Tregaskiss M028-1.2 Robotic Safety Clutch Owner’s Manual

Tregaskiss M028-1.2 Robotic Safety Clutch

Thank You for Choosing Tregaskiss
Thank you for selecting a Tregaskiss product. Before installing, compare the equipment received against the invoice to verify that the shipment is complete and undamaged. It is the responsibility of the purchaser to file all claims of damage or loss that may have occurred during transit with the carrier. The owner’s manual contains general information, instructions and maintenance to help better maintain your MIG gun or peripheral. Please read, understand and follow all

safety precautions.
While every precaution has been taken to assure the accuracy of this owner’s manual, Tregaskiss assumes no responsibility for errors or omissions. Tregaskiss assumes no liability for damages resulting from the use of information contained herein. The information presented in this owner’s manual is accurate to the best of our knowledge at the time of printing. Please reference Tregaskiss.com for updated material. For customer support and special applications, please call the Tregaskiss Customer Service Department at 1-855-MIGWELD (644-9353) (US & Canada) or +1-519-737-3000 (International), fax 1-708-946-6726, or email at [email protected]. Our trained Customer Service Team is available between 8:00 a.m. and 5:30 p.m. EST, and will answer your product application or repair questions. Tregaskiss manufactures premium robotic MIG (GMAW) welding guns, peripherals and consumables. For more information on other premium Tregaskiss products, contact your local Tregaskiss distributor or visit us on the web at Tregaskiss.com.

Subject to Change
 The information presented in this manual is accurate to the best of our knowledge at the time of printing. Please visit Tregaskiss.com for the most up-to-date information.

Additional Material
 For additional support materials such as spec sheets, troubleshooting information, how-to guides and videos, animations, online configurators and much more, please visit Tregaskiss.com. Scan this QR Code with your smart phone for immediate access to Tregaskiss.com/TechnicalSupport

SAFETY PRECAUTIONS

Protect yourself and others from injury – read, follow, and save these important safety precautions and operating instructions.

Symbol Usage

DANGER! – Indicates a hazardous situation which, if not avoided, will result in death or serious injury. The possible hazards are shown in the adjoining symbols or explained in the text. Indicates a hazardous situation which, if not avoided, could result in death or serious injury. The possible hazards are shown in the adjoining symbols or  or explained in the text.

NOTICE
Indicates statements not related to personal injury.

This group of symbols means Warning! Watch Out! ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions to avoid the hazards.

Arc Welding Hazards
The symbols shown below are used throughout this manual to call attention to and identify possible hazards. When you see the symbol, watch out, and follow the related instructions to avoid the hazard. The safety information given below is only a summary of the more complete safety information found in section 1-4 Principal Safety Standards on page 3, and in welding power source Owner’s Manual. Read and follow all Safety Standards. certificate, or professional standing, or who by extensive knowledge, training and experience, has successfully demonstrated ability to solve or resolve problems relating to the subject matter, the work, or the project and has received safety training to recognize and avoid the hazards involved.

ELECTRIC SHOCK can kill.

• Always wear dry insulating gloves.
• Insulate yourself from work and ground.
• Do not touch live electrode or electrical parts.
• Replace worn, damaged, or cracked guns or cables.
• Turn off welding power source before changing contact tip or gun parts.
• Keep all covers and handle securely in place.

FUMES AND GASES can be hazardous.

• Keep your head out of the fumes.
• Ventilate area, or use breathing device. The recommended way to determine adequate ventilation is to sample for the composition and quantity of fumes and gases to which personnel are exposed.
• Read and understand the Safety Data Sheets (SDSs) and the manufacturer’s instructions for adhesives, coatings, cleaners, consumables, coolants, degreasers, fluxes, and metals.

MOVING PARTS can injure.

• Keep away from moving parts.
• Keep away from pinch points such as drive rolls.

WELDING can cause fire or explosion.

• Do not weld near flammable material.
• Do not weld on containers that have held combustibles, or on closed containers such as tanks, drums, or pipes unless they are properly prepared according to AWS F4.1 and AWS A6.0 (see Safety Standards).
• Watch for fire; keep extinguisher nearby.
• Read and understand the Safety Data Sheets (SDSs) and the manufacturer’s instructions for adhesives, coatings, cleaners, consumables, coolants, degreasers, fluxes, and metals.

BUILDUP OF GAS can injure or kill.

• Shut off compressed gas supply when not in use.
• Always ventilate confined spaces or use approved air-supplied respirator.

ARC RAYS can burn eyes and skin.
Arc rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin. Sparks fly off from the weld.

• Wear an approved welding helmet fitted with a proper shade of filter lenses to protect your face and eyes from arc rays and sparks when welding or watching (see ANSI Z49.1 and Z87.1 listed in Safety Standards).
• Wear approved safety glasses with side shields under your helmet.
• Use protective screens or barriers to protect others from flash, glare and sparks; warn others not to watch the arc.
• Wear body protection made from leather or flame-resistant clothing (FRC). Body protection includes oil-free clothing such as leather gloves, heavy shirt, cuffless trousers, high shoes, and a cap.

HOT PARTS can burn.

• Allow gun to cool before touching.
• Do not touch hot metal.
• Protect hot metal from contact by others.

NOISE can damage hearing.
Noise from some processes or equipment can damage hearing.

• Check for noise level limits exceeding those specified by OSHA.
• Use approved ear plugs or ear muffs if noise level is high.
• Warn others nearby about noise hazard.

WELDING WIRE can injure.
Keep hands and body away from gun tip when trigger is pressed.

READ INSTRUCTIONS.

• Read and follow all labels and the Owner’s Manual carefully before installing, operating, or servicing unit. Read the safety information
  at the beginning of the Manual and in each section.

• Use only genuine replacement parts from the manufacturer.

• Perform installation, maintenance, and service according to the Owner’s Manuals, industry standards, and national, state, and local codes.

California Proposition 65 Warnings

WARNING : This product can expose you to chemicals including lead, which are known to the state of California to cause cancer and birth defects or other reproductive harm.For more information, go to www.P65Warnings.ca.gov.

Principal Safety Standards
Safety in Welding, Cutting, and Allied Processes, American Welding  Society standard ANSI Standard Z49.1. Website: www.aws.org. Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute. Website: www.ansi.org. Safe Practices for the Preparation of Containers and Piping for Welding and Cutting, American Welding Society Standard AWS  F4.1. Website: www.aws.org. National Electrical Code, NFPA Standard 70 from National Fire  Protection Association. Website: www.nfpa.org. Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-  1 from Compressed Gas Association. Website: www.cganet.com. Safety in Welding, Cutting, and Allied Processes, CSA Standard  W117.2 from Canadian Standards Association. Website: www.csagroup.org. Standard for Fire Prevention During Welding, Cutting, and Other Hot Work, NFPA Standard 51B from National Fire Protection  Association. Website: www.nfpa.org. OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910.177 Subpart N, Part 1910 Subpart Q, and Part 1926, Subpart J. Website: www.osha.gov. SR7 2022-01

EMF Information
Electric current flowing through any conductor causes localized electric and magnetic fields (EMF). The current from arc welding (and allied processes including spot welding, gouging, plasma arc cutting, and induction heating operations) creates an EMF field around the welding circuit. EMF fields may interfere with some medical implants, e.g. Pacemakers. Protective measures for persons wearing medical implants have to be taken. For example, restrict access for passersby or conduct individual risk assessment for welders. All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit:

1. Keep cables close together by twisting or taping them, or using a cable cover.
2. Do not place your body between welding cables. Arrange cables to one side and away from the operator.
3. Do not coil or drape cables around your body.
4. Keep head and trunk as far away from the equipment in the welding circuit as possible.
5. Connect work clamp to workpiece as close to the weld as possible.
6. Do not work next to, sit or lean on the welding power source.
7. Do not weld whilst carrying the welding power source wire feeder.

About Implanted Medical Devices:
Implanted Medical Device wearers should consult their doctor and the device manufacturer before performing or going near arc welding, spot welding, gouging, plasma arc cutting, or induction heating operations. If cleared by your doctor, then following the above procedures is recommended.

Product Warranty

Limited Warranty
Tregaskiss’ Products shall, from the date of original purchase (or, solely with respect to Low Stress Robotic Unicables packaged with any Tregaskiss® Robotic MIG Gun, from the date the product goes into production for its intended use) and for the period set forth below, be free from defects in material and workmanship. To obtain repair or replacement of any Product, the covered Product must be delivered, transportation pre-paid by Purchaser, to the address specified by Tregaskiss on its Returned Materials Authorization, with: (i) written proof of warranty coverage (e.g., Purchaser dated purchase order); (ii) serial number on product (if any); (iii) the Product’s installed location within Purchaser’s facility and usage of the Product; and (iv) written specification of any alleged defect(s). In the event the foregoing materials are not timely provided to Tregaskiss by claimant, warranty coverage will be determined by Tregaskiss, in its sole discretion. For the avoidance of doubt, the warranty period for any Product or part/component of any Product that is replaced or repaired by Tregaskiss under the foregoing warranty is not extended or renewed at the time of such replacement or repair. The Warranty against defects does not apply to: (1) consumable components or ordinary wear items; (2) products which are improperly altered, modified, stored, installed, operated, handled, used or neglected or use of the Products with equipment, components or parts not specified or supplied by Tregaskiss or contemplated under the Product documentation; or (3) Products which have not been operated, maintained, and repaired pursuant to Product documentation provided by Tregaskiss. Purchaser shall pay Tregaskiss for all warranty claim costs incurred by Tregaskiss (including inspection, labor, parts, testing, scrap and freight) due to warranty claims submitted by Purchaser which are not covered by Tregaskiss’ warranty.

• Bernard® BTB Semi-Automatic Air-Cooled MIG Guns: 1 year; Lifetime warranty on straight handles, straight handle switches, and rear strain relief
• Bernard® W-Gun™ and T-Gun™ Semi-Automatic Water-Cooled MIG Guns: 180 days
• Bernard® TGX® Chassis and Bernard TGX Ready To Weld MIG Guns: 90 days
• Tregaskiss® Robotic MIG Guns and Components: 1 year
• Tregaskiss® Automatic MIG Guns: 1 year
• Tregaskiss® TOUGH GUN® Reamer: 1 year
• When factory-equipped with lubricator: 2 years when factory-equipped with lubricator
• When (i) factory-equipped with lubricator and (ii) used exclusively with Tregaskiss® TOUGH GARD® Anti-Spatter Liquid: 3 years when both (i) and (ii)
• Tregaskiss® TOUGH GUN® Robotic Peripheral (Clutch, Sprayer, Wire Cutter, Arms): 1 year
• Tregaskiss® Low-Stress Robotic Unicables (LSR Unicables): 6 months

Service Warranty
Tregaskiss warrants the Services shall conform to any mutually agreed upon specifications or statements of work. Purchaser’s sole remedy, and Tregaskiss’s sole liability, for a breach of the foregoing warranty is for Tregaskiss, at its option, to re-perform the Services or credit Purchaser’s account for such Services.

Limitation of Liability and Remedies
TREGASKISS WILL NOT BE LIABLE, AND PURCHASER WAIVES ALL CLAIMS AGAINST TREGASKISS FOR INDIRECT, INCIDENTAL, SPECIAL, PUNITIVE OR CONSEQUENTIAL DAMAGES, DOWN TIME, LOST PROFITS OR COMMERCIAL LOSSES, WHETHER OR NOT BASED UPON TREGASKISS’ NEGLIGENCE OR BREACH OF WARRANTY OR STRICT LIABILITY IN TORT OR ANY OTHER CAUSE OF ACTION. IN NO EVENT WILL TREGASKISS’ LIABILITY IN CONNECTION WITH THE AGREEMENT OR SALE OF TREGASKISS’ PRODUCTS OR SERVICES EXCEED THE PURCHASE PRICE OF THE SPECIFIC PRODUCTS OR SERVICES AS TO WHICH THE CLAIM IS MADE.

INSTALLATION

Installing Insulating Disc to Robot

1. Ensure robot face is in SYNC before mounting insulating disc.
2. Install insulating disc with mounting bolts (not provided).
3. Torque screw 45 in-lbs (5 Nm).

• M6/M5
• Head Height Max.
• 0.0236″ (6 mm)
• Head Height Max.
• 0.0197″ (5 mm)

Installing Clutch to Insulating Disc.

1. Remove dust boot and install safety mount with bolts supplied.
2. Ensure that switch assembly is facing up.
3. Reinstall dust boot.
4. Torque screw 45 in-lbs (5 Nm).

NOTE: Make sure flat on stud is oriented in home position (between switch and air assist hole), as shown in Figure 5-B.

Installing Gun Mount Arm to Clutch

1. Loosen lock screw and install gun mount 90-degrees to the horizontal.
2. Torque screw 50 in-lbs (6 Nm).
3. Insert hex bolt through hole in arm and tighten to 50 in-lbs (6 Nm).

MAINTENANCE

Switch Operation

The TOUGH GUN robotic safety clutch is equipped with a normally closed switch for safe reliable operation. Remote indication of status is supplied by means of two LEDs (see ‘A’ in Figure 6-A) housed in connector on cord set. The green LED indicates power on and the amber light indicates normal operating state. During a crash or fault condition, piston is shifted towards mounting face (see ‘B’ in Figure 6-A) of clutch. The shifting of piston (see ‘C’ in Figure 6-A) activates switch (see ‘D’ in Figure 6-A) and drops out +24 volt signal (output), which will be indicated by amber light in cord set deactivating. Upon correction or return to normal operating state, amber light will be on and +24 volt signal (output) re-established.

Switch Replacement

1. Remove cord set (see ‘E’ in Figure 5-A in section 6-1 Switch Operation on page 13), jam nut (see ‘F’ in Figure 6-B), and two socket head cap screws (see ‘G’ in Figure 6-B).
2. Remove switch holder from clutch, allowing switch assembly to be removed from housing.
3. Before replacing new switch assembly in housing, turn adjusting sleeve (see ‘H’ in Figure 6-B) counterclockwise until sleeve is flush with switch housing base (reference Figure 6-B).
4. Insert switch assembly (see Figure 6-C) into housing and reattach housing assembly to clutch by means of two socket head cap screws.
5. Reassemble jam nut on adjusting sleeve but do not tighten until switch is set in proper position.
6. Reconnect cord set to switch with power on. At this point, both LEDs should be on.

Switch Setting
With both LEDs active, you may proceed to adjust switch for proper sensitivity. With jam nut free on adjusting sleeve, rotate adjusting sleeve clockwise using adjusting wrench until amber light is switched off (switch activated). Now slowly turn adjusting sleeve counterclockwise until amber LED is lit. At this point, switch is set for maximum sensitivity.
Depending on application, you may wish to reduce sensitivity by further adjustment of adjusting sleeve (counterclockwise rotation) by additional 10-15 degree increments (approximately). Once desired sensitivity is achieved, lock position of switch by torquing jam nut 100 in-lbs (11 Nm) on adjusting sleeve against switch housing base.

Wiring Diagram

WARNING: Current draw for relay must not exceed 200 mA (loading capacity of switch) or damage to switch will occur.

Recommended Relay (if necessary) Potter & Brumfield 24 VDC 1.2 watts 50 mA

NOTE: Pin #3 (0 volts DC) required to enable LEDs only.

Technical Specifications

• Force and moment diagram for air assist (refer to DIAGRAM #1)
• Range of travel
  • X and Y direction ±20°
  • Z direction 0.250″
  • Rotational ±360°
• Physical dimension (refer to DIAGRAM #2)
• Weight: 1.99 lbs (0.91 kg)
• Trip / Activation points
  • X and Y direction ±1.0°
  • Z direction 0.018″
  • Rotational about Z axis ±1.0°
• Electrical data
  • Micro switch P.N.P. / N.C.
  • Operational voltage 10 to 30 VDC indicator LED

DIAGRAM 1

DIAGRAM 2

PARTS LIST

Robotic Safety Clutch

Jumper cable (12′ (3 m) with LEDs, coiled)
4b| AS-708-14-2| Jumper cable (15′ (5 m))
NS| AS-709-14| Cable assembly, 2-pc Motoman
NS| AS-709-14-2| Main cable assembly, Motoman, 5′
NS| AS-709-14-3| Main cable asssembly, Motoman, 10′
5| 194547-1| O-ring
6| AS-708-13| Micro switch assembly

7

| ****

AS-707-12

| Switch housing (includes 2x 5-40X3/8 cap screws serial # 0001 to 5393 , and 2x M3X0.5X10 cap screws

after serial # 5394)

8| AS-707-16| Switch protector
NS| AS-707-15| Switch adjusting wrench
NS| AS-708| Replacement clutch (with jumper and long cord)
NS| AS-720| Replacement clutch (with 12′ (3 m) jumper cord only)
NS| AS-707-40| Velcro clutch cable wrap

Insulating Discs

AS-101-2

| ABB® IRB-1400, IRB-1500, IRB-2000, IRB6 MILLER® MRV- 2, MRV-10, FANUC® S6, 100 MOTOMAN® SK6, OTC MRV-6,

DR-4400

AS-101-4| ABB® IRB-2400
AS-101-5| OTC DR200 / MILLER
AS-101-6| OTC / MILLER
AS-101-12| PANASONIC® W0500, ABB AC500
AS-102-5| KUKA®
AS-102-6| HITACHI® PW-10
AS-102-7| MILACRON® T3-776
AS-102-8| COMAU® SMART-3S®
AS-102-10| MOTOMAN® K6, K10, HITACHI M6060,
AS-102-11| HITACHI® M5030, M6030
AS-102-12| PANASONIC® AW-500
AS-102-13| INSULATING DISC
AS-102-14| INSULATING DISC
AS-103-3| FANUC ARCMATE® JR (55), SR (510)
AS-103-4| KUKA®
AS-104-3| MILACRON®
AS-105-1| MILLER® MRK-5 / OTC
AS-105-2| MILLER® MRH-2, MR-1000 / OTC
AS-106-1| MOTOMAN® L10W, L106, PANASONIC® AW7000
AS-106-3| MITSUBISHI® MZ10
AS-106-4| PANASONIC AW-010A, AW-8010, VR-008A, VR006A AND VR-

006ALII, PANASONIC® AW-005A, AW-010A

AS-106-5| SAMSUNG® FARA AM1
AS-106-7| MOTOMAN: SV3
AS-106-8| FANUC ARC MATE 50IL
AS-106-9| KAWASAKI FS-10L
AS-107-1| NACHI® 7603
AS-107-2| NACHI® VORG-35
AS-107-3| NACHI® SC15
AS-107-4| NACHI® SC 35-01
AS-107-6| NACHI
AS-107-7| NACHI SC06F-01, SC06F-02
AS-110-1| PUMA® ALL, KAWASAKI® ALL

TROUBLESHOOTING

Troubleshooting Table

PROBLEM| CAUSE|
---|---|---
1. Ensuring

repeatability of TCP.

| 1.     Check neck for damage; Most often the robot has had some sort of crash and this has resulted in the neck being bent. Check the neck before checking other components.

2.     Ensure that the torque specs of the bolts for the insulting disc, clutch, and mounting pin are correct. Too much

torque can cause the insulating disc to deform, strip threads when mounting the clutch, and deform the aluminum on the mounting arm. All of these will affect TCP location.

•  Insulating disc: 45 in-lbs (5 Nm)

•  Clutch bolts: 45 in-lbs (5 Nm)

•  Mounting pins: 50 in-lbs (6 Nm)

•  Switch jam nut: 100 in-lbs (11 Nm)

3.     Ensure the housing is fully seated in the gun mount and that both bolts are tightened with even pressure.

4.     Ensure that in both the quick-change air-cooled and quick-change water- cooled, that the necks are fully seated and tightened correctly.

|

ADDITIONAL SUPPORT MATERIALS

For additional support materials such as Spec Sheets, troubleshooting information, how-to guides and videos, animations, online configurators and much more, please visit Tregaskiss. Scan the QR Code with your smart phone for immediate access to Tregaskiss.com/TechnicalSupport. For more information, visit us at Tregaskiss.com

References

• Semi-Automatic MIG Guns, Robotic MIG Guns, Fixed Automatic Torches, Nozzle Cleaning Stations, and Welding Consumables - Tregaskiss and Bernard
• American Welding Society (AWS) - Welding Excellence Worldwide
• Product Certification & Standards Development - CSA Group
• NFPA | The National Fire Protection Association
• P65Warnings.ca.gov

Read User Manual Online (PDF format)

Download This Manual (PDF format)

Download this manual  >>