Tregaskiss Motoman XRC EA1400 Installation and operating instructions

Technical Addendum
Tregaskiss.com/TechnicalSupport
1-855-MIGWELD (644-9353) (US&Canada)
[phone] (International)
May 2021 M066-1.0
Low-Stress Robotic (LSR) System
Installation Instructions for
Motoman® XRC EA1400/1900 Robots
ADDENDUM

Protect yourself and others from injury – read, follow,
and save these important safety precautions and
operating instructions.
1-1 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
explained in the text.
NOTICE–Indicatesstatementsnotrelatedtopersonalinjury.
– Indicatesspecialinstructions.
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.
1-2 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.ReadandfollowallSafetyStandards.
Onlyqualifiedpersonsshouldinstall,operate,maintain,
andrepairthisequipment.Aqualifiedpersonisdefined
asonewho,bypossessionofarecognizeddegree,
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.
Duringoperation,keepeverybody,especiallychildren,
away.
ELECTRIC SHOCK can kill.
lAlwaysweardryinsulatinggloves.
lInsulateyourselffromworkandground.
lDonottouchliveelectrodeorelectricalparts.
lReplaceworn,damaged,orcrackedgunsorcables.
lTurnoffweldingpowersourcebeforechangingcontacttipor
gunparts.
lKeepallcoversandhandlesecurelyinplace.
FUMES AND GASES can be hazardous.
lKeepyourheadoutofthefumes.
lVentilate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.
lRead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.
lKeepawayfrommovingparts.
lKeepawayfrompinchpointssuchasdrive
rolls.
WELDING can cause fire or explosion.
lDonotweldnearflammablematerial.
lDo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).
lWatchforfire;keepextinguishernearby.
lRead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.
lShutoffcompressedgassupplywhennotin
use.
lAlwaysventilateconfinedspacesoruseapprovedair-
suppliedrespirator.
M066-1.0 1
SECTION 1 — SAFETY PRECAUTIONS — READ BEFORE USING

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.
lWear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PrincipalSafetyStandards).
lWearapprovedsafetyglasseswithsideshieldsunderyour
helmet.
lUseprotectivescreensorbarrierstoprotectothersfrom
flash,glareandsparks;warnothersnottowatchthearc.
lWearbodyprotectionmadefromdurable,flame-resistant
material(leather,heavycotton,wool).Bodyprotection
includesoil-freeclothingsuchasleathergloves,heavyshirt,
cufflesstrousers,highshoes,andacap.
NOISE can damage hearing.
Noisefromsomeprocessesorequipmentcan
damagehearing.
lCheckfornoiselevellimitsexceedingthose
specifiedbyOSHA.
lUseapprovedearplugsorearmuffsifnoiselevelishigh.
lWarnothersnearbyaboutnoisehazard.
WELDING WIRE can injure.
lKeephandsandbodyawayfromguntipwhen
triggerispressed.
READ INSTRUCTIONS.
lRead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.
lUseonlygenuinereplacementpartsfromthemanufacturer.
lPerforminstallation,maintenance,andserviceaccordingto
theOwner'sManuals,industrystandards,andnational,state,
andlocalcodes.
2 M066-1.0

1-3 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.
1-4 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
fromGlobalEngineeringDocuments.Website:
www.global.ihs.com.
Safe Practices for Welding and Cutting Containers that have Held
Combustibles,AmericanWeldingSocietyStandardAWSA6.0from
GlobalEngineeringDocuments.Website:www.global.ihs.com.
National Electrical Code,NFPAStandard70fromNationalFire
ProtectionAssociation.Website:www.nfpa.organd
www.sparky.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2020–02
1-5 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while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.
M066-1.0 3

1-6 Commercial Warranty
Productiswarrantedtobefreefromdefectsinmaterialand
workmanshipfortheperiodspecifiedbelowafterthesalebyan
authorizedBuyer.
lBernard®BTBSemi-AutomaticAir-CooledMIGGuns:1 year;
Lifetime warranty on straight handles, straight handle
switches, and rear strain relief
lBernard®W-Gun™andT-Gun™Semi-AutomaticWater-
CooledMIGGuns:180 days
lBernard®TGX®ChassisandBernardTGXReadyToWeld
MIGGuns:90 days
lTregaskiss®RoboticMIGGunsandComponents:1 year
lTregaskiss®FixedAutomaticMIGGuns1 year
lTregaskiss®TOUGHGUN®Reamer:1 year
lTregaskiss®TOUGHGUN®Reamerwhenfactory-equipped
withLubricator:2 years
lTregaskiss®TOUGHGUN®Reamerwhenfactory-equipped
withLubricatorandusedonlywithTregaskiss®TOUGH
GARD®Anti-SpatterLiquid:3 years
lTregaskiss®RoboticPeripherals(Clutch,Sprayer,WireCutter,
MountingArms):1 year
lTregaskiss®TOUGHGARD®Anti-SpatterMulti-Feed
System:180 days
BernardandTregaskissreservetherighttorepair,replace,or
refundthepurchasepriceofnon-conformingproduct.Product
foundnotdefectivewillbereturnedtotheBuyerafternotificationby
theBernardandTregaskissCustomerServicedepartment.Any
TOUGHGUNReamercomponentpartreplacedorrepairedpursuant
totheWarrantyhereinshallbefurtherwarrantedforaperiodofsix
monthsafterdeliveryofthereplacement.
BernardandTregaskissmakenootherwarrantyofanykind,
expressedorimplied,including,butnotlimitedtothewarrantiesof
merchantabilityorfitnessforanypurpose.BernardandTregaskiss
shallnotbeliableunderanycircumstancestoBuyer,ortoany
personwhoshallpurchasefromBuyer,fordamagesofanykind,
including,butnotlimitedtoanydirect,indirectincidentalor
consequentialdamagesorlossofproductionorlossofprofits
resultingfromanycausewhatsoever,including,butnotlimitedto
anydelay,act,errororomissionofBernardorTregaskiss.
GenuineBernard®orTregaskiss®partsmustbeusedforsafetyand
performancereasonsorthewarrantybecomesinvalid.Warranty
shallnotapplyifaccident,abuse,ormisusedamagesofaproduct,
orifaproductismodifiedinanywayexceptbyauthorizedBernard
andTregaskisspersonnel.Useasdirected.
4 M066-1.0

Pour écarter les risques de blessure pour vous-même
et pour autrui — lire, appliquer et ranger en lieu sûr
ces consignes relatives aux précautions de sécurité et
au mode opératoire.
2-1 Symboles utilisés
DANGER! – Indique une situation dangereuse qui si
on l’évite pas peut donner la mort ou des blessures
graves. Les dangers possibles sont montrés par les
symboles joints ou sont expliqués dans le texte.
Indique une situation dangereuse qui si on l’évite pas
peutdonner la mort ou des blessures graves. Les
dangers possiblessont montrés par les symboles
joints ou sont expliquésdans le texte.
AVIS – Indique des déclarations pas en relation avec des blessures
personnelles.
–Indique des instructions spécifiques.
CegroupedesymbolesveutdireAvertissement!Attention!
DANGERDECHOCELECTRIQUE,PIECESENMOUVEMENT,et
PIECESCHAUDES.Reportez-vousauxsymbolesetauxdirectives
cidessousafindeconnaîtrelesmesuresàprendrepourévitertout
danger.
2-2 Dangers relatifs au soudage à l'arc
Lessymbolesprésentésci-aprèssontutiliséstoutau
longduprésentmanuelpourattirervotreattentionet
identifierlesrisquesdedanger.Lorsquevousvoyezun
symbole,soyezvigilantetsuivezlesdirectivesmentionnéesafin
d'évitertoutdanger.Lesonsignesdesécuritéprésentéesci-après
nefontquerésumerlesinformationscontenuesdanslasection2-
4Principalesnormesdesécuritéonpage7.Veuillezlireet
respectertoutescesnormesdesécurité.
L'installation,l'utilisation,l'entretienetlesréparationsne
doiventêtreconfiésqu'àdespersonnesqualifiées.Une
personnequalifiéeestdéfiniecommecellequi,parla
possessiond'undiplômereconnu,d'uncertificatoud'unstatut
professionnel,ouqui,paruneconnaissance,uneformationetune
expérienceapprofondies,adémontréavecsuccèssacapacitéà
résoudrelesproblèmesliésàlatâche,letravailouleprojeteta
reçuuneformationensécuritéafindereconnaîtreetd'éviterles
risquesinhérents.
Aucoursdel'utilisation,tenirtoutepersonneàl'écartet
plusparticulièrementlesenfants.
UN CHOC ÉLECTRIQUE peut tuer.
lPortertoujoursdesgantssecsetisolants.
lS’isolerdelapièceetdelaterre.
lNejamaistoucheruneélectrodeoudespiècesélectriques
soustension.
lRemplacerlespistoletsoucâblesdesoudagequisont
endommagés,usésoucraquelés.
lMettrelasoudeusehorstensionavantderemplacerunbec
contactoudespiècesdepistolet.
lS’assurerquetouslescouverclesetpoignéessont
fermementassujettis.
LES VAPEURS ET LES FUMÉES peuvent être
nocives.
lÉloignersatêtedesendroitsrenfermantdes
vapeurs.
lAérerlazonedetravailouporterunappareilrespiratoire.
lPourdéterminerlabonneventilation,ilestrecommandéde
procéderàunprélèvementpourlacompositionetlaquantité
defuméesetdegazauxquelsestexposélepersonnel.
lLireetcomprendrelesfichesdedonnéesdesécuritéetles
instructionsdufabricantconcernantlesadhésifs,les
revêtements,lesnettoyants,lesconsommables,lesproduits
derefroidissement,lesdégraisseurs,lesfluxetlesmétaux.
Les PIÈCES MOBILES peuvent causer des
blessures.
lNepass’approcherdesorganesmobiles.
lNepass’approcherdespointsdecoincement
telsquedesrouleauxdecommande.
Ne pas souder à proximité de matériaux
inflammables.
lNepassouderàproximitédematériaux
inflammables
lNepaseffectuerlesoudagesurdesconteneursferméstels
quedesréservoirs,tambours,ouconduites,àmoinsqu’ils
n’aientétépréparéscorrectementconformémentàAWSF4.1
etAWSA6.0(voirlesNormesdeSécurité).
lPrendregardeauxincendiesettoujoursavoirunextincteurà
proximité.
lLireetcomprendrelesfichesdedonnéesdesécuritéetles
instructionsdufabricantconcernantlesadhésifs,les
revêtements,lesnettoyants,lesconsommables,lesproduits
derefroidissement,lesdégraisseurs,lesfluxetlesmétaux.
M066-1.0 5
SECTION 2 — CONSIGNES DE SÉCURITÉ — LIRE AVANT UTILISATION

L'ACCUMULATION DE VAPEURS peut causer
des lésions ou la mort.
lQuandonn’utilisepaslegazcompriméde
protection,fermerlerobinetdelabouteille.
lAssurertoujourslaventilationdeszonesferméesouutiliser
unappareilrespiratoireavecalimentationenair.
LE RAYONNEMENT DE L'ARC peut brûler les
yeux et la peau.
Lerayonnementdel’arcduprocédédesoudage
génèredesrayonsvisiblesetinvisiblesintenses
(ultravioletsetinfrarouges)susceptiblesde
provoquerdesbrûluresdanslesyeuxetsurlapeau.Desétincelles
sontprojetéespendantlesoudage.
lPorteruncasquedesoudageapprouvémunideverres
filtrantsappropriépourprotégervisageetyeuxpendantle
soudage(voirANSIZ49.1etZ87.1énumérédanslesnormes
desécurité).
lPorterdeslunettesdesécuritéavecécranslatérauxmême
sousvotrecasque.
lAvoirrecoursàdesécransprotecteursouàdesrideauxpour
protégerlesautrescontrelesrayonnementsles
éblouissementsetlesétincelles;prévenirtoutepersonnesur
leslieuxdenepasregarderl’arc.
lPorterunéquipementdeprotectionpourlecorpsfaitd’un
matériaurésistantetignifuge(cuir,cotonrobuste,laine).La
protectionducorpscomportedesvêtementssanshuile
commeparex.desgantsdecuir,unechemisesolide,des
pantalonssansrevers,deschaussureshautesetune
casquette.
LES PIÈCES CHAUDES peuvent provoquer
des brûlures.
lLaisserrefroidirlepistoletavantdeletoucher.
lNepastoucherd’objetsmétalliqueschauds.
lAbriterlesobjetsmétalliquescontretoutcontactparles
personnesàproximité.
Le BRUIT peut endommager l’ouie.
Lebruitdesprocessusetdeséquipementspeut
affecterl’ouïe.
lVérifiersilesniveauxdebruitexcèdentles
limitesspécifiéesparl’OSHA.
lUtiliserdesbouche-oreillesoudesserre-têteantibruit
approuvéssileniveaudebruitestélevé.
lAvertirlespersonnesàproximitéausujetdudangerinhérent
aubruit.
.
LES FILS DE SOUDAGE peuvent provoquer
des blessures.
lÉloignerlesmainsetlecorpsdelabusedu
pistoletaprèsavoirappuyésurlagâchette.
LIRE LES INSTRUCTIONS.
lLireetappliquerlesinstructionssurles
étiquettesetleModed’emploiavant
l’installation,l’utilisationoul’entretiende
l’appareil.Lirelesinformationsdesécuritéaudébutdu
manueletdanschaquesection.
lN’utiliserquelespiècesderechangerecommandéesparle
constructeur.
lEffectuerl’installation,l’entretienettouteinterventionselon
lesmanuelsd’utilisateurs,lesnormesnationales,provinciales
etdel’industrie,ainsiquelescodesmunicipaux.
6 M066-1.0

2-3 Proposition californienne 65 Avertissements
AVERTISSEMENT–Ceproduitpeutvousexposeràdes
produitschimiquestelsqueleplomb,reconnusparl’Étatde
Californiecommecancérigènesetsourcesdemalformationsou
d’autrestroublesdelareproduction
Pourplusd’informations,consulterwww.P65Warnings.ca.gov.
2-4 Principales normes de sécurité
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
fromGlobalEngineeringDocuments.Website:
www.global.ihs.com.
Safe Practices for Welding and Cutting Containers that have Held
Combustibles,AmericanWeldingSocietyStandardAWSA6.0from
GlobalEngineeringDocuments.Website:www.global.ihs.com.
National Electrical Code,NFPAStandard70fromNationalFire
ProtectionAssociation.Website:www.nfpa.organd
www.sparky.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_fre2020–02
2-5 Informations relatives aux CEM
Lecourantélectriquequitraversetoutconducteurgénèredes
champsélectromagnétiques(CEM)àcertainsendroits.Lecourant
issud’unsoudageàl’arc(etdeprocédésconnexes,ycomprisle
soudageparpoints,legougeage,ledécoupageplasmaetles
opérationsdechauffageparinduction)créeunchamp
électromagnétique(CEM)autourducircuitdesoudage.Les
champsélectromagnétiquesproduitspeuventcauserinterférenceà
certainsimplantsmédicaux,p.ex.lesstimulateurscardiaques.Des
mesuresdeprotectionpourlesporteursd’implantsmédicaux
doiventêtreprises:parexemple,desrestrictionsd’accèspourles
passantsouuneévaluationindividuelledesrisquespourles
soudeurs.Touslessoudeursdoiventappliquerlesprocédures
suivantespourminimiserl’expositionauxCEMprovenantducircuit
desoudage:
1. Rassemblerlescâblesenlestorsadantouenlesattachant
avecdurubanadhésifouavecunehousse.
2. Nepasseteniraumilieudescâblesdesoudage.Disposerles
câblesd’uncôtéetàdistancedel’opérateur.
3. Nepascourberetnepasentourerlescâblesautourdevotre
corps.
4. Maintenirlatêteetletorseaussiloinquepossibledumatériel
ducircuitdesoudage.
5. Connecterlapincesurlapièceaussiprèsquepossibledela
soudure.
6. Nepastravailleràproximitéd’unesourcedesoudage,ni
s’asseoirousepencherdessus.
7. Nepassoudertoutenportantlasourcedesoudageoule
dévidoir.
En ce qui concerne les implants médicaux :
Lesporteursd’implantsdoiventd’abordconsulterleurmédecin
avantdes’approcherdesopérationsdesoudageàl’arc,desoudage
parpoints,degougeage,ducoupageplasmaoudechauffagepar
induction.Silemédecinapprouve,ilestrecommandédesuivreles
procéduresprécédentes.
M066-1.0 7

Protéjase usted mismo y a otros contra lesiones —
lea, cumpla y conserve estas importantes
precauciones de seguridad e instrucciones de
utilización.
3-1 Uso de símbolos
PELIGRO! – Indica una situación peligrosa que, si no
se la evita, resultará en muerte o lesión grave. Los
peligros posibles se muestran en los símbolos
adjuntos o se explican en el texto.
Indica una situación peligrosa que, si no se la evita,
podríaresultar en muerte o lesión grave. Los peligros
posiblesse muestran en los símbolos adjuntos, o se
explican en eltexto.
AVISO – Indica precauciones no relacionadas a lesiones
personales.
–Indica instrucciones especiales.
Estegrupodesímbolossignifica¡Advertencia!,¡Cuidado!
CHOQUEODESCARGAELÉCTRICA,PIEZASQUESEMUEVEN,y
peligrosdePARTESCALIENTES.Consultelossímbolosylas
instruccionesrelacionadasqueaparecenacontinuaciónparaver
lasaccionesnecesariasparaevitarestospeligros.
3-2 Peligros en soldadura de arco
Seusanlossímbolosmostradosabajoportodoéste
manualparallamarlaatencióneidentificarapeligros
posibles.Cuandoustedveaestesímbolo,tengacuidado,
ysigaalasinstruccionesrelacionadasparaevitarelpeligro.La
informacióndeseguridaddadaabajoessolamenteunresumende
lainformaciónmáscompletadeseguridadqueseencuentrade
seguridaddesección3-4Estándaresprincipalesdeseguridadon
page10.Leaysigatodaslosestándaresdeseguridad.
Solamentepersonalcualificadodebeinstalar,utilizar,
manteneryrepararesteequipo.Ladefiniciónde
personalcualificadoescualquierpersonaque,debidoa
queposeeuntítulo,uncertificadoounaposiciónprofesional
reconocida,ograciasasugranconocimiento,capacitacióny
experiencia,hayademostradoconéxitolacapacidadpara
solucionaroresolverproblemasrelacionadosconeltrabajo,el
proyectooeltemaencuestión,ademásdehaberasistidoauna
capacitaciónenseguridadparareconoceryevitarlospeligrosque
implicaelproceso.
Durantesuoperaciónmantengalejosatodos,
especialmentealosniños.
UNA DESCARGA ELÉCTRICA puede matarlo.
lSiempreuseguantesaislantessecos.
lAísleseustedmismodeltrabajoylatierra.
lNotoqueelectrodoeléctricamentevivoopartes
eléctricamentevivas.
lReemplaceantorchasocablesdesgastados,dañadosorotos.
lRepareoreemplaceaislamientodelapistolaodelcableque
estédesgastado,dañadooagrietado.
lApaguelamáquinadesoldarantesdecambiarlostubosde
contactoopiezasdelaantorcha.
lMantengatodaslastapasyasabiensegurasensitio.
HUMO y GASES pueden ser peligrosos.
lMantengasucabezafueradelhumo.
lVentileellugarouseunaparatopararespirar.
Elmétodorecomendadoparadeterminarla
ventilaciónadecuadaestomarmuestrasdela
composiciónycantidaddehumosygasesalosqueestá
expuestoelpersonal.
lLeayentiendalasHojasdedatosdelmaterial(SDS)ylas
instruccionesdelfabricanterelacionadasconlosadhesivos,
metales,consumibles,recubrimientos,limpiadores,
refrigerantes,desengrasadores,fundentesymetales.
Las PIEZAS MÓVILES pueden provocar
lesiones.
lAléjesedetodaparteenmovimiento.
lAléjesedetodopuntoquepellizque,talcomorodillos
impulsados.
EL SOLDAR puede causar fuego o explosión.
lNosueldecercadematerialinflamable
lNosueldeenrecipientesquehancontenido
combustibles,nienrecipientescerradoscomo
tanques,tamboresotuberías,amenosque
esténpreparadoscorrectamentedeacuerdoconlanorma
AWSF4.1yAWSA6.0(vealasnormasdeseguridad).
lSiempremirequenohayafuegoymantengaunextinguidor
defuegocerca.
lLeayentiendalasHojasdedatosdelmaterial(SDS)ylas
instruccionesdelfabricanterelacionadasconlosadhesivos,
metales,consumibles,recubrimientos,limpiadores,
refrigerantes,desengrasadores,fundentesymetales.
SECTION 3 — PRECAUCIONES DE SEGURIDAD — LEA ANTES DE USAR
8 M066-1.0

EL AMONTONAMIENTO DE GAS puede
enfermarle o matarle.
lCierreelsuministrodegascomprimido
cuandonolouse.
lSiempredéventilaciónaespacioscerradosouseun
respiradoraprobadoquereemplazaelaire.
LOS RAYOS DEL ARCO pueden quemar sus
ojos y piel.
Losrayosdelarcodeunprocesodesuelda
producenuncalorintensoyrayosultravioletas
fuertesquepuedenquemarlosojosylapiel.Las
chispasseescapandelasoldadura.
lUseunacaretadesoldaraprobadaquetengaunmatiz
apropiadodelente-filtroparaprotegersucarayojosmientras
estésoldandoomirando(véaselosestándaresdeseguridad
ANSIZ49.1yZ87.1).
lUseanteojosdeseguridadaprobadosquetenganprotección
lateral.
lUsepantallasdeprotecciónobarrerasparaprotegeraotros
deldestello,reflejosychispas,alerteaotrosquenomirenel
arco.
lUseropadeprotecciónadecuadaparaelcuerpo,dematerial
durableyresistentealallama(cuero,algodóngruesoolana).
Laropadeprotecciónparaelcuerpoincluyeguantesde
cuero,camisadetrabajo,pantalonessinbotamanga(vuelta),
botasdeseguridadyunagorra;ningunodeestoselementos
debecontenercompuestosderivadosdelpetróleo.
PARTES CALIENTES puedan causar
quemaduras severas.
lPermitaquelaantorchaseenfríeantesde
tocarla.
lNotoquemetalcaliente.
lProtejaaotrosdelcontactoconelmetalcaliente.
EL RUIDO puede trastornar su oído.
Ruidoprovenientedealgunosprocesosoequipo
puededañareloído.
lChequeeloslímitesdelniveldelruidosi
excedenaquellosespecificadosporOSHA.
lUsetapasparalosoídosocubiertasparalosoídossielnivel
delruidoesdemasiadoalto.
lAdviertaaotrosqueesténcercaacercadelpeligrodelruido.
El ALAMBRE de SOLDAR puede causarle
heridas.
lMantengalasmanosyelcuerpolejosdeltubo
decontactodelaantorchacuandosehaya
presionadoelgatillo.
LEER INSTRUCCIONES.
lLeaysigacuidadosamentelasinstrucciones
contenidasentodaslasetiquetasyenel
Manualdelusuarioantesdeinstalar,utilizaro
realizartareasdemantenimientoenlaunidad.Leala
informacióndeseguridadincluidaenlaprimerapartedel
manualyencadasección.
lUtiliceúnicamentepiezasdereemplazolegítimasdel
fabricante.
lLostrabajosdeinstalaciónymantenimientodebenser
ejecutadosdeacuerdoconlasinstruccionesdelmanualdel
usuario,lasnormasdelsectoryloscódigosnacionales,
estatalesylocales.
M066-1.0 9

3-3 Advertencias de la Proposición 65 del estado de California
ADVERTENCIA:Esteproductopuedeexponerloaquímicos,
inclusoplomo,queelestadodeCaliforniaconocecomo
causantesdecáncer,defectosdenacimientouotrosdaños
reproductivos.
Paraobtenermásinformación,accedaa
www.P65Warnings.ca.gov.
3-4 Estándares principales de seguridad
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
fromGlobalEngineeringDocuments.Website:www.global.ihs.com.
Safe Practices for Welding and Cutting Containers that have Held
Combustibles,AmericanWeldingSocietyStandardAWSA6.0from
GlobalEngineeringDocuments.Website:www.global.ihs.com.
National Electrical Code,NFPAStandard70fromNationalFire
ProtectionAssociation.Website:www.nfpa.organd
www.sparky.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_spa2020–02
3-5 Información sobre los campos electromagnéticos (EMF)
Lacorrientequefluyeatravésdeunconductorgeneracampos
eléctricosymagnéticos(EMF)localizados.Lacorrientedelarcode
soldadura(yotrastécnicasafinescomolasoldaduraporpuntos,el
ranurado,elcorteporplasmayelcalentamientoporinducción)
generauncampoEMFalrededordelcircuitodesoldadura.Los
camposEMFpuedeninterferirconalgunosdispositivosmédicos
implantadoscomo,porejemplo,losmarcapasos.Porlotanto,se
debentomarmedidasdeprotecciónparalaspersonasqueutilizan
estosimplantesmédicos.Porejemplo,apliquerestriccionesal
accesodepersonasquepasanporlascercaníasorealice
evaluacionesderiesgoindividualesparalossoldadores.Todoslos
soldadoresdebenseguirlosprocedimientosqueseindicana
continuaciónconelobjetodeminimizarlaexposiciónaloscampos
EMFgeneradosporelcircuitodesoldadura:
1. Mantengaloscablesjuntosretorciéndolosentresío
uniéndolosmediantecintasounacubiertaparacables.
2. Noubiquesucuerpoentreloscablesdesoldadura.Disponga
loscablesaunladoyapártelosdeloperario.
3. Noenrollenicuelgueloscablessobresucuerpo.
4. Mantengalacabezayeltroncotanapartadosdelequipodel
circuitodesoldaduracomoleseaposible.
5. Conectelapinzademasaenlapiezalomáscercaposibledela
soldadura.
6. Notrabajecercadelafuentedealimentaciónparasoldadura,ni
sesienteorecuestesobreella.
7. Nosueldemientrastransportalafuentedealimentaciónoel
alimentadordealambre.
Acerca de los aparatos médicos implantados:
Laspersonasqueusenaparatosmédicoimplantadosdeben
consultarconsumédicoyelfabricantedelaparatoantesdellevara
cabooacercarseasoldaduradearco,soldaduradepunto,ranurar,
hacercorteporplasma,uoperacionesdecalentamientopor
inducción.Sisudoctorlopermite,entoncessigalos
procedimientosdearriba.
10 M066-1.0

SPECIAL INSTALLATION INSTRUCTIONS
#M066
Low-Stress Robotic (LSR) Systems Installation Instructions
For Motoman XRC EA1400/1900 Robots
Summary
Unlike the most recent through-arm robots from Motoman (EA1400N/1900N and the SSA2000), the
original ES1400 and EA1900 robots are unique.
This document provides a summary as to why these robots are unique and includes installation
instructions for the LSR Unicable.
Spare parts and other information can be found in the M058 (LSR Systems Tech Guide for Motoman
EA1400N, EA1900N, and SSA2000).
NOTE: TOUGH GUN I.C.E.™System is NOT compatible with the Tregaskiss LSR System. Use the
Motoman OEM unicable in these situations.
Motoman EA1400 and EA1900
This through-arm model was the first one release by Motoman.
Often times, this series is referred to as the “XRC” series (XRC is the model of the robot controller for
these robots).
These systems are unique and provide limitations that are not found on the newer systems.
KEY POINT: the LSR Unicable for this series is unique and will NOT work for other Motoman models.
Distinguishing Features of the EA1400 and EA1900
The logo on the side of the robot reads “EA1400” or “EA1900”.
There is an offset feeder at the rear of the robot.
The casting of the robot features a bend near the upper arm.
February 2008
EA1400N Cable
Route
EA1400 Cable
Route
Figure 1 –The EA1400 and 1900 (XRC Series) robots are
unique from the EA1400N, EA1900N and SSA2000.
M066-1.0 11

Installation Instructions for the LSR Unicable
These instructions are based on the assumption that the 5800 Clutch System (below) is already installed
on the faceplate of the robot.
NOTE: Clutch System (5800) Components
*NOTE: 2008 Model shown below with NEW outer cover. Older models have an all aluminum outer cover but the
instructions for the LSR Unicable installation are applicable for this system as well.
STEP #1: Remove the Outer Cover of the 5800
*NOTE: 2008 Model shown below with NEW outer cover. Older models have an aluminum outer cover but (other
than step #1) the instructions for the LSR Unicable installation are applicable for this system as well.
Unthread (3) M4 SBHCS, using 2.5 mm Allen key.
Unthread (1) M3 SHCS, using 2.5 mm Allen key and pull apart both cover halves.
Insulating disc should remain in place, located by dowel.
OUTER COVER (2008 MODEL)
GOOSENECK
CONNECTOR
CONSUMABLES
CLUTCH SYSTEM
*(BEHIND OUTER COVER)
INSULATING
DISC
GOOSENECK
M4 x 8 SBHCS
M3 x 6 SHCS
Figure 2 –The 5800 Clutch System is compatible with the Motoman EA1400, EA1900, EA1400N, EA1900N and the
SSA2000. The most recent model is shown here with a black outer cover, rather than the original Aluminum design.
Figure 3 –The most recent 5800 features the black outer cover that splits into two pieces, using a total
of 4 fasteners to hold it together.
12M066-1.0

STEP #2: Install the LSR Unicable at the Front of the EA1400/1900
Connect wire connectors (they are not polarity specific).
Insert LSR Unicable Connector through mounting face of robot.
Insert LSR Unicable Connector into flange-cable connector of the 5800.
NOTE: Push the LSR Unicable down into the Flange Cable Connector and hold.
While applying pressure to the LSR Unicable, secure the connector by tightening M6x20 SHCS, using 5
mm Allen key.
STEP #3: Re-Install the Outer Cover
Reverse the directions of STEP #1.
STEP #4: Install Gooseneck to the 5800
STEP #4a: Insert new Gooseneck into connector housing until neck is fully seated.
FLANGE-CABLE
CONNECTOR
TIGHTEN THE
M6 x 20 SHCS
Insert LSR Unicable through wrist of the Robot
LSR UNICABLE CONNECTOR
WIRE CONNECTORS
NOTE: For best results,
install the gooseneck
without the consumables!
Figure 4 –When installing the LSR unicable to the 5800 Clutch System, be sure to maintain pressure
towards to the 5800 when tightening the M6 screw to ensure a reliable connection.
WRIST OF THE ROBOT
Apply constant pressure
when tightening the
connection!
Figure 5 –For best results, remove the consumables from the gooseneck and re-install them during
STEP #9. This technique will allow for the new QUICK LOAD Liner to be correctly installed.
CONNECTOR HOUSING
M066-1.0 13

STEP #4b: Tighten Gooseneck bolt clockwise with 5 mm Allen key to torque specifications
(60 in.-lbs. or 7 Nm).
STEP #5: Installation of LSR Unicable at the Rear of the EA1400/1900
Remove the cover on the side of the robot (Figure 7).
Figure 7 –On the side of the robot, remove the 3 screws holding the cover in place. Doing so provides
access to the LSR Unicable as it is fished through the casting of the robot.
CONNECTOR HOUSING
GOOSENECK BOLT
NOTE: For best results,
install the gooseneck
without the consumables!
Figure 6 –When adding the gooseneck, apply just enough pressure to hold it in place as you tighten the
gooseneck bolt to 60 in.-lbs. (7 Nm).
14M066-1.0

Install the back-end of the LSR Unicable through the casting of the robot (Figure 8)
oNOTE: The LSR Unicable must be installed through the casting of the robot WITHOUT the power
pin or Euro connection. Otherwise, it will not fit through the casting
Fish the cable through the robot using the access provided when the cover is removed
STEP #6: Install Power Pin (or Euro connection)
Once the back-end of the LSR Unicable is pulled through the robot, add the power pin (or Euro
connection to the LSR Unicable.
oNOTE: Use wrenches to ensure the pin is secure and will not come loose. Adjustable wrenches
are NOT recommended and they may strip the brass components!
Tighten the power pin (or Euro connection) to the rear block using a 1” (25 mm) wrench on the rear block
and a 5/8” (16 mm) or 3/4” (19 mm) wrench on the power pin
Figure 8 –Insert the back-end of the LSR unicable through the hole in the casting of the upper arm.
Figure 9 –Once the LSR Unicable
is pulled through the robot, add
the power pin (or Euro
connection).
NOTE: Make sure a wrench is used
to provide a tight connection.
Adjustable wrenches are NOT
recommended!
M066-1.0 15

STEP #7: Installation of the QUICK LOAD™Liner (first installation only)
NOTE: The Initial installation of the QUICK LOAD Liner (QLL) is from the rear of the LSR Unicable (just like a
conventional liner); however, subsequent liner replacements will be completed at the front of the LSR System.
Add the QUICK LOAD Liner Retainer (Part #415-26) to the back of the QUICK LOAD Liner.
From the rear of the LSR Unicable, feed replacement liner through the unicable using short strokes to avoid
kinking.
Secure the liner retainer in place with either the thread, or the power pin cap.
If power pin is thread-in type:
oUsing a 10 mm wrench, turn thread-in liner retainer in a clockwise direction and tighten in power pin.
At the front of the gooseneck, trim the liner (See Figure 10).
Push liner back into front of gun and hold in place.
Trim conduit to a 5/8” (16 mm) stick out.
Remove any burr that may obstruct wire feed.
STEP #8: Installing LSR Unicable into the Wire Feeder
Install the control cable.
oConnect the jumper control cable to the main control cable of the LSR Unicable.
oConnect to the wire feeder as per the manufacturer’s instructions.
Install into wire feeder as per the manufacturer’s instructions.
Figure 11 –Install the power pin
or Euro connection to the wire
feeder, as per the
manufacturer’s instructions. The
wire feeder control cable is also
added during this step.
5/8”
(16 mm)
Figure 10 –The recommended cut length for
the QLL is 5/8” (16mm). Make sure the liner is
pushed into the gooseneck when this length
is determined.
TIP: Before cutting the liner,
push the liner into the
gooseneck
16M066-1.0

STEP #9: Install Consumables to the Gooseneck
IMPORTANT
Be sure all parts are tightened well before welding to prevent overheating of contact tip.
Torque specs - Retaining Head 80 in.-lbs. / Contact Tip 30 in.-lbs.
When installing the retaining head make sure it is tightened with a 5/8” (16 mm) wrench.
To prevent scoring on retaining head do not use pliers.
Removal and Replacement
Pull slip-on nozzles off with a clockwise twisting motion.
When installing nozzle, exposed insulator should nest inside TOUGH GUN I.C.E.™insulator to assure
concentricity.
Replace retaining head with large bore toward the gooseneck. Tighten until retainer is secure.
External gooseneck thread can be cleaned with a 9/16” - 18 die.
STEP #10: Replace the Cover on the Robot
Reverse the instructions from step #5 and re-install the cover to the robot
MAINTENANCE/SPARE PARTS/PARTS BREAKDOWN
Refer to the following Tech Guide for this information:
oLow-Stress Robotic (LSR) System for MOTOMAN EA1400N, EA 1900N and SSA2000 Robots.
oPart Number: M058.
RETAINING HEAD
NOZZLE
TOUGH LOCK™
CONTACT TIP
GOOSENECK
Figure 13 –To complete the installation, return
the cover that was removed in STEP #5.
Figure 12–Install the consumables to the gooseneck using the instructions listed below.
M066-1.0 17

NOTES
18M066-1.0

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.
M066-1.0