motor and
3 exposed connector. 0.1H ― ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
(Loosening)
Tighten the cover and main
4 0.5H ― ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
bolt.
Remove spatter, trash, dust
5 0.1H ― ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
etc.
Cleaning and replacing
6 0.1H ― ○ ● ○ ● ○ ● ○ ● ○ ● ○
liner
Cleaning and replacing
7 0.1H ― ● ● ● ● ● ● ● ● ● ● ●
neck liner
8 Replacing roller 0.5H ― ● ●
9 Replacing flexible conduit 0.5H ― ● ●
10 Replacing torch cable 1.0H ― ● ●
11 Replacing grease 0.1H 50g
*1 Confirm status of roller and replace inlet guide liner every months.
See Chapter 4 about daily check.
*2 ●: requires order of parts
○: does not require order of parts

- 78 -
B-83074EN/05 APPENDIX C. PERIODIC MAINTENANCE TABLE

3 4 5 6 7 8
years years years years years years Item
11520 12480 13440 14400 15360 16320 17280 18240 19200 20160 21120 22080 23040 24000 24960 25920 26880 27840 28800 29760 30720

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ 1

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ 2

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ 3

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ 4

Overhaul
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ 5

● ○ ● ○ ● ○ ● ○ ● ○ ● ○ ● ○ ● ○ ● ○ ● ○ 6

● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● 7
● ● ● ● ● 8
● ● ● ● ● 9
● ● ● ● ● 10
● ● 11

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D. STRENGTH OF BOLT AND BOLT TORQUE LIST APPENDIX B-83074EN/05

D STRENGTH OF BOLT AND BOLT TORQUE

LIST
NOTE
In apply the LOCTITE to designate part, spread to the entire length area of the
engaging part of female thread. If applied to the male threads, poor adhesion
provoke loose bolt. Clean the bolts and the threaded holes and wipe off the oil on
the engaging section. Make sure that there is no solvent left in the threaded holes.
In this case remove all the excess LOCTITE finished screwing.

Adopt following strength bolts.

Comply with the instruction prescribed in a manual if the bolt specified.
Hexagon socket head bolt made by steel
Size M22 or less: Tensile strength 1200N/mm2 or more
Size M24 or more: Tensile strength 1000N/mm2 or more
All size plating bolt: Tensile strength 1000N/mm2 or more

Hexagon bolt, stainless bolt, special shape bolt (button bolt, low-head bolt, flush bolt .etc.)
Tensile strength 400N/mm2 or more
Refer to the following tables if the bolts tightening torque are not specified.

Recommended bolt tightening torques Unit: Nm

Hexagon socket head
button bolt
Hexagon socket head
Hexagon socket head Hexagon socket head Hexagon bolt
bolt
Nominal bolt (stainless) flush bolt (steel)
(steel)
diameter Low-head bolt
(steel)
Tightening torque Tightening torque Tightening torque Tightening torque
Upper limit Lower limit Upper limit Lower limit Upper limit Lower limit Upper limit Lower limit
M3 1.8 1.3 0.76 0.53 ―――― ―――― ―――― ―――
M4 4.0 2.8 1.8 1.3 1.8 1.3 1.7 1.2
M5 7.9 5.6 3.4 2.5 4.0 2.8 3.2 2.3
M6 14 9.6 5.8 4.1 7.9 5.6 5.5 3.8
M8 32 23 14 9.8 14 9.6 13 9.3
M10 66 46 27 19 32 23 26 19
M12 110 78 48 33 ―――― ―――― 45 31
(M14) 180 130 76 53 ―――― ―――― 73 51
M16 270 190 120 82 ―――― ―――― 98 69
(M18) 380 260 160 110 ―――― ―――― 140 96
M20 530 370 230 160 ―――― ―――― 190 130
(M22) 730 510 ―――― ―――― ―――― ―――― ―――― ――――
M24 930 650 ―――― ―――― ―――― ―――― ―――― ――――
(M27) 1400 960 ―――― ―――― ―――― ―――― ―――― ――――
M30 1800 1300 ―――― ―――― ―――― ―――― ―――― ――――
M36 3200 2300 ―――― ―――― ―――― ―――― ―――― ――――

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B-83074EN/05 INDEX

INDEX
Replacing the Motor Cable ............................................57
<A> REPLACING THE MOTOR COVER...........................41
ADJUSTING ROLLER JAMMING FORCE ................37 REPLACING THE ROLLER ........................................41
ADJUSTMENT..............................................................37 REPLACING THE TORCH ..........................................39
AIR BLOW OPTION.....................................................10 Replacing the Welding Power Cable .............................53
Air Purge Function.........................................................20
ATTACHING ROLLER ................................................11 <S>
ATTENCTIONS AND LIMITATIONS FOR USE .......28 SAFETY PRECAUTIONS ........................................... s-1
SENSE LEAD CABLE....................................................9
<B> SERVO TORCH FOR ALUMINUM ............................63
BASIC SPECIFICATION................................................1 Servo torch for mild steel...............................................67
SERVO TORCH FOR TIG............................................71
<C> SERVO TORCH FUNCTION .......................................19
CABLE CONNECTION................................................13 Servo Torch Setup Screen..............................................18
CABLE REPLACEMENT.............................................52 SETUP FOR SERVO TORCH ......................................15
CABLE WIRING...........................................................52 Setup in Weld Equipment Setup Screen.........................17
CHECKS AND MAINTENANCE ................................29 Setup Servo Torch Axis .................................................15
CIRCUIT DIAGRAM....................................................72 Setup touch retract start..................................................22
CONFIGURATION .........................................................1 SOFTWARE SETUP .....................................................15
STRENGTH OF BOLT AND BOLT TORQUE LIST ..80
<D> STRUCTURE OF THE SERVO TORCH .......................8
DAILY CHECKS...........................................................29 SYSTEM STRUCTURE..................................................5

<I> <T>
INSTALLATION...........................................................11 Teaching of Arc Welding Instructions ...........................19
Touch Retract Start Function .........................................20
<M> TROUBLESHOOTING .................................................35
MAINTENANCE PARTS .............................................61
MAINTENANCE TOOLS.............................................32
Manual setup touch retract start .....................................26
Manual Wire Inching .....................................................19
MASTERING ................................................................37
Mastering of the Main Robot Unit .................................37
Mastering of the Servo Torch.........................................37

<O>
Outline............................................................................20

<P>
PERIODIC CHECK AND MAINTENANCE ...............31
PERIODIC MAINTENANCE .......................................33
PERIODIC MAINTENANCE TABLE..........................78

<R>
REPLACING CABLES .................................................53
REPLACING PARTS ....................................................39
REPLACING THE FLEXIBLE CONDUIT AND
LINER (SERVO TORCH FOR ALUMINUM) .........45
REPLACING THE FLEXIBLE CONDUIT AND
LINER (SERVO TORCH FOR MILD STEEL).........49
REPLACING THE FLEXIBLE CONDUIT AND
LINER (Servo torch for TIG) .....................................50
REPLACING THE MOTOR (SERVO TORCH FOR
ALUMINUM/TIG).....................................................43
REPLACING THE MOTOR (SERVO TORCH FOR
MILD STEEL) ...........................................................44
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B-83074EN/05 REVISION RECORD

REVISION RECORD
Edition Date Contents
• Addition of the air blow
05 Jan., 2020
• Correction of errors
04 Sep., 2015 • Correction of errors
• Addition of R-30iB controller
• Addition of servo torch for TIG
03 Feb., 2013 • Change of spare parts list
• Addition of periodic maintenance table
• Correction of errors
02 Nov., 2010 • Addition of servo torch for aluminum and CE specification
01 Mar., 2010

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 B-83074EN/05

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