CM Industries Kool Run KR502HW User manual

505 Oakwood Rd. Lake Zurich, IL 60047
ph: 847-550-0033 fx: 847-550-0444
email: [email protected]
www.cmindustries.com
July 2017 v17.5.1
DO NOT INSTALL, OPERATE, OR REPAIR THIS EQUIPMENT
WITHOUT READING THIS OPERATING MANUAL
Operating Manual and Parts List
Air-Cooled MIG Torches for
Hollow Wrist Robots
KR502HW
MADE IN USA

All reference to genuine manufacture’s equipment numbers, and/or trade names or trademarks are for identification and convenience only.
The trademarks and trade names are the property of their respective owners. ® Indicates a registered trade name or product name, that is the property of the above-named companies.
2
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Complete Assembly Overview ....................................................
Installation & Removal of Consumables ....................................
Installation & Removal of Cable Assembly ..................................
Installation of Clutch ...................................................................
Installation & Removal of X.KOOLTM Neck ..................................
Technical Data ..............................................................................
Parts List for Solid Mount ............................................................
Parts List for Solid Mount w/ X.Kool ........................................
Parts List for Solid Mount w/ Wire Brake ....................................
Parts List for Clutch Mount ..........................................................
KR502HW Ordering Instructions .................................................
Nozzle & Gas Diffuser Selection .................................................
Checking Fixture .........................................................................
Nozzle Cleaning Station ..............................................................
General Safety ..............................................................................
Table of Contents

2
Nozzle
-Push slip-on nozzle until it bottoms on the insulator.
-Pull slip-on nozzle off to remove it.
®TM
CMI Taper Lock Contact Tip
-Thread tip into retaining head and tighten.
-Unscrew to remove (use pliers if tight).
Gas Diffuser
-Screw onto the end of neck.
(Use 5/8” wrench to tighten)
-Unscrew to remove.
Neck Insulator
-Slip onto the front of the neck.
-Unscrew retaining head and pull off to remove.
Neck
-Push neck into torch body.
(Make sure the pins line up with the slot inside the Torch Body)
-To remove, loosen the neck clamp under the collar.
-Pull neck out.
Neck Clamp
-Turn collar on torch body to expose screw.
-Once neck is inserted, tighten screw
using a 4mm Hex wrench to secure
neck in place.
-Turn collar to to hide screw hole
Hollow Wrist Body
Spacer
M5 Screws
M4 Screws Insulating Disc
-Line up pin to pinhole
on robot
(Use M4 screws to hold to robot)
Torch Body Cover
Spacer
Sleeve
Complete Assembly Overview for Solid Mount System
-Installation & Removal of Consumables-

3
Removal
- Remove the neck from the hollow wrist torch body.
- Pull the power pin out of the wire feeder and remove the liner.
- Unscrew the (3) buttonhead screws on the torch body cover.
- Slide off the torch body cover and sleeve and loosen the M4 screw on the cable connector.
- Pull the front of the cable assembly from the cable connector.
- Remove the cable assembly from the robot.
Power PinCable AssemblyCable Connector
Installation of New Cable Assembly
- Install the insulating disc by lining up the pin to the pin hole of the turning disk, and use the (4) M4 screws to tighten.
- Line up the torch body w/ spacer with the pin hole of the insulating disc and screw in the (4) M5 screws
that hold the torch body to the insulating disc.
- Slide the cable assembly through the robot arm. Do not connect the power pin.
- Push the front of the cable assembly into the torch body and tighten the M4 screw of the cable connector.
- Slide on the spacer sleeve over the torch body and spacer, then the torch body cover over the torch
body and tighten the (3) buttonhead screws.
- Install the liner through the power pin, and make sure the power pin is connected to the wire feeder properly.
(Tighten set screw if necessary.)
- Install the neck without consumables and cut the liner to the proper length as needed.
Cable Assembly Overview
-Installation & Removal of Cable Assembly-

4
Installing the Clutch
- Begin with removing the disc from the clutch.
- Install the clutch disc to the face of the robot with
the screws that were provided.
- Install the clutch to the disc by lining up the locating
pins and using a hex wrench to tighten the (6) M4 screws.
- Feed the cable assembly through the robot and push
it through the clutch.
- Once the cable assembly and the wires of the cable assembly are
throught the clutch, take the cover off the torch body and attach
the it to the cable assembly with the (1) M5 clamp screw.
- Connect the male terminals of the power cable to the female
terminals of the clutch.
- Carefully tuck the wires back into the clutch, and begin
pushing the torch body and cable assembly back towards the robot.
- Line up the locating pin of the torch body with the clutch and press fit together.
- Use the (6) M4 screws to secure the torch body to the clutch.
- Slide on the torch body cover and secure it with the (3) M4 buttonhead screws.
- Slide the rubber boot for the clutch over the torch body over and fit it into the groove of the clutch,
making sure none of the interals are visible.
1
2
Clutch Assembly
-Installation of Torch Assembly with Clutch-

5
- Slide the X.KOOLTM neck into the torch body and tighten the neck clamp screw.
- Pull the 2 black water lines through the torch body cover.
- Connect the female coupler fitting to it’s male counterpart.
- Install the consumables the same as the standard KR502 neck.
Female Coupler Fitting
Male Coupler Fitting
Installing the X.KOOLTM Neck
Installation of Water Lines
- Install the torch body to the robot.
- Start with the torch body cover off of the torch body.
- Run both water lines through the holes of the torch body cover so that the quick disconnects are
hanging out the front.
- Next, with the water lines lined up so they are on the top of the torch, find the 2 holes in the torch body
base the lines will run through, and feed them through the torch body base and through the arm of the robot.
(Make sure to push enough hose though so that you can pull from the back of the 1’ cable cover.)
- Attach the torch body cover to the torch body with the water lines facing the top of the torch.
- Once you’ve pushed the water lines through the robot, attached the torch body cover, and out of the 1’ foot
cable cover, carefully pull the rest of the 15’ of water hose so that you have the desired length at the front.
Run lines
-Installation of Water Lines & Neck-

6
NOTE: Ratings are based on tests that comply with NEMA ARC Welding Section Standard 11-6-1975 for Duty Cycle.
The time period of one complete cycle shall be 10 minutes (60%=6 minutes) National Electrical Manufacturers Association
2101 L Street N.W. Washington D.C. 20037.
Torch Amperage Ratings
Mixed Gas
500 AMP
CO2
600 AMP
60% Duty Cycle
Mixed Gas
350 AMP
CO2
500 AMP
100% Duty Cycle
Kool Run Torch Model
KR502HW
C
-
3.960” [100.6]
3.960” [100.6]
3.960” [100.6]
3.960” [100.6]
3.960” [100.6]
3.960” [100.6]
B
16.632” [422.4]
17.094” [434.2]
15.945” [405.0]
18.495” [470.0]
17.323” [440.0]
20.465” [520.0]
19.292” [490.0]
A
180°
22°
45°
22°
45°
22°
45°
NECK
KR502-180
KR502-22
KR502-45
KR502-22L1
KR502-45L1
KR502-22L2
KR502-45L2
Clutch Mount w/ Wire Brake
C
-
3.960” [100.6]
3.960” [100.6]
3.960” [100.6]
3.960” [100.6]
3.960” [100.6]
3.960” [100.6]
B
15.451” [392.4]
15.913” [404.2]
14.764” [375.0]
17.314” [440.0]
16.142” [410.0]
19.284” [490.0]
18.111” [460.0]
A
180°
22°
45°
22°
45°
22°
45°
NECK
KR502-180
KR502-22
KR502-45
KR502-22L1
KR502-45L1
KR502-22L2
KR502-45L2
Clutch Mount
*Wire Stick-Out = 15mm
A
B
C
C
-
3.960” [100.6]
3.960” [100.6]
3.960” [100.6]
3.960” [100.6]
3.960” [100.6]
3.960” [100.6]
B
16.238” [412.4]
16.700” [424.2]
15.551” [395.0]
16.920” [460.0]
16.930” [430.0]
20.070” [510.0]
18.352” [480.0]
A
180°
22°
45°
22°
45°
22°
45°
NECK
KR502-180
KR502-22
KR502-45
KR502-22L1
KR502-45L1
KR502-22L2
KR502-45L2
Solid Mount w/ Wire Brake
C
-
3.960” [100.6]
3.960” [100.6]
3.960” [100.6]
3.960” [100.6]
3.960” [100.6]
3.960” [100.6]
B
15.057” [382.4]
15.519” [394.2]
14.370” [365.0]
16.920” [430.0]
15.748” [400.0]
18.890” [480.0]
17.717” [450.0]
A
180°
22°
45°
22°
45°
22°
45°
NECK
KR502-180
KR502-22
KR502-45
KR502-22L1
KR502-45L1
KR502-22L2
KR502-45L2
Solid Mount
*Wire Stick-Out = 15mm
A
B
C
Technical Data
TCP Dimensions &
Std. Neck Options

7
10
9
8
7h
7g
7f
7d
7e
7c
7b
7a
7
6
5
4
32
1
1. 152-xx-xxP See Page 10 “Plated Nozzle Selection”
2. CMI TAPER LOCKTM CONTACT TIP
155-1-030 Heavy Duty, .030” (0.8mm)
155-1-035 Heavy Duty, .035” (0.9mm)
155-1-040 Heavy Duty, .040” (1.0mm)
155-1-045 Heavy Duty, .045” (1.2mm)
155-1-364 Heavy Duty, 3/64” (1.3mm)
155-1-052 Heavy Duty, .052” (1.4mm)
155-1-062 Heavy Duty, .062” (1.6mm)
155-1-564 Heavy Duty, 5/64” (2.0mm)
155-1-332 Heavy Duty, 3/32” (2.4mm)
155-2-xxx Heavy Duty Tapered Contact Tip
155-3-xxx Extra Heavy Duty Contact Tip
155-7-xxx Heavy Duty CrZr Contact Tip
3. 154-Rxxx See Page 10 “Gas Diffuser Selection”
4. KR50-1 Neck Insulator
5. KR502-22 Neck, 22 °
KR502-45 Neck, 45 °
KR502-180 Neck, 180 °
6. KR502-6 O-Ring
7. KHW-200A1 Solid Mount Assembly - ABB IRB 1600ID
KHW-200D1 Solid Mount Assembly - OTC AX MV4AP/ AX MV4LAP
KHW-200F Solid Mount Assembly - Fanuc/Motoman MA1440
KHW-200M Solid Mount Assembly - Motoman [excludes MA1440]
7a. KHW-201 Hollow Wrist Torch Body [Included in ITEM 7]
7b. KHW-211 Hollow Wrist Torch Body Cover [Included in ITEM 7]
7c. Not Sellable M4x0.7x17 SHCS [Included in ITEM 7]
7d. KHW-103 Spacer - Fanuc/Motoman [Included in ITEM 7]
KHW-105 Spacer - ABB/OTC
7e. KHW-104 Spacer Sleeve [Included in ITEM 7]
7f. Not Sellable M5x0.8x18 SHCS [Included in ITEM 7]
7g. KHW-AB160 Insulating Disc - ABB IRB 1600ID
KHW-FA100 Insulating Disc - Fanuc/Motoman MA1440
KHW-MM1 Insulating Disc - Motoman
KHW-OAX1 Insulating Disc - OTC AX MV4AP/MV4LAP
7h. Not Sellable M4x0.7x12 SHCS [Fanuc/Motoman]
8. KHW-A160 Cable Assembly, ABB IRB 1600ID
KHW-A261 Cable Assembly, ABB IRB 2600ID 1.65
KHW-F100 Cable Assembly, Fanuc 100iC, 100iC-12
KHW-F100-6L Cable Assembly, Fanuc 100iC-6L, 100iC-7L
KHW-F100-8L Cable Assembly, Fanuc 100iC-8L
KHW-F120 Cable Assembly, Fanuc 120iC
KHW-F120-10L Cable Assembly, Fanuc 120iC-10L,120iC-12L
KHW-F710-12L Cable Assembly, Fanuc M-710iC-12L
KHW-M140 Cable Assembly, Motoman EA / MA1400
KHW-M190 Cable Assembly, Motoman EA / MA1900
KHW-M310 Cable Assembly, Motoman MA3100
KHW-M144 Cable Assembly, Motoman MA1440
KHW-OMV4 Cable Assembly, OTC AX MV4AP/MV4LAP
9. KDP-101 Power Pin, Miller®
KDP-103 Power Pin, Panasonic®
KDP-104 Power Pin, Tweco®#4
KDP-106 Power Pin, OTC®
KDP-107 Power Pin, Fronius®
KDP-108 Power Pin, Lincoln®“4R”
KDP-109 Power Pin, Lincoln®“AutoDrive®S
10. 164-30-6 Liner, 6’, .030”
164-45-6 Liner, 6’, .035” - .045”
164-45A-6 Liner, 6’, .035” - .045”
(for Lincoln®AutoDrive®S Only)
164-116-6 Liner, 6’, .045” - 1/16”
164-116TF-6 Teflon Liner, 6’, 3/64” - 1/16”
ITEM PART # DESCRIPTION
Exploded View & Parts List for Solid Mount

8
14
13
12
11h
11g
11f
11d
11e
11c
11b
11a
11
10
9
8
7
6
5
4
32
1
1. 152-xx-xxP See Page 10 “Plated Nozzle Selection”
2. CMI TAPER LOCKTM CONTACT TIP
155-1-030 Heavy Duty, .030” (0.8mm)
155-1-035 Heavy Duty, .035” (0.9mm)
155-1-040 Heavy Duty, .040” (1.0mm)
155-1-045 Heavy Duty, .045” (1.2mm)
155-1-364 Heavy Duty, 3/64” (1.3mm)
155-1-052 Heavy Duty, .052” (1.4mm)
155-1-062 Heavy Duty, .062” (1.6mm)
155-1-564 Heavy Duty, 5/64” (2.0mm)
155-1-332 Heavy Duty, 3/32” (2.4mm)
155-2-xxx Heavy Duty Tapered Contact Tip
155-3-xxx Extra Heavy Duty Contact Tip
155-7-xxx Heavy Duty CrZr Contact Tip
3. 154-Rxxx See Page 10 “Gas Diffuser Selection”
4. KR512-22 X.KOOL Neck, 22 °
KR512-45 X.KOOL Neck, 45 °
KR512-180 X.KOOL Neck, 180 °
5. KR512-1 X.KOOL Quick Disconnect
6. KR512-1-15 X.KOOL Water Line, 15’ (each) [Includes ITEM 5]
7. KR512-14B X.KOOL Cable Cover Robot Bracket
8. Not Sellable M5x0.8x35 SHCS [Included in ITEM 7]
9. KR512-14C X.KOOL Cable Cover, 14”
10. KR502-6 O-Ring
11. KHX-200A1 Solid Mount Assembly - ABB IRB 1600ID
KHX-200D1 Solid Mount Assembly - OTC AX MV4AP/ AX MV4LAP
KHX-200F Solid Mount Assembly - Fanuc/Motoman MA1440
KHX-200M Solid Mount Assembly - Motoman [excludes MA1440]
11a. KHW-201 Hollow Wrist Torch Body [Included in ITEM 11]
11b. KHX-211 Hollow Wrist Torch Body Cover [Included in ITEM 11]
11c. Not Sellable M4x0.7x17 SHCS [Included in ITEM 11]
11d. KHW-103 Spacer - Fanuc/Motoman [Included in ITEM 11]
KHW-105 Spacer - ABB
11e. KHW-104 Spacer Sleeve [Included in ITEM 11]
11f. Not Sellable M5x0.8x18 SHCS [Included in ITEM 11]
11g. KHW-xxxxxx Insulating Disc [Included in ITEM 11]
11h. Not Sellable M4x0.7x12 SHCS [Fanuc/Motoman]
12. KHX-A160 XK Cable Assembly, ABB IRB 1600ID
KHX-A261 XK Cable Assembly, ABB IRB 2600ID 1.65
KHX-A262 XK Cable Assembly, ABB IRB 2600ID 1.85
KHX-F100 XK Cable Assembly, Fanuc 100iC, 100iC-12
KHX-F100-6 XK Cable Assembly, Fanuc 100iC-6L, 100iC-7L
KHX-F100-8 XK Cable Assembly, Fanuc 100iC-8L
KHX-F120 XK Cable Assembly, Fanuc 120iC
KHX-F120-10 XK Cable Assembly, Fanuc 120iC-10L,120iC-12L
KHX-F710-12L XK Cable Assembly, Fanuc M-710iC-12L
KHX-M140 XK Cable Assembly, Motoman EA / MA1400
KHX-M190 XK Cable Assembly, Motoman EA / MA1900
KHX-M310 XK Cable Assembly, Motoman MA3100
KHX-M144 XK Cable Assembly, Motoman MA1440
KHX-OMV4 XK Cable Assembly, OTC AX MV4AP/MV4LAP
13. KDP-101 Power Pin, Miller®
KDP-103 Power Pin, Panasonic®
KDP-104 Power Pin, Tweco®#4
KDP-105 Power Pin, Tweco®#5
KDP-106 Power Pin, OTC®
KDP-107 Power Pin, Fronius®
KDP-108 Power Pin, Lincoln®“4R”
KDP-109 Power Pin, Lincoln®“AutoDrive®S
14. 164-30-6 Liner, 6’, .030”
164-45-6 Liner, 6’, .035” - .045”
164-45A-6 Liner, 6’, .035” - .045”
(for Lincoln®AutoDrive®S Only)
164-116-6 Liner, 6’, .045” - 1/16”
164-116TF-6 Teflon Liner, 6’, 3/64” - 1/16”
ITEM PART # DESCRIPTION
Exploded View & Parts List for Solid Mount w/ X.KOOL

9
15
14
13
7h
7g
7f
7d
7e
7c
7b
7a
7
6
8
9
10
11
12
5
4
32
1
1. 152-xx-xxP See Page 10 “Plated Nozzle Selection”
2. CMI TAPER LOCKTM CONTACT TIP
155-1-030 Heavy Duty, .030” (0.8mm)
155-1-035 Heavy Duty, .035” (0.9mm)
155-1-040 Heavy Duty, .040” (1.0mm)
155-1-045 Heavy Duty, .045” (1.2mm)
155-1-364 Heavy Duty, 3/64” (1.3mm)
155-1-052 Heavy Duty, .052” (1.4mm)
155-1-062 Heavy Duty, .062” (1.6mm)
155-1-564 Heavy Duty, 5/64” (2.0mm)
155-1-332 Heavy Duty, 3/32” (2.4mm)
155-2-xxx Heavy Duty Tapered Contact Tip
155-3-xxx Extra Heavy Duty Contact Tip
155-7-xxx Heavy Duty CrZr Contact Tip
3. 154-Rxxx See Page 10 “Gas Diffuser Selection”
4. KR50-1 Neck Insulator
5. KR502-22 Neck, 22 °
KR502-45 Neck, 45 °
KR502-180 Neck, 180 °
6. KR502-6 O-Ring
7. KWB-200A1 Solid Mount Assembly - ABB IRB 1600ID
KWB-200D1 Solid Mount Assembly - OTC AX MV4AP/ AX MV4LAP
KWB-200F Solid Mount Assembly - Fanuc/Motoman MA1440
KWB-200M Solid Mount Assembly - Motoman [excludes MA1440]
7a. KWB-201 Hollow Wrist Torch Body [Included in ITEM 7]
7b. KWB-211 Hollow Wrist Torch Body Cover [Included in ITEM 7]
7c. Not Sellable M4x0.7x17 SHCS [Included in ITEM 7]
7d. KHW-103 Spacer - Fanuc/Motoman [Included in ITEM 7]
KHW-105 Spacer - ABB/OTC
7e. KHW-104 Spacer Sleeve [Included in ITEM 7]
7f. Not Sellable M5x0.8x18 SHCS [Included in ITEM 7]
7g. KHW-AB160 Insulating Disc - ABB IRB 1600ID
KHW-FA100 Insulating Disc - Fanuc/Motoman MA1440
KHW-MM1 Insulating Disc - Motoman
KHW-OAX1 Insulating Disc - OTC AX MV4AP/MV4LAP
7h. Not Sellable M4x0.7x12 SHCS [Fanuc/Motoman]
8. 164-45J Jump Liner, .045“
164-116J Jump Liner, 1/16“
9. KWB-GT1 Wire Brake Wire Guide Tool
10. KWB-G045 Wire Brake Wire Guide, .045”
KWB-G116 Wire Brake Wire Guide, 1/16”
11. KWB-V1 Wire Brake Valve
12. KWB-A18-15 Wire Brake Air Line, 15’
13. KHW-xxx See Page 6
14. KDP-101 Power Pin, Miller®
KDP-103 Power Pin, Panasonic®
KDP-104 Power Pin, Tweco®#4
KDP-106 Power Pin, OTC®
KDP-107 Power Pin, Fronius®
KDP-108 Power Pin, Lincoln®“4R”
KDP-109 Power Pin, Lincoln®“AutoDrive®S
15. 164-30-6 Liner, 6’, .030”
164-45-6 Liner, 6’, .035” - .045”
164-45A-6 Liner, 6’, .035” - .045” (for Lincoln®AutoDrive®S Only)
164-116-6 Liner, 6’, .045” - 1/16”
164-116TF-6 Teflon Liner, 6’, 3/64” - 1/16”
ITEM PART # DESCRIPTION
Exploded View & Parts List for Solid Mount w/ Wire Brake