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Operator's Manual
Magnum
External Dress Robotic Torch
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Date Purchased
Code: (ex: 10859)
Serial: (ex: U1060512345)
IM10653-B
| Issue
Date Apr
© Lincoln Global, Inc. All Rights Reserved.
PRO Water Cooled
®
- 24
For use with machines having Code Numbers:
K5415-4
K5415-4L
K5415-5L
K5415-6L
K5415-8
K5415-9L
K5415-11
K5415-13
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Summary of Contents for Lincoln Electric Magnum PRO K5415-4
- Page 1 Operator’s Manual Magnum PRO Water Cooled ® External Dress Robotic Torch For use with machines having Code Numbers: K5415-4 K5415-4L K5415-5L K5415-6L K5415-8 K5415-9L K5415-11 K5415-13 Register your machine: www.lincolnelectric.com/registration Authorized Service and Distributor Locator: www.lincolnelectric.com/locator Save for future reference Date Purchased Code: (ex: 10859) Serial: (ex: U1060512345)
- Page 2 THANK YOU FOR SELECTING A QUALITY PRODUCT BY KEEP YOUR HEAD OUT OF THE FUMES. LINCOLN ELECTRIC. DON’T get too close to the arc. Use corrective lenses if necessary to stay a reasonable distance away from the arc. READ and obey the Safety Data...
- Page 3 2.a. Electric current fowing through any conductor W117.2. A Free copy of “Arc Welding Safety” booklet E205 causes localized Electric and Magnetic Fields (EMF). is available from the Lincoln Electric Company, 22801 Welding current creates EMF fields around welding cables St. Clair Avenue, Cleveland, Ohio 44117-1199.
- Page 4 SAFETY ARC RAYS CAN BURN. ELECTRIC SHOCK CAN KILL. 4.a. Use a shield with the proper filter and cover plates to protect your 3.a. The electrode and work (or ground) circuits are eyes from sparks and the rays of the arc when welding or electrically “hot”...
- Page 5 SAFETY CYLINDER MAY EXPLODE IF WELDING AND CUTTING DAMAGED. SPARKS CAN CAUSE FIRE OR EXPLOSION. 7.a. Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operating regulators designed for 6.a. Remove fire hazards from the welding area. If the gas and pressure used.
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Page 6: Table Of Contents
TABLE OF CONTENTS GENERAL DESCRIPTION ................................ A-1 GENERAL FUNCTIONAL DESCRIPTION ........................A-1 RECOMMENDED PROCESSES ............................A-1 PROCESS LIMITATIONS..............................A-1 EQUIPMENT LIMITATIONS ............................A-1 COMMON EQUIPMENT PACKAGES ..........................A-2 TECHNICAL SPECIFICATIONS .............................A-3 EXPENDABLES............................A-4 TORCH CONFIGURATIONS............................A-7 INSTALLATION ...............B-1 STANDARD ROBOT ASSEMBLY ..........................B-1 WIRE BRAKE ROBOT ASSEMBLY ..........................B-2 ACCESSORIES . -
Page 7: General Description
GENERAL DESCRIPTION MAGNUM PRO WATER COOLED EXTERNAL DRESS ROBOTIC TORCH GENERAL DESCRIPTION Wire feeders: • Torches are designed only to work with 4R100 & 4R220 Feeders. The Magnum Pro WC External Dress GMAW torch and cable • It is not recommended that the torches be used with any non assemblies have been designed to meet IEC 60974-7 specification robot-mounted wirefeeder. -
Page 8: Common Equipment Packages
GENERAL DESCRIPTION MAGNUM PRO WATER COOLED EXTERNAL DRESS ROBOTIC TORCH COMMON EQUIPMENT PACKAGES The available replacement parts for the WC External Dress are shown in Table A.1. TABLE A.1 MAGNUM® PRO WC EXTERNAL DRESS REPLACEMENT EQUIPMENT PRODUCT # DESCRIPTION K5386 WATER COOLED EXTERNAL DRESS NOSE CONE ASSEMBLY K5386-2 WATER COOLED EXTERNAL DRESS NOSE CONE ASSEMBLY WITH WIRE BRAKE... -
Page 9: Technical Specifications
GENERAL DESCRIPTION MAGNUM PRO WATER COOLED EXTERNAL DRESS ROBOTIC TORCH TECHNICAL SPECIFICATIONS Welding process GMAW, FCAW Type of cooling Water Cooling Min. Coolant flow rate (l/min) Coolant min. Pressure (bar) Coolant max. Pressure (bar) Min. Cooling power at 1 l/min * (kW) IEC 60974-7 Min. - Page 10 GENERAL DESCRIPTION MAGNUM PRO WATER COOLED EXTERNAL DRESS ROBOTIC TORCH MAGNUM PRO WATER COOLED EXTERNAL DRESS 4 FT WIRE SIZE CONTACT TIPS PRODUCT / TORCH CABLE NOSE CONE RANGE IN STANDARD DIFFUSER GAS NOZZLE CABLE LINER GUN TUBE JUMP LINER DESCR.
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Page 11: Torch Configurations
GENERAL DESCRIPTION MAGNUM PRO WATER COOLED EXTERNAL DRESS ROBOTIC TORCH TORCH CONFIGURATIONS STANDARD NOSECONE FIGURE A.2 WIRE BRAKE NOSECONE FIGURE A.3... -
Page 12: Installation
INSTALLATION MAGNUM PRO WATER COOLED EXTERNAL DRESS ROBOTIC INSTALLATION 5. With the 3 cable hose fittings on the torch cable passing through torch housing, install Power Cable Clamp onto the three hose Read this entire installation section before you start installation. fittings. -
Page 13: Wire Brake Robot Assembly
INSTALLATION MAGNUM PRO WATER COOLED EXTERNAL DRESS ROBOTIC INSTALLATION With the 3 cable hose fittings on the torch cable passing through torch housing, install Power Cable Clamp onto the three hose fittings. The dimple on the power cable clamp will be facing the o- Read this entire installation section before you start installation. -
Page 14: Accessories
ELECTRODES AND EQUIPMENT The Magnum Pro Water Cooled External dress Robotic has been designed for use with Lincoln Electric GMAW wire electrodes. Refer to the appropriate Lincoln Electric Process and Procedure Guidelines for the electrode used for information on recommended electrical and visible stickouts. -
Page 15: Maintenance
MAINTENANCE MAGNUM PRO WATER COOLED EXTERNAL DRESS ROBOTIC TORCH _________________________________________________________________________________ MAINTENANCE REMOVAL, INSTALLATION AND TRIMMING INSTRUCTIONS FOR MAGNUM PRO LINERS Refer to AutoDrive S Feeder literature for liner replacement. For Wire Brake refer to Wire Brake Installation Section GUN TUBES AND NOZZLES (See Figure D-3) 1. - Page 16 MAINTENANCE MAGNUM PRO WATER COOLED EXTERNAL DRESS ROBOTIC TORCH _________________________________________________________________________________ TO REPLACE THE WIRE BRAKE COMPONENTS, FOLLOW THESE STEPS: (See Section B-2 thru B-4 to help follow these steps also see Figure D.4) 1. Remove Gooseneck. 2. Remove plug cover from Housing. Loosen socket head cap FIGURE D.4 screw.
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Page 17: Troubleshooting
MAGNUM PRO WATER COOLED EXTERNAL DRESS ROBOTIC TORCH _________________________________________________________________________________ TROUBLESHOOTING Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual. - Page 18 MAGNUM PRO WATER COOLED EXTERNAL DRESS TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEM POSSIBLE CAUSE RECOMMENDED COURSE OF ACTION NO WIRE FEED OCCURS. OUT OF WIRE INSTALL FULL SPOOL OF SPECIFIED WIRE. CONTACT TIP BURN BACK. REPLACE CONTACT TIP. FULLY OR PARTIALLY BLOCKED REMOVE AND CLEAN OR REPLACE GUN LINER.
- Page 19 MAGNUM PRO WATER COOLED EXTERNAL DRESS TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEM POSSIBLE CAUSE RECOMMENDED COURSE OF ACTION FREQUENT OCCURRENCE OF IMPROPER WELDING SEE WELDING WIRE LITERATURE FOR PROPER SETTINGS. CONTACT TIP BURNBACK. PARAMETERS OR TECHNIQUE (EXAMPLE: ESO “ELECTRICAL STICK OUT”...
- Page 20 MAGNUM PRO WATER COOLED EXTERNAL DRESS TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Lincoln Authorized Service Facility for technical troubleshooting assistance before you proceed. WWW.LINCOLNELECTRIC.COM/LOCATOR...
- Page 21 Do not touch electrically live parts or Keep flammable materials away. Wear eye, ear and body protection. WARNING electrode with skin or wet clothing. Insulate yourself from work and ground. Spanish No toque las partes o los electrodos Mantenga el material combustible Protéjase los ojos, los oídos y el AVISO DE bajo carga con la piel o ropa moja-...
- Page 22 Keep your head out of fumes. Turn power off before servicing. Do not operate with panel open or WARNING Use ventilation or exhaust to guards off. remove fumes from breathing zone. Spanish Los humos fuera de la zona de res- Desconectar el cable de ali- No operar con panel abierto o AVISO DE...
- Page 23 Lincoln Electric is a responsive manufacturer, but the de nition of speci cations, and the selection and use of speci c products sold by Lincoln Electric is solely within the control of, and remains the sole responsibility of the customer. Many variables beyond the control of Lincoln Electric affect the results obtained in applying these types of fabrication methods and service requirements.
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