3L11804-E-3 AC Servo Pull Feeder

For MIG AC Servo Pull Feeder
ＭＩＧＡＦＡＰＳ－２５０３
Ｌ－１１７０７
Ｌ－１１７４３
Instruction Manual
= Safety and Operation = Instruction Manual No.
３Ｌ１１８０４－Ｅ－3
Thoroughly read this Contents

instruction manual to ① NOTES ON SAFETY......................... S1
operate the units correctly. ② PRECAUTIONS FOR SAFETY ......... S2
③ NOTES ON USE ............................. S7
 Installation, maintenance, and repair of this
AC servo pull feeder shall be made by 1. Specifications ...................................... 1
qualified persons or persons who fully 1.1 AC Servo Pull Feeder.............................. 1
understand welding machines to secure the 1.2 Adapter for Pull feeder ............................ 2
safety. 1.3 Applicable Torch ...................................... 2
1.4 AC Servo Wire Feed Control unit ............ 3
 To secure the safety, operation of this AC 1.5 Prepared by Users .................................. 5
servo pull feeder shall be made by persons 2. Preparation for welding ........................ 8
who have knowledge and technical skill to 2.1 Checking the Contents ............................ 8
fully understand the contents of this manual 2.2 Mounting of the adapter for pull feeder . 14
2.3 Mounting on Manipulator ....................... 17
and handle the machine.
2.4 Wire Installation..................................... 25
 Regarding safety education, utilize courses 2.5 Pressure Adjustment of
and classes held by head/branch offices of AC Servo Push Feeder ......................... 26
the Welding Society /Association and the 2.6 Mounting of high duty cycle kit and
related societies/associations, and qualifying air blow unit............................................ 27
examinations for welding experts/consultant 3. Coaxial Power Cable for Robot ...........45
engineers. 3.1 Type of Coaxial Power Cable ................ 45
3.2 Connecting the Shock Sensor Cable and
 After thoroughly reading this manual, be sure Voltage Detection Cable ....................... 46
to retain it with the warranty in the place 3.3 Insert Parts ............................................ 49
where the persons concerned can read any 3.4 Connecting of Coaxial Power Cable...... 49
time. Read it again as occasion demands. 4. Maintenance and Repairs ...................50
 If incomprehensible, contact our offices. For 4.1 Operation Inspection ............................. 50
servicing, contact our local distributor or sales 4.2 Replacement of Liner ASSY .................. 51
4.3 Replacement of Feeding Roll ................ 52
representatives in your country. 4.4 Replacement of Pressure Roll............... 53
Our addresses and telephone numbers are 5. Parts List ............................................54
listed in the back cover of this Instruction
6. Tool parameter....................................65
Manual.
7. Electrical connection diagram .............66
NOTES ON SAFETY
1. Notes on Safety
●Before operating this product, thoroughly read this instruction manual first to operate the product
correctly.
●Cautions described in this instruction manual are to prevent you and other people from being injured or
damaged by having the product operated correctly and safely.
●Although this product is designed and manufactured in due consideration of safety, carefully follow the
notes and cautions described in this manual. Otherwise, there may occur an accident causing
serious injury or death.
●Various ranks of accidents resulting in injury, damage, or death may occur if mishandling the product.
The caution alert symbols and signals are classified into three ranks as below, used throughout these
instruction manual as well as warning labels put on each unit and device.
Symbol Signal Description
Mishandling may cause seriously dangerous

DANGER situation that could result in serious injury or death to
personnel. Limited situation of great urgency.
Mishandling may cause a dangerous situation that

WARNING could cause serious injury or death to personnel.
Mishandling may cause a dangerous situation that

CAUTION could cause medium or slight injury to personnel, or
material damage.
Hazards and special instructions described by CAUTION are very important as well. Neglect of
them may occasionally cause serious injury or death to personnel. Therefore, be sure to follow the
instructions described by all three safety alert symbols and signal words.
The meanings of "serious injury", "medium or slight injury", and "material damage" are as follows.
Serious injury ： Injury with a sequela due to a loss of eyesight, injury, burn (high
temperature and low temperature), electric shock, a bone fracture,
poisoning and so on as well as injury that requires hospital
treatment or long treatment as an outpatient.
Medium or slight injury ： Injury, burn, electric shock and so on that require no hospital
treatment nor long treatment as an outpatient.
Material damage ： Damage to property, and direct and incidental / consequential

damage due to the damage to devices.
Ref.: IMPORTANT : The sign “IMPORTANT” indicates special instructions

necessary for the most efficient operation.
－S1－
IMPORTANT SAFEGUARD
2. Important Safeguard
2.1 Read, understand, and comply with all safety rules described at the beginning of each
instruction manual in addition to the following ones before starting Arc welding operation.
● Observe the following notices to prevent a serious

WARNING accident that results in serious injury or death.
1) This AC Servo Pull Feeder is designed and manufactured in due consideration of safety, but you
must follow the handling precautions described in this instruction manual. If you fail to do so, there
may occur an accident resulting in serious injury or death.
2) Related laws, regulations, and your company's standards should be observed in constructing input
power source, selecting an installation area, handling/storing/piping high pressure gas, storing
welded products, and disposing wastes.
3) Keep out of the robot operating zone and the welding area.
4) A person with pacemaker should not approach the operating welding machine and the welding
area unless his or her doctor permits. A welding machine generates a magnetic field around it
during powered, which will have a bad effect on the pacemaker.
5) Installation, maintenance, and repair of this torch should be performed by qualified personnel or
those who fully understand a AC Servo Pull Feeder for further safety.
6) Operation of this AC Servo Pull Feeder should be done by personnel who have knowledge and
technical skill to fully understand the contents of this manual and to handle the torch safely.
7) This AC Servo Pull Feeder must not be used for purposes other than welding.
2.2 Observe the following to prevent electric shock.
WARNING ● Do not touch live electrical parts.
● Touching live electrical parts can cause fatal shock or severe

burns.
－S2－
IMPORTANT SAFEGUARD (continued)
1) Only qualified personnel should perform grounding work of the welding power supply and
workpiece, or a workpiece and powered peripheral jigs while abiding by domestic regulations.
2) Do not touch live electrical parts.
3) Always wear dry insulating gloves and other body protection. Do not wear torn or wet gloves/
work clothes.
4) Before doing the installation, inspection, maintenance, etc. of this product be sure to turn off all the
input power sources and check, several minutes later, that there is no charging voltage since the
condenser and the like may have been recharged.
5) Do not use cables with insufficient capacity, with damage, or with naked conductors.
6) Be sure to tighten the connections of cables and insulate them in order to prevent personnel from
touching those parts easily.
7) DO NOT use a welding machine with its case or cover removed.
8) Secure a firm foothold before initiating work. DO NOT perform work with an unstable foothold or
with a foothold at a height of two meters or above.
9) Make periodic inspection and maintenance. Damaged parts should be repaired before use.
10) Turn off POWER switch when not in use.
2.3 All the personnel in and around the working area including an operator should wear
appropriate protection to protect themselves from arc rays, spatters, slag, and noise
produced by welding.
● Install a lightproof wall where arc is generated.

WARNING ● Wear appropriate eye, ear, and body protection.
● Arc rays may cause inflammation of eyes and burns on skin

● Spatters and slag may cause eye troubles and burns.
● Noise may cause hearing problems.
1) Wear lightproof glasses or a welder’s shield helmet with a proper shade of filter when welding or
watching a welder work.
2) INSTALL ARC PROTECTIVE CURTAINS in between an operator and arc rays.
3) WEAR PROPER SAFETY GLASSES in work area at all times.
4) WEAR PROPER EAR PROTECTION.
5) WEAR PROPER BODY PROTECTION including woolen clothing, flameproof apron and gloves,
leather leggings, high boots and leather arm and shoulder gauntlets.
6) WEAR PROPER SAFETY GLASSES to protect eyes and skin from spatters and slag.
－S3－
2.4 All the personnel in and around the working area including an operator should wear
appropriate protection to protect themselves from fumes and gases produced by
welding.
● DO NOT inhale fumes and gases generated by welding.

WARNING ● Ventilate the area sufficiently and wear a welder’s shield mask if
necessary.
● Fumes and gases generated by welding have a harmful effect

on human body.
● Welding in a small area may cause suffocation due to the lack
of air.
1) KEEP YOUR HEAD out of fumes and DO NOT inhale any.

2) USE FORCED EXHAUST VENTILATION at the arc.
3) VENTILATE the area to prevent build-up of fumes and gases.
4) If ventilation is insufficient, USE APPROVED BREATHING DEVICES.
5) READ AND FOLLOW WARNING LABELS on all containers of welding materials.
6) Before use, READ AND UNDERSTAND the manufacturer’s instructions, Material Safety Data
Sheets (MSDSs), and follow your employer's safety practices.
7) To prevent gas poisoning and suffocation, use a local ventilator or a respirator specified by your
country’s domestic laws.
8) Be sure to ventilate the area or wear a respirator by welding in a small place. A well-trained
watchman should observe the work.
9) Do not weld near the place where degreasing, cleaning or spraying is carried out. The heat and
rays of the arc can react with vapors to form highly toxic and irritating gases. If welding is carried
out there, harmful gases may be produced.
10) Toxic fumes and gases are produced when coated steel is welded. Be sure to ventilate the area
sufficiently or use a respirator.
2.5 Prevent fire, explosion, burns and injury caused by heated workpiece, spatters, slag,
and arc sparks right after welding as described below.
● Do not weld near flammable materials.
● Watch for fire: keep a fire extinguisher nearby.
WARNING ● NEVER do welding on inflammables such as a piece of wood or
cloth.
● Do not weld on closed containers.
● Heated workpiece, spatters, slag and arc sparks right after
welding may cause fire.
● Incomplete cable connections, incomplete contacts in the current
circuit of the workpiece such as steel frames may cause a fire due
to the heat generated when powered.
● Arc generated on containers of inflammables such as gasoline
may cause an explosion.
● Welding of airtight tanks and pipes may cause a bursting.
● Touching a heated workpiece, spatters, slag or arc sparks will
cause a serious burn.
● Leaving pile-up dust in the welding torch may cause insulation
deterioration and result in electrical shock and fire.
－S4－
1) KEEP FLAMMBLE MATERIALES out of the robotic cell.
2) Welders should wear appropriate protection such as flameproof leather gloves, work clothes with
long sleeves, a leg cover, a flameproof leather apron in order to prevent burns caused by touching
heated workpiece, spatters, slag and arc sparks right after welding.
3) WATCH for fire.
4) Have a fire extinguisher nearby Operators should know how to use it.
5) DO NOT touch heated workpiece and peripheral jigs with inflammables such as a piece of wood or
cloth. Doing so might cause not only a fire but also burns.
6) DO NOT put heated workpiece close to inflammables right after welding.
7) Remove inflammables from the place where welding is carried out so that spatters and slag will not
strike them.
8) Do not use inflammable gases near the welding sight.
9) Tighten and insulate the cable connections completely.
10) Connect the cables on the workpiece side as close to the welding area as possible to prevent the
welding current from traveling along unknown paths and causing electric shock and fire hazards.
11) A gas pipe with gas sealed in, an airtight tank and a pipe must not be welded because they might
explode.
12) NEVER do welding on inflammables such as a piece of wood or cloth.
13) When welding a large-size structure such as a ceiling, floor, wall, etc., remove any inflammables
hidden behind a workpiece.
14) Remove dust by blowing moisture-free compressed air on each part periodically.
15) Be sure to observe the following precautions in order to prevent dust explosions from being
caused by aluminum dust:
・Clean the inside of the torch by applying air blow in an area away from the welding area. Clean it
by applying air blow once a day for a period of five seconds or more. Increase the frequency of
cleaning by applying air blow according to the state of accumulation of aluminum dust.
・Ensure that the evacuation area used for cleaning is free from fire and high-temperature heat
source.
2.6 Directions
● Do not alter or remodel our products.
● You may get injured or have your equipment damaged because of fire,
DANGER failure or malfunction caused by altering or remodeling the product.
● The warranty does not cover any altered or remodeled products.
－S5－
For reference
PRINCIPAL SAFETY STANDARDS
Safety in Welding and Cutting, ANSI Standard Z49.1, from American Welding
Society.
Safety and Health Standards, OSHA 29 CFR 1910, from Superintendent of

Documents, U.S. Government Printing Office.
Recommended Practices for Plasma Arc Cutting, American Welding Society

Standard AWS C5.2, from American Welding Society.
Recommended Safe Practices for the Preparation for Welding and Cutting of
Containers That Have Held Hazardous Substances, American Welding Society
Standard AWS F4.1, from American Welding Society.
National Electrical Code, NFPA Standard 70, from National Fire Protection
Association.
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, from

Compressed Gas Association.
Code for Safety in Welding and Cutting, CSA Standard W117.2, from Canadian
Standards Association, Standards Sales.
Safe Practices For Occupation And Educational Eye And Face Protection, ANSI
Standard Z87.1, from American National Standards Institute.
Cutting And Welding Processes, NFPA Standard 51B, from National Fire
Protection Association.
NOTE: The codes listed above may be improved or eliminated. Always refer to
the update codes.
－S6－
NOTES ON USE
3. Notes on Use
3.1 Duty cycle
●Use the AC servo pull feeder with the specified rated duty cycle or under
CAUTION Otherwise, the AC servo pull feeder may be deteriorated or burned out.
Operating　cycle of 70% duty cycle ● The rated duty cycle of 70% indicates that the torch shall
be used at the rated welding current for 7 minutes and
then suspended for 3 minutes out of 10 minutes.
Sus- ● Use of the AC servo pull feeder with the excess rated duty
Powered
pended cycle may lead to the temperature rise exceeding the
allowable value, resulting in damage or burn.
７　ｍｉｎｕｔｅｓ３　ｍｉｎｕｔｅｓ ● To supply compressed air (50 L/min / 1.77 cfm or more)
１０　ｍｉｎｕｔｅｓ for forced cooling of the AC servo pull feeder makes it
possible to use at the rated duty cycle of 100%.
Rated duty cycle

Welding process MIG
Wire type φ 1.2
Max. operating current 100 A
Rated duty cycle 100%
3.2 Inching
●Do not look into the tip hole in inching to cheek.
WARNING ●In inching, the welding torch tip must not be put near to your
face, eye, and body.
●Do not look into the tip hole in inching to check if the wire is fed.
The wire may spring out and stick into your face, eyes, and
body. It is very dangerous.
●In inching, the welding torch tip must not be put near to your face,
eyes, and body. The wire may spring out and stick into your face,
eyes, and body to injure.
－S7－
3.3 Replacement of Parts
CAUTION ●To prevent burns, comply with the following cautions.
● Do not directly touch the high-temperature parts of a nozzle, an electrode and so on.
● When welding, wear suitable protection such as leather gloves for welding.
● Do not replace torch tip elements before they cool off.
●If any parts are damaged, replace them with new ones for further
CAUTION safety and better quality.
●Be sure to place an order for replacement parts at our sales office or our agency.
●Do not disassemble the shock sensor. If disassembled, gas leak

CAUTION and malfunction may be caused.
3.4 Cable hose

●Never let cable hoses neither touch any heated part of the welded, put
CAUTION something heavy on top nor bend them excessively because the welding
torch might become damaged.
3.5 Shock sensor

●In the main body of shock sensor inside, a powerful coil spring is had
built-in.
CAUTION Because there is a threat that a coil spring protrudes, please do not
dismantle a shock sensor.
●The shock sensor absorbs damage at the speed of the manual operation
CAUTION (or equal with the manual operation).
The shock sensor is damaged at the speed faster than manual operation.
－S8－
Thank you for purchasing DAIHEN MIG AC servo pull feeder.
Before use, read this instruction manual thoroughly to use the product correctly.
[N ot e] 1. The contents in this instruction manual are subject to change without prior notice.
2. We have carefully written the instruction manual to eliminate as many errors as possible. Even if any
errors are found in the contents, we are not responsible for any damage resulting from those errors.
3. No part of this instruction manual may be reproduced or stored in any form without the express written
permission.
● Do not alter or remodel our products.

● You may get injured or have your equipment damaged because of
DANGER fire, failure or malfunction caused by altering or remodeling the
product.
● The warranty does not cover any altered or remodeled products.
１． Specifications
This product is provided with a wire feeding unit on top of the shock sensor. The shock sensor unit and the
pull feeding unit are integrated to be used as a servo torch, which realizes constant wire feeding performance.
The AC servo push feeder, a wire buffer, a wire feeder controller and a feeder control cable should be
separately prepared.
A combination of this AC servo pull feeder with the high duty cycle kit (+ the power supply unit for air control
+ the air control cable) to supply compressed air for forced cooling makes the feeder available at a high duty
cycle.
1.1 AC servo pull feeder

The AC servo pull feeder, in combination with the adapter for pull feeder, can be used to mount on
various manipulators.
AC servo pull feeder is combined with welding torch and used.
The specifications are shown in Table 1.1. (Refer to Fig.1.2 for the outline drawing.)
Table1.1 Specifications of AC servo pull feeder
Model AFAPS-2503
Welding process MIG (100% Ar)
Rolling system 2-roll drive system
Max.operating current 100A
Rated duty cycle 100%(note 6)
Wire type
Hard Aluminum wire φ1.2
(Applicable wire)
Wire feed rate Max. 18 m／min (Note 1)
Shock sensor Built-in
Weight 2.0 kg (4.41 lb) (Note 2)
Applicable Manipulator NB6 / NV6S / NV8 / NV20A / NV20S / NV25 (Note 3,4,5)
Air flow (Note 6) 50 L/min (1.77 cfm) or more

Recommended value 0.3 MPa (3.1 kgf/cm 2) (43.51 psi) or more
Air pressure (Note 6) Adjustable range 0.05 ～ 0.75 MPa (0.5 ～ 7.6 kgf/cm2) (7.25 ～ 108.78 psi)
2
Capacity to resist air pressure 1.5 MPa (15.3kgf/cm ) (217.56 psi)
Note) 1. This is the average feeding speed at synchro feeding.
2. Shock sensor is included, but torch and bracket are not included.
3. Operation range is limited in the case of 7 shaft robot because of interference of wire buffer.
4. Bus bar ASSY is necessary in rigging options of NV20A / NV20S / NV25.
5. To mount on manipulators, the adapter for pull feeder (optional accessory) is required. For details,
refer to subsection 1.2.
6. It is necessary to flow cooling air (50 L/min or more) when using with the rated duty cycle of
100%.
7. This AC servo pull feeder is only applicable to synchro feed welding system.
－1－
1.2 Adapter for Pull feeder
To mount the AC servo pull feeder on manipulators, the adapter for pull feeder is required.
The specifications are shown in Table 1.2. For the outline drawing of combination of AC servo pull
feeder and its adapter, refer to Fig. 1.3 Fig. 1.4.
Table1.2 List of adapter for pull feeder

Installation
Model Weight Applicable Manipulator
diagram
L-11707 0.8 kg (1.76 lb) NB6 Fig.1.3
L-11743 1.8 kg (3.97 lb) NV6S / NV8 / NV20A / NV20S / NV25 Fig.1.4
1.3 Applicable torch

This AC servo pull feeder is used in combination with a welding torch shown in the following table. (Refer
to Fig. 1.6 ~1.8 for the installation diagram with a torch.)
Table1.3 List of applicable torch

Torch Torch Installation
Model Welding process Remarks
model type diagram
L-11707 Curved Air-cooled 250A Fig.1.5
MIG RTA2500H
L-11743 (45°) torch Fig.1.6
Table1.4 Specifications of welding torch

Category Air-cooled 250A curved torch
Model RTA2500H
Torch type Curved (45°)
Welding process MIG
Max. Operating current 250A
Rated duty cycle 70%
Wire type Hard Aluminum wire
Applicable wire φ1.2
Cooling system Air cooling
Shock sensor SSV, SSB
Note) The above specification shows that for the torch alone.
For the specification of sunchro-feed welding system, refer to Table 1.1.
－2－
1.4 AC Servo Wire Feed Control Unit
This AC servo pull feeder is used in combination with AC servo wire feed control unit as shown in the
following table.
Table1.5 List of AC servo wire feed control unit
AC servo wire feed
Welding power supply Applicable robot controller
control unit
WB-P500L AFCA-S1W04 FD controller
Note) Refer to the instruction manual of the AC servo wire feed control unit (1L22780-E-*) for its
specification.
IMPORTANT
This AC servo wire feed control unit is only applicable to FD controller.
Table1.6 Synchro feed welding components (For NB6)

No. Item Model
1 Air-cooled 250A MIG curved torch R T A 2 5 0 0 H
2 AC servo pull feeder A F A P S - 2 5 0 3
3 Adapter for pull feeder (For NB6) L - 1 1 7 0 7
4 Wire buffer L - 1 1 8 0 5
5 AC servo push feeder A F A S - 2 3 0 1
6 Coaxial power cable(For NB6) L - 1 1 7 3 3
7 Plaliner L 7 0 6 2 J 0 1
8 AC servo wire feed control unit AF CA - S1W 04
9 High duty cycle kit L - 1 1 7 4 1 D
10 Power supply unit for air control L 2 3 2 3 0 A
11 Air control cable AL AFRB-AL20□□(Note)
12 Air blow unit L - 1 1 8 0 0
Note) For NB6
□□：05 5m(standard)
10 10m
15 15m
－3－
Table 1.7 Synchro feed welding components (For NV6S / NV20 type)
No. Item Model
3 Adapter for Pull feeder (For NV6) L - 1 1 7 4 3
Coaxial power cable
6 L - 1 1 6 2 2
(For NV6S / NV20 / NV20S / NV20A)
7 Plaliner (For L-11622) L 7 0 6 2 J 0 1
9 Busbar ASSY (For NV6S / NV20S / NV20A） L 1 1 1 9 6 D
10 High duty cycle kit L - 1 1 7 0 2 G
Note) For NV6S / NV20A / NV20S
13 13m
18 18m
Table1.8 Synchro feed welding components (For NV8 / NV25)

No. Item Model
3 Adapter for pull feeder (For NV6) L - 1 1 7 4 3
6 Coaxial power cable(For NV8 / NV25) L - 1 1 6 2 2
7 Plaliner (For L-11622) L 7 0 6 2 J 0 1
9 Busbar ASSY(For NV25) L 1 1 1 9 6 D
10 High duty cycle kit L - 1 1 7 0 2 G
Note) For NV8 / NV25
10 10m
15 15m
－4－
Features
○ The specifications of a synchro-feed aluminum welding system can be provided by combining the
components listed in Tables 1.6, 1.7, and 1.8. The synchro-feed aluminum welding system features are
the followings:
- High-quality aluminum welding is achieved at a low input heat and a low smut level, while ultralow
spatter is realized in the current region of 40A to 100A;
- Forced air cooling of the pull wire feeder achieves continuous welding at a 100% duty cycle with the
maximum set current;and
- Air blow unit using air for forced air cooling discharges wire shavings that cause the tip to get stuck to
prevent short time breakdown.
○ Wire feeding independent from robot motion

Stable wire feeding can be performed even if a conduit was twisted, swung and so on by the robot
motion. Then, high-quality welding performance is achieved with less welding start error caused by
arc outage and less fluctuation of welding conditions associated with the change of power feeding
point inside the tip.
Aiming deviation(φ1.2)
○ Stability of the wire aiming position [With using the wire reel]
Normally, a welding wire fluctuates
inside the tip due to the twisted or
swung conduit. But when using this
pull feeding unit, a wire is pressured
in the upper part of the torch, more
independent from this influence. This
mechanism allows constant welding
performance with minimum aiming
deviations.
Fig.1.1 Wire aiming deviation
○ Enhancement in the Arc start performance
Adapting AC servo type wire feeding system improves the arc start performance and reduces sputter
occurrence at ark start. Also it prevents wire’s blowing off and bead’s chipping at arc start. The function
of outputting a pulse current immediately after arc start prevents lack of penetration in the starting
portion of welding to suppress the height of reinforcement of weld and improve the quality of the
starting portion of arc.
1.5 Prepared by Users

This section describes the specification and items to be prepared by users for use of the AC servo pull
feeder.
Table 1.9 Items prepared by users
No. Items SpecifDetails ications
This set is required when using the product with a rated

service factor of 100%.
Air pressure of approx. 0.3MPa is required.
Applicable tube outer diameter is φ6.
The following lists the outer diameter accuracy tolerances by
tube material:
・Nylon tube…Within ±0.1mm
・Soft nylon tube…Within ±0.1mm
1 Set of air tubes ・Polyurethane tube…Within +0.15~ -0.2mm
Hi-coupler (plug) 20PM is used for the connection point of air
piping. Prepare a connectable coupler.
Be sure to keep the air dry by installing equipment such as a

filter, mist separator and air dryer, etc., preventing it from any
oil or moisture contaminated.
Use of oily or moist air cause malfunction or defect.
In addition, due to the air blow function, oil and moisture are
mixed into the shielding gas at the time of welding, causing
bad welding and defects.
－5－
(Unit: mm)
Fig.1.2 Outline drawing of the AC servo pull feeder Fig.1.3 Outline drawing of the AC servo pull feeder
<AFAPS-2503> <AFAPS-2503+L-11707>
Fig.1.4 Outline drawing of the AC servo pull feeder

<AFAPS-2503+L-11743>
－6－
(Unit: mm)
Fig.1.5 Installation diagram of the AC servo pull feeder <AFAPS-2503> , L-11707 and RTA2500H
(Unit: mm)
Fig.1.6 Installation diagram of the AC servo pull feeder <AFAPS-2503> , L-11743 and RTA2500H
－7－
２．Preparation for Welding
2.1 Checking the Contents
2.1.1 AC servo pull feeder
AFAPS-2503
AC servo pull feeder ·······································································································································································1piece

Liner assembly (For synchro feed, RTA2500H)·······························································································································1piece
Wrench(15) (Note 1) ·······································································································································································1piece
Fig.2.1 Checking the contents of package (AFAPS-2503)
Note) 1. Wrench (15) attached to AFAPS-2503, is used when replacing the feeding roll.
2. This product is a drive unit of the AC servo pull feeder. It can be mounted on a manipulator in
combination with the adapter for pull feeder (L-11707、L-11742、L-11743) (optional accessory).
－8－
2.1.2 Adapter for Pull feeder
The adapter for pull feeder consists of the following components.
For the mounting method, refer to “2.2 Mounting of the adapter for pull feeder”.
Table 2.1 Standard configuration of the adapter for pull feeder (For NB6, L-11707)
No. Item Model・Design No. Qt Remarks
① Mounting assembly L11707C00 1st For NB6
② Bracket assembly（For NB6） L11707D00 1st For NB6
L-11707
L11707C00 L11707D00
Insulating flange ·····································································1 piece Bracket ·················································································1 piece

Power shaft ···········································································1 piece Motor cover ···········································································1 piece
Liner guide ············································································1 piece Hood·····················································································1 piece
Inlet guide··············································································1 piece Under cover ···········································································1 piece
Lock nut (note 1) ····································································1 piece Dowel pin (φ5x10) (note 4)··················································1 piece
Hexagon socket head cap screw (M4x16) (note 2)··············· 4 pieces Dowel pin (φ6x10) (note 4)··················································1 piece
C-type cap (note 2) ······························································· 4 pieces Resin bolt (M5x10) (note 5) ················································ 2 pieces
Dowel pin (φ6x10) (note 3) ·················································1 piece Hexagon socket head cap screw (M5x16) (note 6) ··············· 4 pieces
Alcan compound ····································································1 piece Hexagon socket head cap screw (M5x14) (note 6) ··············· 4 pieces
Hexagon socket head cap screw (M3x12) (note 6) ··············· 3 pieces
Hexagon socket head cap screw (M3x6) (note 6) ················· 4 pieces
Washer (M3) (note 6) ···························································· 3 pieces
Spring washer (M3) (note 6)··················································· 3 pieces
Cable tie (note 7) ····································································1 piece
PE bag (note 7) ······································································1 piece
Fig.2.2 Checking the contents of package (L-11707)
Note) 1．The lock nut attached to L11707C00, is used to connect the power shaft.
2．The hexagon socket head cap screws and C-type caps attached to L11707C00, are used to
assemble the insulation flange.
3．The dowel pin attached to L11707C00, is used to position the insulation flange when mounting it on
AFAPS-2503.
4．One of the insulating dowel pins attached to L11707D00, is inserted into the output flange to position
the bracket. The other one is inserted into the bracket to position the AC servo pull feeder.
5．The resin bolts attached to L11707D00, is used to connect the undercover.
6．The hexagon socket head cap screws, washers and spring washers attached to L11707D00, are
used to connect the bracket, motor cover and hood.
7．The cable tie and PE bag attached to L11707D00, are used to protect the connector of cables.
－9－
Table 2.2 Standard configuration of the adapter for Pull feeder (For NV type, L-11743)
① Mounting assembly for NV6 L11609C00 1st For NV type
② Mounting bracket assembly L11609D00 1st For NV type
③ Torch gauge assembly L11609E00 1st For NV type
L-11743
L11609C00 L11609D00
Insulating flange ···································································· 1 piece

Power shaft··········································································· 1 piece
Liner guide ············································································ 1 piece
Inlet guide ············································································· 1 piece
Lock nut (note 1)···································································· 1 piece
Hexagon socket head cap screw (M4x16) (note 2) ···············4 pieces
Alcan compound ··································································· 1 piece Mounting bracket assembly ················································· 1 piece
L11609E00 Insulating dowel pin (note 3) ················································· 1 piece
Spring washer (M5) (note4)····················································4 pieces
Washer (M5) (note4) ·····························································4 pieces
Silicon tube (φ25x200mm) (note 5) ········································· 1 piece
Torch gauge assembly························································· 1 piece Silicon tube (φ15x250mm) (note 5) ········································· 1 piece
Hexagon socket head cap screw (M10x65) (note 6) ·············· 1 piece Cable tie (note 5) ·································································8 pieces
Fig.2.3 Checking the contents of package (L-11743)
Note) 1．The lock nut attached to L11609C00, is used to connect the power shaft.
2．The hexagon socket head cap screws attached to L11609C00, are used to connect the insulation
flange.
3．The insulating dowel pin attached to L11609D00, is inserted into the output flange to position the
mounting bracket assembly.
4．The hexagon socket head cap screws, washers and spring washers attached to L11609D00, are
used to connect the mounting bracket assembly and the AC servo pull feeder to the manipulator.
5．The silicon tubes and cable ties attached to L11609D00, are used to cure the cables.
6．The hexagon socket head cap screws attached to L11609E00, are used to mount the torch gauge
assembly.
－10－
2.1.3 High duty cycle kit
The high duty cycle kit consists of following parts.
For the installation and setting method, see 2.6 “Mounting of the high duty cycle kit and the air blow
unit.”
Table 2.3 List of Applicable manipulator

Model Applicable Manipulator
L-11702G NV6S / NV8 / NV20A / NV20S / NV25
L-11741D NB6
Table 2.4 Standard configuration of High duty cycle kit (For NV type, L-11702G)
① Air regulator assembly L11701E00 1st
② Flow switch assembly (For V type) L 1 1 7 0 2 F 0 0 1st For NV type
③ Air hose assembly L11741G00 1st 10M
Table 2.5 Standard configuration of High duty cycle kit (For NB6, L-11741D)
① Air regulator assembly L11701E00 1st
② Flow switch assembly (For NB type) L1170 1F00 1st For NB6
③ Air hose assembly L11741G00 1st 10M
－11－
L11701E00 L11701F00
Air regulator assembly ··························································1 piece Flow switch assembly (For NB4 type) ····································· 1 piece
Mounting bolt (M8x20) (Note1) ·········································2 pieces
Cable tie (145mm) (Note2) ···············································3 pieces
L11702F00 L11741G00
Flow switch assembly (For NV6 type) ····························· 1 piece Sputter tube (TE-06-AF-LB, 10m) (Note 3,4) ·················· 1 piece
Mounting bolt (M5x10) (Note 1) ···································· 2 pieces Sputter tube (TE-06-AF-LB, 2m) (Note 3,4) ·················· 1 piece
Cable tie (145mm) (Note 2) ·········································· 3 pieces Hose elbow (M-5HL-6-X112) (Note 5) ··························· 2 pieces
Male connector (KQ2H06-03AS) (Note 6) ························ 1 piece
Different diameter straight (KQ2H06-08A) (Note 7) ············ 1 piece
Fig.2.4 Checking the contents of package (High duty cycle kit)
Note) 1. Hexagon socket head bolts attached to L11701F00 and L11702F00 are used to fix the bracket of the flow
switch assembly to the manipulator.
2. Cable tie attached to L11701F00 and L11702F00 are used to fix cables to the bracket.
3. For NV6S / NV20 type manipulator, A 10m-length type, one of sputter tubes attached to L11741G00 is
used to connect between the air regulator assembly and the cooling unit of the AC servo pull feeder. A
2m-length type, another one of those is used to connect between the cooling unit and the flow switch
assembly.
4 For NV8 / NV25 / NB6 manipulator, cut the 10m sputter tube attached to L11741G00, into 8m and 2m
portions to make one 8m tube and two 2m tubes. Use one 8m tube to connect the air regulator assembly
to the air hose inlet of the manipulator. Use two 2m tubes to connect the air hose and the flow switch
assembly of the manipulator shoulder portion to the cooling unit of the AC servo pull feeder.
5. Hose elbows attached to L11741G00 are used to fit the sputter tube into the cooling unit.
6 The male connector attached to L11741G00, is used to connect a φ6 sputter tube when being used with
the NV8 / NV25 / NB6 manipulator. Remove the hexagon socket head taper plug (PT3/8) from the
manipulator axis 1 unit and connect the male connector in place.
7 The straight tube with different diameter attached to L11741G00, is used to connect the sputter tube (φ6)
attached to the air hose ASSY, to the sputter tube (φ8) extruded from the NV8 / NV25 / NB6 manipulator
shoulder portion.
－12－
2.1.4 Air blow unit
The air blow unit consists of following parts.
For the installation and setting method, see 2.6 “Mounting of the high duty cycle kit and the air blow
unit.”
Table 2.6 List of Applicable manipulator
Model Applicable Manipulator
L-11799 NV6S / NV8 / NV20A / NV20S / NV25
L-11800 NB6
Table 2.7 Standard configuration of Air blow unit (For NV type, L-11799)
① Air regulator assembly L11799B00 1st
L11799B00
Air solenoid valve assembly ············································ 1 piese

Mounting bolt (M5x10) ················································ 2 pieces
Fig.2.5 Checking the contents of package (Air blow unit for NV type)
Table 2.8 Standard configuration of Air blow unit (For NB type, L-11800)
① Air regulator assembly L11800B 00 1st
L11800B00
Air solenoid valve assembly ············································ 1 piese
Mounting bolt (M8x12) ················································ 2 pieces
Fig.2.6 Checking the contents of package (Air blow unit for NB type)
－13－
2.2 Mounting of the adapter for pull feeder
2.2.1 Mounting of the adapter for pull feeder (for NB6)(AFAPS-2503 and L-11707)
Liner guide
3
C-CAP
2 Inlet guide
4×C4
3
Hexagon socket head screw
2 4×M4×16
Insulating flange Power shaft

2 1
Dowel pin
2 Lock nut
MSH6-10 1
AC servo pull feeder

AFAPS-2503
Fig.2.7 Mounting of the adapter for pull feeder (for NB6)(AFAPS-2503 and L-11707)
(1) Mount the power shaft with the lock nut mounted to it to the AC servo pull feeder. (For the detailed
mounting procedure, refer to 2.2.4).
(2) Insert the dowel pin (φ6x10) into the AC servo pull feeder. Mount the insulation flange on the AC servo
pull feeder. (using four hexagon socket head cap screws (M4x16) with tightening torque of 1.5N·m).
Make sure to align the dowel pin hole of the insulating flange to the dowel pin. After mounting the
insulating flange, fit the C-type cap on each bolt head.
(3) Combine the liner guide with the inlet guide (with tightening torque of 1.5N·m) and insert them into the
power shaft.
－14－
2.2.2 Mounting of the adapter for pull feeder (for NV type)(AFAPS-2503 and L-11743)
Liner guide
3
Inlet guide
3
Power shaft Hexagon socket head screw

1 2
4×M4×16
Lock nut Insulating flange

1 2

AFAPS-2503
Fig.2.8 Mounting of the adapter for pull feeder (for NV type)(AFAPS-2503 and L-11743)
(1) Mount the power shaft with the lock nut mounted to it to the AC servo pull feeder. (For the detailed
mounting procedure, refer to 2.2.4).
(2) Mount the insulation flange on the AC servo pull feeder (using four hexagon socket head cap screws
(M4x16) with tightening torque of 1.5N·m).
(3) Combine the liner guide with the inlet guide (with tightening torque of 1.5N·m) and insert them into the
power shaft.
2.2.3 Installing of the power shaft
Important
When installing the power shaft, please observe the following procedure. Please observe the
tightening torque as instructed below.
Be sure to install the power shaft correctly to prevent trouble and burnout.
＜Power shaft (L11609C10)＞
－15－
①Install the lock nut to the power shaft, lightly tighten the lock nut until a end of screw.
②Apply the Alcan compound to power shaft end and the lock nut contact area of housing.
Lock nut contact

Power shaft end area of housing
③ Tighten the power shaft to the housing until it no longer turns.

Make sure that the length of from housing end to shaft end are the following values.
※L11609C10：L＝45 ｍｍ
Tighten the power shaft with specified torque using the width across flats.
※Tightening torque：10 N・m
Housing
Power shaft Tightening torque：10 N・m
④Tighten the lock nut with specified torque.

※Tightening torque：30 N・m
Lock nut Tightening torque ：30 N・m
－16－
2.3 Mounting on Manipulator
2.3.1 Mounting of AC servo pull feeder (AFAPS-2503 and L-11707) on NB6 manipulator
Protect the connectors with
the PE bag.Then,store them
in a space above the motor
and mount the hood
to secure protection.
Dowel pin hole
Coaxial power cable
Pass the motor cable,
the encoder cable,
the shock sensor cable,
and the voltage detection cable
through the hole.
Dowel pin
1 φ5×10
Bracket Hexagon socket head cap screw

5 13 3xM3x12(W,SW付)
4xM5x16
Hexagon socket head cap screw
2 4xM5x14
Tightening torque：3.0 N・m Tightening torque：0.63 N・m
Tightening torque：3.0 N・m

Dowel pin
φ6x10 4
Power cable cover

Coaxial power cable
AFPS-2503 Resin bolt
2xPEKB5-10 10 L-11733
* Adjust the phases of the
Tightening torque：0.63 N・m shock sensor unit to those
Under cover
of the coaxial power cable
Hexagon socket head cap screw as shown this figure.
14 M5x14
Hood Tightening torque：6.5 N・m

M5x20
Liner ASSY Tightening torque：8.0 N・m
Welding torch
Output flange
Fig.2.9 Mounting of AC servo pull feeder (AFAPS-2503 and L-11707)
(1) Insert the dowel pin into the output flange of the manipulator.
(2) Mount the bracket to the output flange of the manipulator using four hexagon socket head cap screws
(M5x14). At that time, align a hole of the bracket for the dowel pin with the position of the dowel pin.
(3) Draw out the coaxial power cable above the J6 axis. Pass the motor cable, encoder cable, voltage
detection cable and shock sensor cable of the pull feeder downwards through the J6 axis and the
bracket.
－17－
(4) Insert the dowel pin from the bottom into the other dowel pin hole of the bracket.
(5) Align the pin hole of the AC servo pull feeder to the dowel pin on the bracket and mount the AC servo
pull feeder on the bracket (using four hexagon socket head cap screws (M5x16)).
Make sure to prevent cables from being caught in-between when fitting the AC servo pull feeder into
the bracket.
Dowel pin
insertion position Hexagon socket head
cap screw
4×M5×16
4×M5×16
Dowel pin
insertion portion
Fig.2.10 Mounting of bracket Fig.2.11 Mounting of AC servo pull feeder
(6) Remove the hood.

(7) Pass the voltage detection cable on the coaxial power cable side through the J6 shaft (wrist) space up
to near the nozzle holder of the AC servo pull feeder.
(8) Connect a round terminal of the voltage detection cable to the nozzle holder.
(9) Push the voltage detection cable into the groove of the shock sensor body. At that time, loosen the
voltage detection cable slightly between the round terminal and the groove.
Groove of the shock sensor

The voltage detection cable
Nozzle holder
Connect a round terminal
Fig.2.12 Connect the voltage detection cable
(10) Mount the undercover (using two resin bolts (PEKB5-10)) and re-mount the hood as before.
(11) Connect the sputter tube (for shielding gas) to the one-touch joint on the pull feeder side.
(12) Connect the connectors of the motor cable and the encoder cable. After connection, put the
connectors in the PE bag and fix the bag opening with a cable tie. Then, mount the motor cover and
store them in a space behind the bracket. (Refer to Fig. 2.15 and Fig. 2.16.)
－18－
Cable tie
Shock sensor cable

Encoder cable
Store the connectors in the hood
Motor cable behind the bracket.
PE bag
One-touch joint
Sputter tube
Fig.2.13 Connection method of connectors Fig.2.14 Mounting of connectors
(13) Mount the hood. (using three hexagon socket head cap screws(M3x12,W,SW))
(14) Fit the coaxial power cable from the upper side. As a procedure to do this, temporarily remove the
fixing bolt (M5x14) of the coaxial power cable, adjust the phase of the power shaft to insert the cable
into the shaft, and put the bolt back in place to fix it.
(15) Fix cables except for the sputter tube to the rubber sleeve with cable ties at 1 point. At that time,
loosen the cables so that a round bar (φ15) passes through the interspace between the cables and
the sleeve. (Refer to Fig. 2.15)
Fig.2.15 Fixing method of cables
(16) Wind the cables around the coaxial power cable 1.5 loops in a direction shown in Fig. 2.16 to connect
the connector inside a harness cover on the wire buffer side.
(For details, refer to the instruction manual for the wire buffer (1L11610-E-*))
(17) Cure them with wiring protection tube that come with the coaxial power cable.
Fig.2.16 Wiring method of cables
－19－
2.3.2 Mounting of AC servo pull feeder (AFAPS-2503 and L-11743) on manipulator
(NV6S / NV8 / NV20S / NV20A /NV25)
Fig.2.17 Mounting of AC servo pull feeder (AFAPS-2503 and L-11743)
(1) Remove mount cover from mounting bracket by loosening two pieces hexagon socket head cap
screw (M5x8).
(2) Assemble the mounting bracket (L11609D00) onto the output flange of manipulator using 4 pieces of
hexagon socket head cap screws (M6×20).
(3) Assemble the mount cover onto the mounting bracket using two pieces of hexagon socket head cap
screws (M5×8).
(4) Remove insulating bracket from mounting bracket. Assemble the insulating bracket onto the AC servo
pull feeder using four pieces of hexagon socket head cap screws (M5×20).
(5) Assemble the insulating bracket onto the mounting bracket using 2 pieces of hexagon socket head
cap screws (M8×25).
－20－
(6) Attach the coaxial power cable. (* For details, refer to the instruction manual for wire buffer
(1L11610-E-*)).
* Make sure to adjust the phase as shown in Fig. 2.17, when fitting the coaxial power cable.
(7) Wind the motor cable, the encoder cable and the sputter tube around the coaxial power cable twice.
Fig. 2.18 Wiring method of coaxial power cable and cables

2.3.3 Wiring method of motor cables, encoder cables and shock sensor cables
(1) Remove the motor cover, round the motor cable and the encoder cable and put them in the motor
cover. At the time, adjust the cables to stick out from the motor cover about 120 mm from the
connector ends.
(2) Pass the silicon glass tube (φ15x250) through the shock sensor cable extruded from the side of the
shock sensor.
(3) Put the end of the silicon glass tube deep inside the housing and fix it with the cable tie. (Fig. 2.19)
(4) Put them connected with connector of each cable in the silicon glass tube as shown in Fig. 2.20.
Shielding gas supply port
Cable take-out port
To the relay box

To the Pull Feeder of wire buffer
Sputter Tube
Motor cable, Encoder cable Silicon glass tube
Motor cover (φ25×200)
Encoder side connector
So that the two connectors

do not overlapPlace it
Storing(B) in the up and down.
Silicon glass tube Cable tie
Motor side sonnector
(φ15x250)
Shock sensor cable
Voltage Detection Cable
Fold up
Push voltage detection cable Cable tie
in the groove.
Fig.2.19 Wiring method of motor cable, encoder cable, Fig.2.20 Storing (A) is detailed
shock sensor cable, and sputter tube
－21－
(5) Storage (A) and (B) using the three holes in the mounting bracket, and fix it with the binder.
(6) Fix the cables with the binder at the position of 40mm from the edge of the rubber sleeve of coaxial
power cable.
Cable tie
Motor cable
Encorder cable
Silicon glass tube Cable tie

（φ25×200）
To a harness cover
Pass the shock sensor cable and

voltage detection cable to bottom Cable tie
side of the motor.
Shock sensor cable
Silicon glass tube
（φ15×250）
Fig.2.2 1 Strage (A), strage (B) and curing of Fig.2.22 Method of fixing to L-bracket
voltage detection cable
(7) Open the front cover of the AC servo pull feeder and remove the hexagon socket head bolt with nose
(CBBG4-12). (Refer to Fig 2.23.)
(8) Insert the liner ASSY from underneath, bring the dent of the liner ASSY and the hole together, and
assemble them with the hexagon socket head bolt with nose (CBBG4-12).
※Use caution with the liner ASSY not to stick out too high as it contacts the feeding roll and
affects welding.
(9) Dismount the liner ASSY from the welding torch.
(10) Loosen the hexagon socket head bolt (M5x20)of AC servo pull feeder to insert the torch. Fix it by
hexagon socket head bolt.
Hexagon socket head bolt with dog point

CBBG4-12 Tightening Torque: 1.5 N m
Pressure lever
The handing chief
rule of thumb
Front cover
Bring the dent of the liner ASSY

and the hole together and assemble them
with the socket head bolt with nose
M5×20
Liner ASSY
Fig.2.23 Mounting of Liner ASSY
－22－
2.3.4 Mounting the torch gauge (AFAPS-2503 and L-11743)
(1) Dismount the nozzle and the contact tip from the torch.
(2) Mount the tip gauge firmly to the torch. Purchase the tip gauge separately.
(3) Dismount the mount cover from the mounting bracket.
Hexagon socket
head bolt
M10x65
Torch gauge ASSY

L11609E00
Reference point
Nozzle
Tip gauge
Detail drawing
Fig. 2.24 Mounting the torch gauge
(4) Mount the torch gauge ASSY with the hexagon socket head cap screws (M10x65).
(The screw is attached components of the torch gauge Assy.)
(5) Make sure that the reference point of torch gauge matches with the tip gauge end. If not, make
adjustments for the reference point to align with it.
－23－
2.3.5 Adjusting procedure of the torch (AFAPS-2503 and L-11743)
Note: that you need to create the origin position checking program before removing the tip gauge and
mounting the nozzle and the contact tip onto the torch.
L　bracket
Loosen the bolts that fixes the torch and （L11609D02）
adjust the torch right and left so that Insulating bracket
edge of the tip gauge can align with the （L10620B04）
reference position.
Mount
（L11609D01）
Loosen the screw that fixes the Nozzle body,
and adjust the torch right and left so that
the point of tip gauge can align with the
reference point.
Loosen the screw (2 pieces) that fixes
Upward the mount,and adjust the torch back and
forth so that the point of tip gauge
can align with the reference point.
Downward
Feeding cable
(L10601D)
Loosen the screw (2 pieces) that fixes the
insulating bracket, and adjust the torch up
and down so that the point of tip gauge can
Nozzle holder align with the reference point.
（L11608B29）
Left Right
Forward Backward
Hood
Reference point
(L10602B02)
Tip gauge
Fig. 2.25 Adjusting procedure of the torch
(1) If the tip gauge end slips out of the reference point of torch gauge in the upward or downward direction,
loosen the 2 pieces of hexagon socket head cap screws that fix the insulating bracket onto the
L-bracket. Correct the position, moving the insulating bracket upward or downward, and then fix it firmly
by tightening the screws.
(2) If the tip gauge end slips out of the reference point of torch gauge in the forward or backward direction,
loosen the 2 hexagon socket head cap screws that fix the mount onto the L-bracket. Correct the
position, moving the mount frontward or rearward, and then fix it firmly by tightening the screws.
(3) If edge of the tip gauge is displaced in horizontal direction from refernce point of the torch gauge,
loosen the four bolts (M5×12) that fix the shock sensor and the insulating bracket and adjust it. After
adjusting, re-tighten the bolts firmly.
(4) If displacement in horizontal direction cannot be adjusted by the method of (3), adjust it following the
procedure shown below. Remove the hood (L10602B02). Remove the feeding cable (L10601D00)
connected to the nozzle holder (L11608B29), loosen the Hexagon socket head cap screws (M5x12)
that fix the nozzle holder and adjust it by rotating it in the direction of displacement (right or left). Then,
tighten the nozzle holder and the feeding cable firmly (tightening torque: 5.0 N･m) and mount the hood.
Since front-back displacement occurs due to rotation adjustment, execute front-back re-adjustment
following the procedure of (2).
Note) 1. The nozzle holder should be only rotated for adjustment and should not be pulled out or inserted.
2. Conductive grease is applied on the contact surface of the feeding cable and the nozzle holder
and it should not be cleaned off when removing the feeding cable.
－24－
Dismount the hood (L10602B02) Dismount the bolt to fix feeding cable The bolt to fix nozzle holder
comes out.
Hood
Nozzle holder
Fig. 2.26 Right and left direction adjusting procedure of the torch
(5) In case that the torch tip is not correctly positioned even after making adjustments as shown in (1) - (2),
it is possible that there is a distortion in the L-bracket or the nozzle assembly. Follow the procedures (1)
- (2) once again, and if it remains uncorrected, please contact to your nearest sales distributor of our
company.
(6) Dismount the torch gauge when the adjusting procedure of torch is finished.
2.4 Wire Installation

(1) Pull the pressure lever up and release the pressure roll.
(2) Draw the wire from the liner of coaxial power cable to put it through the inlet guide and insert the outlet
guide of torch.
(3) Turn the pressure lever and adjust pressure scale. (Refer to Table 2.9 and Fig. 2.27)
※Increasing the setting value will also increase the response level but will be liable to generate noise.
Table 2.9 Recommended wire pressure adjustment

Wire diameter Pressure scale
Recommendation value: 1.0,
φ1.2
Setting level : 1.0~2.0
Pressure lever
IMPORTANT
Wire pressure scale The pressure handle is provided with a
scale. Therefore, adjust the pressure volume
using the scale.
Fig. 2.27 Pressure scale for wire
－25－
Table 2.10 Method of adjustment for force of pressure of the AC servo pull feeder
Phenomenon Method of adjustment
Occurrence of motor oscillation sound Reduce pressure.
Much occurrence of sputtering Increase pressure.
Increase of occurrence of sputtering Replace contact tip.
Inlet guide
Feeding roll Pressure roll
Pressure lever
Spring case
Outlet guide
Pressure arm
Fig. 2.28 Wire installation
2.5 Pressure Adjustment of AC Servo Push Feeder

Set the pressure adjustment scale of the AC servo push feeder. (Refer to table 2.11)
Refer to the instruction manual for AC servo push feeder.
Table 2.11 Rough indication for pressure adjustment amount of AC servo push feeder
Wire diameter Pressure scale
φ1.2 2
● If you carelessly touch the rotating part, you may get entangled and
WARNING injured. Be sure to follow the note below.
●Keep your hands, fingers, hair, clothes etc. away from a rotating part such as the
feeding roll of wire feeding unit. Otherwise, you may get entangled and injured.
●Do not use the wire feeding unit with case or cover opened.
●When required to unfix the cover of welding power supply for maintenance,
inspection, or repair work, only the personnel who has taken the specified course
and fully understands the welding power supply must perform the operation.
Also, during the operation, keep other people away from the work area by
enclosing it.
●Be sure to turn off the welding power supply and wire feeder controller or input the
emergency stop signal of the robot (Teach pendant, Operation box, External
controller etc.) before connecting the torch or replacing the wire and other
consumable parts such as the feeding roll.
－26－
2.6 Mounting of high duty cycle kit and air blow unit
2.6.1 Mounting to NB6 manipulator (AFAPS-2503 and L-11707)
(1) Connect the air control cable AL (FL, SV relay cable) to the connector parts of the flow switch assembly
(for NB6). At that time, fix the air control cable to the bracket using the attached cable tie (SKB-2MC) so
that a load is not applied on the connector parts during the robot operation. (Refer to Fig. 2.29)
(2) Fix the bracket to the manipulator using two hexagon socket head cap screws (M8x20). (Refer to Fig.
2.30)
(3) Fix the bracket of the solenoid valve assembly to the manipulator using two hexagon socket head bolts
(M8x12) (Refer to Fig. 2.30)
(4) Route the air control cable AL (FL, SV relay cable) from the position shown in Fig. 2.31 to the
manipulator body and connect it to CN26 (white 3-pin connector). After connection, cover the connector
with a PE bag and fix them with cable ties.
Fig.2.29 Cable routing (AFAPS-2503 and L-11707)
Fig.2.30 Mounting of flow switch assembly and solenoid valve assembly

(AFAPS-2503 and L-11707)
Draw in position
Fig.2.31 Draw in position
－27－
2.6.2 Mounting to NV type manipulator (NV6S / NV8 / NV20S / NV20A / NV25)
(AFAPS-2503 and L-11743)
(1) Connect the air control cable AL to the connector parts of the flow switch assembly (for NV type). At
that time, fix the air control cable to the bracket using the attached cable ties (3 x SKB-2MC) so that a
load is not applied on the connector parts during the robot operation. (Refer to Fig. 2.32)
When folding back the cable, fix the air control cable so that the length of portion projecting from the
bracket end is about 10 mm.
(2) Fix the bracket to the fixing plate using 2 hexagon socket head bolts (M5x10). (Refer to Fig. 2.33)
(3) Fix the bracket of the solenoid valve assembly to the fixed plate using two hexagon socket head bolts
(M510) (Refer to Fig. 2.33).
(4) Cure the air control cable, which is routed backward to pass under the harness cover of the wire buffer,
together with the motor and encoder cables.
Fig. 2.32 Cable routing (AFAPS-2503 and L-11743)
Fig. 2.33 Mounting of flow switch assembly and solenoid valve assembly
(AFAPS-2503 and L-11743)
－28－
2.6.3 Mounting of air hose assembly
(1) For AFAPS-2503 and L-11707, unscrew four hexagon socket head cap screws (M3x6) to remove the
motor cover in reference to Fig. 2.34.
Fig.2.34 Removing of motor cover (AFAPS-2503 and L-11707)
(2) For AFAPS-2503 and L-11743, unscrew 4 hexagon socket head bolts (M5x20) to remove the AC servo
pull feeder from the mounting bracket in reference to Fig. 2.35.
HEXAGON SOCKET HEAD

BOLT (4xM5x20)
Fig. 2.35 Removing of pull feeder (AFAPS-2503 and L-11743)
－29－
(3) Unscrew the low head bolts embedded in the cooling unit (2 x CBSST5-5) and fit the attached hose
elbows (2 x M-5HL-6-X112) with the air hose assembly. (Refer to Fig. 2.36)
Fig. 2.36 Mounting portion of hose elbow
(4) For NB6 / NV8 / NV25 manipulator, cut the sputter tube (TE-06-AF-LB, 10m) into 8m and 2m portions
to make one 8m tube and two 2m tubes. Use one 8m tube to connect the air regulator assembly to the
gas (air) inlet 2 behind the manipulator axis 1. Before connection, remove the taper plug from the gas
(air) inlet 2 and mount the provided male connector on the air hose assembly. Then, connect it to the
sputter tube (Refer to Fig. 2.37).
Fig. 2.37 Air / gas piping diagram (Base part NB6 / NV8 / NV25)
－30－
(5) Use two 2m tubes to connect the cooling units to the air hose 2 (φ8x5, white) extruded from the
manipulator shoulder portion and to the flow switch assembly mounted on the shoulder portion. Make
sure to use the straight tube with different diameter (attached to the air hose assembly) to relay
between the air hose 2 (φ8x5) and the sputter tube. Perform a piping to shoulder portion and air blow
unit in reference to Fig. 2.38 and Fig 2.39. Lay one sputter tube for gas and two for air (three tubes in
all) along the one-wire power cable.
Fig. 2.38 Air / gas piping diagram (Shoulder part NB6)
Fig. 2.39 Air / gas piping diagram (Shoulder part NV8 / NV25)
－31－
(6) For NV6S / NV20A / NV20S type manipulator, fit the sputter tube (TE-06-AF-LB, 10m) into the cooling
unit along with the coaxial power cable through the shoulder of the manipulator. Connect the other end
of the sputter tube to the solenoid valve of the air regulator assembly.
(7) Fit 2m tube into the hose elbow on the other side fitted according to the step (6). Connect the other
end of the sputter tube to the flow switch assembly positioned in the shoulder of the manipulator.
Refer to Fig. 2.40 when you perform a piping to air blow unit.
Fig. 2.40 Air / gas piping diagram (NV6S / NV20A / NV20S)
－32－
(8) To pass the sputter tube and cure it along the coaxial power cable. Cut or wind the excessive sputter
portions. Be careful not to fold the sputter tube when cutting or winding it. (Refer to Fig.2.41 and Fig.
2.42)
*) For curing of the sputter tube along with the coaxial power cable, refer to 2.3.1 and
2.3.2.
Route sputter tubes along

with the motor.
Fig.2.41 Hose routing for NB6 (AFAPS-2503 and L-11707)
Fig. 2.42 Hose routing for NV type (AFAPS-2503 and L-11743)
－33－
2.6.4 Connecting to robot controller
(1) Remove the rear panel of the robot controller to install the power supply unit for air control inside the
device.
Fig. 2.43 Mounting of power supply unit for air control
(2) Draw out the cable assembly (black) in the front of the robot controller and fit the connector for
CN200P into CN200P of the robot controller.
(3) Draw out the cable assembly (blue) in the front of the robot controller and connect the rod terminal
(DB_OUT, DB_OUTCOM) to TBOUT either of the relay unit or the arc I/F board. Fig. 2.44 shows the
examples for connecting “Feeder cooling ON/OFF” output to OUT1 or OUT97.
(4) Route the CNDB1 connector side of the air control cable AL into the robot controller and fix the flange.
(5) Connect the earth cables (2) of the air control cable AL to the earth stud near the lead-in inlet.
(6) Connect the air control cable AL and the CNDB1 connector of the cable assembly (blue).
(7) Connect the rod terminal (EXP1, FL_IN, INCOM) of the air control cable AL to TBIN either of the relay
unit or the arc I/F board. Connect the rod terminal (DB_OUT2) to TBOUT either of the relay unit or the
arc I/F board. Fig. 2.44 shows the examples for connecting “Feeder cooling check” input to IN1 or IN97
and connecting “Air blow switching” output to OUT2 or OUT98.
(8) Mount the rear panel of the robot controller.
The following is only when you connect to NB6 manipulator.

(9) Connect the adapter cable AL to the robot CN4.
(10) Connect the air control cable AL (on the robot controller) and the CNFL1 connector of the adapter
cable AL.
For connecting to the relay unit For connecting to the arc I/F board
(Note 1)
Relay unit Arc I/F
Note 1. Use CNSW shorting connector of (Note 2)

注1 リレーユニットのCNSW短絡コネクタは、 Jumper wire
the relay unit with factory default
出荷時設定(NPN入力)のまま、ご使用くだ Note 2. When connecting to the arc
setting (NPN input) without
さい。注2. アークI/F基板に接続する場合は、
I/F board, use the jumper wire
change.
エアー制御用電源ユニット付属の
attached to the power supply
　　ジャンパ線をご使用ください。
unit for air control.
Fig. 2.44 Connection examples for TBOUT and TBIN
－34－
2.6.5 Setting of flow switch
System installation at the time and of, in the case of replacing the flow switch, flow rate and requires a set
of hysteresis. Flow rate detection in the original factory state does not function properly. According to the
following procedure, please set the flow rate and hysteresis. For each name of the flow switch the display unit,
see Fig. 2.45.
LED display
button (SET) button (UP)

Operation
button (DOWN)
indicator
Fig. 2.45 Flow switch indicator
Table 2.12 Setting options, shipping initial value and set value of the flow switch
option Initial value Set value
[P_1] Flow rate 100 [L/min] 50 [L/min]
[F_1]
[H_1] Hysteresis 10 [L/min] 0 [L/min]
(1) Hold down button for over 2 seconds in the measurement mode after power-up. Then, the function
selecting mode is activated, and [F 0] and [rEF] are displayed alternately on LED indicator.
Displayed alternately
(2) Press or button in the function selecting mode to have [F 1] displayed. Then, [F 1] and [oU1]
are displayed alternately. Press button once to enter the selection of output mode.
(3) [oU1] and [HYS] are displayed alternately on LED indicator, press button once.
Output mode Current set value

(4) [lot] and [1_P] are displayed alternately on LED indicator, press button once.
Inversion of output Current set value

(5) [P_1] and [Current set value] ([100] as factory default setting) are displayed alternately on LED
indicator. Press or button to have the set value changed to [50], press button once.
Current set value
－35－
(6) [H_1] and [Current set value] ([10] as factory default setting) are displayed alternately on LED indicator.
Press or button to have the set value changed to [ 0], press button once.
Hysteresis Current set value

(7) [CoL] and [SoG] are displayed alternately on LED indicator, press button once to return to the
function selecting mode.
Display color Current set value

(8) Hold down button for over 2 seconds in the function selecting mode to return to the measurement
mode.
2.6.6 Reset to factory state of flow switch (setting reset procedure)

By the following procedure it is possible to return the setting to the state at the time of shipment.
(1) Hold down button for over 2 seconds in the measurement mode after power-up. Then, the function
selecting mode is activated, and [F 0] and [rEF] are displayed alternately on LED indicator.
(2) Press or button in the function selecting mode to have [F99] displayed. Then, [F99] and [ini] are
displayed alternately. Press button once to enter the selection of return to factory state.
(3) [ini] and [Current set value] ([oFF] as factory default setting) are displayed alternately on LED indicator.
Return to factory state Current set value
(4) Press or button to have the set value changed to [ on].
Not return Return to factory state

(5) The set value changed to [ on], hold down button and button for over 5 seconds. Return
factory state, to return to the function selection mode.
(6) According to the procedures of 2.6.6 Setting of flow switch, perform the initial setting of the flow switch
again.
For a more details setting method, refer to the instruction manual of the manufacturer (SMC Co., Ltd.).
Manual can be downloaded from the following URL.
http://www.smcworld.com/manual/en/ (Please search for “PFMB7201” under the Product Type Search.)
－36－
2.6.7 Setting and checking of air flow
Follow the following procedure in order to set and check of the flow volume of the cooling air.
(1) Turn on the output port installed as shown in 2.6.4 using a general-purpose output monitor. For the
operating method, refer to “Chapter 7 Useful functions” in the FD series instruction manual “Basic
operations manual.” The solenoid valve for cooling air is opened and cooling air flows into the forced
cooling unit of the AC servo pull feeder.
(2) Adjust the filter regulator of the air regulator assembly so that indication of the pressure gauge is equal
2
to or more than 0.3 [MPa] (3.1 [kgf/cm ] / 43.51 [psi]).
(3) After adjusting the pressure, check that the flow volume shown on the flow switch is equal to or more
than 50 [L/min]. If the flow volume is less than 50 [L/min], adjust it to be equal to or more than 50 [L/min]
by increasing pressure of the filter regulator or opening the flow control valve of the flow switch.
(4) After controlling the flow volume, fix the control valve of the filter regulator and the flow control valve of
the flow switch to keep them from moving.
(5) Check the operation of input signals using ON/OFF switching of the general-purpose output and the
general-purpose input monitor. Check that turning OFF/ON the general-purpose output according to the
step (1) allows the input port (installed as shown in 2.6.4) displayed on the general-purpose input
monitor to switch to OFF/ON. For the operating method, refer to “Chapter 7 Useful functions” in the FD
series instruction manual “Basic operations manual.”
(6) Turn off the general-purpose output port which has been operated according to the step (1) and (5) to
power off FD11 control device.
Flow control valve
Indicator Lock ring
Connector
Piping port (OUT side)
Through-hole
Body
Piping port (IN side)
Fig. 2.46 Flow switch
－37－
2.6.8 Setting of robot controller
When using the high duty cycle kit, set the robot controller according to the following steps:
Setting of constant of weld

1 Select f5 <Arc constant> - [3 Constant of weld] in the instruction mode.
>> The setting screen for the constant of weld is displayed.
2 Press f9 <Page up> key or f10 <Page down> key and move the cursor
to the item [The feeder cooling function].
3 “ON” the feeder cooling function using [Enable] + [Left / Right].

＋
Selecting “ON” makes the temperature and the judgement time of [The
cooling condition of the feeder] settable.
Make sure to usually employ the temperature and the judgement time set as
default values without change.
4 Press f12 <Complete> key to exit.
－38－
Setting of output signals (feeder cooling ON/OFF)
1 Select [Enable] + f5 <Constant setting> - [6 Signals] - [3 Output signal
＋ Assignment] - [3 Arc Outputs] in the instruction mode.
>> The setting screen for the arc outputs is displayed.
to the item [The feeder cooling ON/OFF].
3 Enter the number of port to which the air control cable is connected
(its destination is the solenoid valve for cooling air) on each welding
Number machine using the numeric keys and press [Enter].
－39－
Setting of output signals (air blow switching)
１ Select [Enable]  f5 Constant setting - [6 I/O signals] - [3 Output
＋ signal assignment] - [3 Arc output signals] in the teach mode.
２ Press the f9 Page up key or the f10 Page down key, and move the
cursor onto [Air blow (Torch)].
３ Enter a port number to which DB_OUT2 of the air control cable is

connected using the numeric keys for each welding machine, and
Number press the [Enter] key.
４ Press the f12 Write key to exit.
●In order to weld hard aluminum, clean the inside of the torch by applying air blow once a
day for a period of five seconds or more.
WARNING Increase the frequency of applying air blow according to the state of accumulation of wire
shavings in the torch.
Not doing so may result in damage to the equipment, a fire, or an electric shock.
－40－
Setting of input signals (feeder cooling comfirmation)
1 Select [Enable] + f5 <Constant setting> - [6 Signals] - [2 Input signal
＋ Assignment] - [3 Arc Inputs] in the instruction mode.
>> The setting screen for the arc input signal is displayed.
to the item [Feeder cooling comfirmation].
3 Enter the number of port to which the air control cable is connected
(its destination is the flow switch) on each welding machine using the
Number numeric keys and press [Enter].
－41－
Setting of input signals (torch air blow)
１ Select [Enable]  f5 Constant setting - [6 I/O signals] - [2 Input signal
＋ assignment] - [3 Arc input signals] in the teach mode.
２ Press the f9 Page up key or the f10 Page down key, and then move
the cursor onto [Air blow (Torch)].
３ Enter the port number of input signal that applies air blow using the
Number numeric keys for each welding machine, and press the [Enter] key.
４ Press the f12 Write key to exit.
－42－
Setting of feeder temperature anomaly
The synchro feed welding system monitors constantly the pull feeder temperature to protect the motor.
Furthermore, the cooling air is controlled based on the pull feeder temperature when the high duty cycle
kit is used.
This section describes settings regarding temperature anomaly of the pull feeder and flow anomaly
when the high duty cycle kit is used.
Table 2.13 Setting items and default values of “Feeder temperature anomaly”
Default
Setting item Description
value
Information display When the feeder temperature continues to exceed 80°C
temperature the information display temperature during the
Information judgement time, Information is displayed. 30 sec
judgement time
When the feeder temperature exceeds this
Emergency stop
temperature, emergency stop is executed to protect 90°C
temperature
the motor.
The time required to detect any flow anomaly of the
Detection time for
feeder cooling air can be set. Any flow anomaly is
detecting flow 10 sec
detected by monitoring ON/OFF status of the feeder
anomaly
cooling check signal during feeder cooling.
Setting is changed to Information only if the
Measures for the
operation is needed to continue even after any flow Alarm
flow anomaly
anomaly has been detected.
1 Select f5 <Arc constant> - [21 Setting of arc welding error] in the

instruction mode.cs
>> The setting screen for the arc welding error is displayed.
－43－
to the item [Feeder temperature abnormality.
3 Press f8 <Refer> key.

>> The setting screen for the feeder temperature abnormality is displayed.
Make sure to usually employ the parameters set as default values without
change.
－44－
３. Coaxial Power Cable for Robot
3.1 Type of Coaxial Power Cables
Table 3.1 Type of coaxial power cables
Nominal
Type Applicable manipulator Remarks
cable length
L - 1 1 6 2 2 1.1m NV6S / NV8 / NV20S / NV20A / NV25 ●
L - 1 1 7 3 3 0.9m NB6 ●
●:Standard
Note 1) Use the pla-liner (separately).
Note 2) The attached liner (for steel Φ1.2 ~Φ1.6) is not used.
Note 3) This power cable comes with wiring protection tube. Refer to the instruction manual for wire
buffer (1L11610-E-*) to cure the cables.
(Unit: mm)
Fig. 3.1 Outline drawing of the coaxial power cable (L-11622)
(Unit: mm)
Fig. 3.2 Outline drawing of the coaxial power cable (L-11733)
※This product (AC Servo pull feeder) requires dedicated coaxial power cable. This dedicated power
cable must be used in the event of a replacement.
－45－
3.2 Connecting the Shock Sensor Cable and Voltage Detection Cable
3.2.1 Mounting of shock sensor cable and voltage detection cable (AFAPS-2503 and L-11707)
A coaxial power cable incorporates the shock sensor cable and the voltage detection cable.
Connect each cable referring to the following.
・Connection procedure for the shock sensor cable and the voltage detection cable (on the AC servo pull
feeder side)
(1) Dismount hood, motor cover and under cover from AC servo pull feeder.
(2) Connect the attached extension sensor cable to the shock sensor cable that sticks out from the AC
servo pull feeder. Refer to Fig. 3.4 for the cable routing.
(3) Mount motor cover, under cover and hood onto AC servo pull feeder.
Hexagon socket bolt

M3x6（4 pieces）
Tightening Torque：0.2 N・m
undercover
L11608B16
motor cover
L11707G00
Resin bolts
PEKB5-10（2 pieces）
Tightening Torque：0.63 N・m
Fig. 3.3 Mounting / dismounting each cover
Extension sensor cable

Voltage detection cable L11608D00
Shock sensor cable
Fig. 3.4 Connecting the shock sensor cable and voltage detection cable (to the AC servo pull feeder )
－46－
・Connection procedure for the shock sensor cable and the voltage detection cable (on the shoulder side)
(1) Connect the shock sensor cable to the connector of the shoulder part.
(2) Remove the side cover of the shoulder.
(3) Draw out the wiring inside the shoulder and temporarily remove the protective PE bag for connectors.
[Caution] Don’t discard the removed PE bag because it is reused after wiring is completed.
(4) Route the voltage detection cable through a hole of the blind cover.
(5) Connect it to the cable inside the body. For details regarding cable connection, refer to Electrical
connection diagram in Clause 7.
(6) After wiring is completed, put the connector in the PE bag which has been removed according to the
step (3) the way it was and close the PE bag with a cable tie to store it inside the shoulder, then place
the side cover back together.
Fig.3.5 Connection of the voltage detection cable (on the shoulder side)
IMPORTANT
Be sure to properly connect the voltage detection cable.
Wrong connection of this cable badly affects the welding quality.
－47－
3.2.2 Mounting of shock sensor cable and voltage detection cable (AFAPS-2503 and L-11743)
The shock sensor cable and the voltage detection cable are integrated in the coaxial power cable.
Connect each cable in reference to the following steps:
・Connection procedure for the shock sensor cable and the voltage detection cable (on the AC servo pull
feeder side)
Connect the attached extension sensor cable to the shock sensor cable portion drawn out of the AC
servo pull feeder. Screw the voltage detection cable on the nozzle holder.
・Connection procedure for the shock sensor cable and the voltage detection cable (on the shoulder side)
(1) Connect the shock sensor cable to the connector of the shoulder part.
(2) Remove the side cover of the shoulder.
(3) Draw out the wiring inside the shoulder and temporarily remove the protective PE bag for connectors.
[Caution] Don’t discard the removed PE bag because it is reused after wiring is completed.
(4) Route the voltage detection cable through a hole of the shoulder positioned under the mounting bracket.
(5) Connect it to the cable inside the body. For details regarding cable connection, refer to Electrical
connection diagram in Clause 7.
(6) After wiring is completed, put the connector in the PE bag which has been removed according to the
step (3) the way it was and close the PE bag with a cable tie to store it inside the shoulder, then place
the side cover back together.
ROUTE THE CONNECTORS OF THE VOLTAGE DETECTION

CABLE INTO THE MANIPULATOR.
Fig.3.6 Connection of the voltage detection cable (on the shoulder side)
－48－
3.3 Insert Parts
Always use a coaxial power cable by incorporating the pla-liner.
IMPORTANT
Clean up the liner inside with the compressed air system about once a week.
Sludge and dust inside the liner may cause defective wire feeding, resulting in a
poor welding quality.
3.4 Connection of Coaxial Power Cable

3.4.1 Cutting the Liner
Fig. 3.7 Cutting the liner from the coaxial power cable (L-11622 / L-11733)
・ Before use, insert the liner into the coaxial power cable and cut it as shown in the figure.
・ Rasp the edge of the liner’s cut section to eliminate burrs.
・ Take enough care not to bend a liner or burr the hole when cutting.
－49－
４．Maintenance and Repairs
4.1 Operation Inspection
Table 4.1 List of inspection
Inspection
No. Wire 3 Location Item Corrective Action
Daily
replacement mths
Adjust the wire pressure to the
1 ○ Pressure scale Checking pressure scale
recommended value
Checking friction on the Replace with new part(s) if it is
contact surface with wires worn-out
2 ○ Feeding roll
Checking the insulating nut Replace the part with new one if it
and insulating collar is damaged
Checking the rotation
Replace with new part(s) if it
status
3 ○ Pressure roll does not rotate smoothly or it is
Checking friction on the
worn-out.
contact surface with wires
Cleaning
Coaxial power Worn liner Replace with new part(s) if it is
4 ○
cable worn-out
Looseness Retightening
Wire feeding Adherence of chips or
5 ○ Cleaning
part shavings
Replace with new part(s) if the
Defects and damage coating (covering) is torn or
- ○ Welding cable
damaged.
Looseness Retightening
Cleaning
6 ○ Liner ASSY Worn liner Replace with new part(s) if it is
worn-out
Checking surface deposits
7 ○ Motor Cleaning
of motor and motor cover
Cleaning
8 ○ Torch Adherence of tips, etc.
Apply the air blow function
IMPORTANT
Remove chips and foreign particles attached to the wire feeding part.
(Regularly cleaning with compressed air is recommended.)
Piled chips or foreign particles could result short circuit and burnout.
※ Do not disassemble the feed motor.

It will cause a failure. When abnormality is
recognized, immediately stop the use of the
equipment and contact our customer service.
Fig. 4.1 Check point of AC servo pull feeder

－50－
4.2 Replacement of liner ASSY
(1) Remove the nozzle, the orifice, the insulator and the tip body from the welding torch.
(2) Open the cover of the AC servo pull feeder and remove the socket head cap screws with nose
(CBBG4-12).
(3) Pull out the liner ASSY from underneath.
(4) Bring the dent of the liner ASSY and the hole together as described in the Fig. 4.2, and assemble them
with the socket head cap screws with nose (CBBG4-12).
※Use caution with the liner ASSY not to stick out too high as it contacts the feeding roll and affects
welding.
(5) Cut the liner ASSY according to the length of each torch. For detail, refer to Fig. 4.3 and Table4.2.
(6) After replacing the liner ASSY, assemble by reversing the steps described above.
Hexagon socket head bolt with dog point
CBBG4-12 Tightening Torque: 1.5 N m
Pressure lever
Bring the dent of the liner ASSY

and the hole together and assemble them
with the socket head bolt with nose
Liner ASSY
Fig. 4.2 Replacement of liner ASSY
(Unit: mm )
Fig. 4.3 Length of liner ASSY
Table 4.2 Length of inner liner (Rough measure)

Torch model L（mm）
RTA2500H 55
－51－
4.3 Replacement of feeding roll
This subsection describes how to replace a feed roll applied in response to the welding wire diameter and change of
material. Before starting replacement, be sure to prepare for safety operation by properly positioning the robot and the
torch and turning off the robot, wire feed control unit and welding power supply.
(1) Open the cover of the AC servo pull feeder and release the pressure lever.
(2) Attach a dedicated tool (see Note 4) to the insulating nut, and then lock the unit.
Attach a Box wrench (10) to the U-nut, fasten the U-nut, and then detach the Box wrench
Fig. 4.4 Replacement of feeding roll
(3) Remove the washer and remove the insulating nut and insulating collar together with the feeding roll.
(4) After replacing the feeding roll, assemble by reversing the steps described above.
At the time, if there is break or crack in the insulating nut or insulating collar, replace with new one.
(5) Replace with appropriate feeding roll.
(6) After replacing the feeding roll, assemble by reversing the steps described above.
※The insulating nut could be damaged when the U-nut is tightened with higher torque than specified. It
must be tightened with specified torque.
※Turn off the powers of the manipulator and wire feeding control device when working on the
replacement.
IMPORTANT
When fixing a feeding roll, the tightening
torque to fix the nuts shall be :
Tightening torque : 7.4 N･m
Fig. 4.5 Replacement of feeding roll
－52－
4.4 Replacement of pressure roll (AFPS-2503)
(1) Open the cover of the AC servo pull feeder and remove the fulcrum plate.
(2) Remove the retaining rings-E type and pull out the pressure arm together with the pressure roll.
(3) After replacing with a new pressure roll, assemble by reversing the steps above.
※Turn off the powers of the manipulator and wire feeding control device when working on the replacement.
Fig. 4.6 Replacement of pressure roll
－53－
５．Parts List
If the components are worn out or damaged while using this torch, see the following table and contact our
sales agent. When ordering, be sure to provide the item name and part No. (or the specification).
Table 5.1 Parts list for AFAPS-2503

No. Part No. Item Qt. Remarks
1 L 1 1 6 0 8 B 0 2 I n s u l a t i o n f l a n g e 1
2 L 1 1 6 0 8 B 4 4 Insulation bracket 1
3 L 1 1 8 0 4 B 0 2 Feeding roll (AL1.2V) 1
4 L 1 1 6 0 8 B 2 6 I n s u l a t e n u t 1
5 L 1 1 6 0 8 B 3 2 I n s u l a t e c o l l a r 1
6 L 1 1 6 0 8 B 3 3 W a s h e r 1
7 L 1 1 6 0 8 B 4 5 W r e n c h 1 5 1 Dedicated tool(Accessories)
8 L 1 1 8 0 4 F 0 0 Pressing roll assembly (AL1.2V) 1
9 L 1 1 6 0 8 G 0 0 Pressing lever assembly 1
10 L 1 1 8 0 4 H 0 0 L i n e r a s s e m b l y 1 For RTA2500H
11 1 0 0 - 2 4 8 0 Retaining rings – E type 1 NETW-3
12 1 0 0 - 2 6 5 8 O – r i n g 2 S-5
13 L 11 6 0 8 M 0 0 Motor exchange unit 1
14 L 1 1 6 0 8 Q 0 0 Forced cooling unit 1
15 L 1 0 6 0 2 B 0 2 H o o d 1
16 L 1 1 6 0 8 B 2 0 S i d e c o v e r 1
Fig.5.1 Exploded diagram for AFAPS-2503
－54－
Table 5.2 Parts list for L-11707
No. Part No. Item Qt. Remarks
1 L 1 1 7
0 7 C 0 1 I n s u l a t i o n f l a n g e 1
2 L 1 1 6
0 9 G 0 0 Power shaft assembly 1 Include lock nut
3 L 1 1 6
0 9 C 0 3 L i n e r g u i d e 1
4 L 1 1 6
0 8 C 0 6 I n l e t g u i d e 1
5 - Hexagon socket head cap screw 4 M4x16
6 3 3 6 4 - 1 3 1 C - t y p e c a p 4 C4
7 - D o w e l p i n 2 φ6x10
8 L 1 1 7 0 7 D 0 1 B r a c k e t 1
9 L 1 1 7 0 7 G 0 0 Motor cover assembly 1
10 L 1 1 7 0 7 D 0 3 H o o d 1
11 L 1 1 6 0 8 B 1 6 U n d e r c o v e r 1
12 - D o w e l p i n 1 φ5x10
13 1 0 0 - 2 9 7 6 R e s i n b o l t 2 PEKB5-10
17 - W a s h e r 3 M3
18 - S p r i n g w a s h e r 3 M3
Fig.5.2 Exploded diagram for L-11707
－55－
Table 5.3 Parts list for L-11743
№ Part No. Item Qt. Remarks
1 L 1 1 6
0 9 C0 1 I n s u l a t i o n f l a n g e 1
2 L 1 1 6
09G0 0 P o w e r s h a f t 1 Include lock nut
3 L 1 1 6
0 9 C0 3 L i n e r g u i d e 1
4 L 1 1 6
0 8 C0 6 I n l e t g u i d e 1
6 L 11 60 9 D0 5 M o u n t 1
7 L 11 7 4 3 F 0 0 L-bracket assembly 1
8 L 11 60 9 D0 7 M o t o r c o v e r 1
9 L 11 60 9 D0 8 M o u n t c o v e r 1
10 - P a r a l l e l p i n 1 φ6x10
12 - S p r i n g w a s h e r 4 M8
13 - W a s h e r 4 M8
16 1 0 0 - 2 6 5 6 Insulating dowel pins 1 φ6x10
17 L 11 6 2 0 F 0 0 Insulation bracket 1 For maintenance
18 L 11 60 9 D0 9 U n d e r c o v e r 1
19 - F l a t h e a d s c r e w 2 M3x6
20 L 11 6 0 9 E0 2 T o r c h g a u g e 1
21 L 6 3 0 0 C 0 2 G a u g e t i p 1
22 - P a r a l l e l p i n 2 φ4x10
25 - N u t 1 M4
Fig.5.3 Exploded diagram for L-11743
－56－
Table 5.4 Parts list for RTA2500H
1 L 1 1 7 6 4 B 0 0 To r c h b o d y A S S Y 1 For 45° curved torch
1-1 3 5 7 4 - 0 1 7 “ O ” - R I N G (1) Include the torch body ASSY
1-2 1 0 0 － 1 2 3 8 P a r a l l e l k e y (1) Include the torch body ASSY
1-3 L 1 0 6 0 3 B 0 4 T e f l o n b u s h i n g (2) Include the torch body ASSY
2 L 1 1 7 6 3 C 0 1 T i p b o d y 1
3 U 5 3 7 7 L 0 0 I n s u l a t o r 1
3-1 L 6 5 7 3 C 0 2 S p r i n g W a s h e r (1) Include the insulator
4 U 2 7 7 4 E 0 3 O r i f i c e 1
5 U 4 1 6 7 H 1 2 T i p 1 . 2 C 1
6 U 5 3 7 7 G 0 1 N o z z l e 1
1-3
1-1
1-2
1-3
2
3
3-1
4
Fig.5.4 Exploded diagram for RTA2500H
－57－
Table 5.5 Parts list for the coaxial power cable (For NB6)
1 L 11 7 3 3 B 0 0 Power cable ASSY （ 0.9M ） 1st For NB6
2 L 1 0 11 0 B 0 4 S l e e v e (1) Include the power cable ASSY
3 L 11 7 3 3 C 0 1 P r o t e c t i v e t u b i n g 1
4 L 11 7 1 3 D 0 0 C a b l e c o v e r A S S Y 1st
5 L 1 0 6 6 6 F 0 0 Shock sensor cable (5) 1
6 L 1 0 6 6 7 J 0 0 Vo l ta g e d e t e c t i o n c a b l e 1
7 L 7 0 6 2 J 0 1 P l a - l i n e r 1
TE-06-AF-BK (CHIYODA MC Co.,
8 ( C omm e rc ia l p ro duc ts ) S p u t t e r t u b e 1.5m
LTD.)(Accessories)
SKB-3MC BK(SK KOHKI CO.,
9 ( C omm e rc ia l p ro duc ts ) C a b l e t i e 3
LTD.)(Accessories)
【For the maintenance of Shock sensor cable】
10 L 1 0 6 3 8 F 0 0 Shock sensor cable(For maintenance) 1st
11 L 1 0 6 5 1 G 0 0 Voltage detection cable (For maintenance) 1st
Note) When the shock sensor cable is replaced, purchase the shock sensor cable for maintenance.
The SUMITUBE and the Cable tie for the installation are contained in the shock sensor cable for maintenance .
Fig. 5.5 Exploded diagram for the coaxial power cable (For NB6)
－58－
Table 5.6 Parts list for the coaxial power cable (For NV type)
1 L 1 1 6 2 2 B 0 0 Power cable ASSY（1.2M） 1st For NV6S / NV8 / NV20A / NV20S / NV25
2 L 1 1 6 2 2 C 0 0 Cable clamp ASSY 1st
3 L 1 1 6 2 2 D 0 1 Protective tubing 1
4 L 1 0 6 6 6 J 0 0 Shock sensor cable(8) 1
5 L 1 0 6 6 7 K 0 0 Vo l ta g e d e t e c t i o n c a b l e 1
6 L 7 0 6 2 J 0 1 P l a - l i n e r 1
7 (Commercial products) S i l i c o n t u b e 0.1m φ20 SSG-2 W(NISSEI ELECTRIC CO.,LTD.)
For L-11622
8 (Commercial products) S p u t t e r t u b e 1.7m TE-06-AF-BK (CHIYODA MC Co.,
LTD.)(Accessories)
SKB-3MC BK(SK KOHKI CO.,
9 (Commercial products) C a b l e t i e 2
LTD.)(Accessories)
Fig. 5.6 Exploded diagram for the coaxial power cable (For NV type)
－59－
Table 5.7 Parts list for the air regulator assembly (L11701E00)
1 - S t a n d 1
2 1 0 0 - 2 8 3 1 F i l t e r r e g u l a t o r 1 AW30-02BG-R-1(SMC)
3 - S t o p v a l v e 1 TYPE 600 RZ 1/4
4 4 7 3 9 - 1 3 1 N i p p l e 2 PTN-1/4
5 1 0 0 - 2 7 7 4 F i t t i n g 1 E01-C202 (MISUMI)
6 4 7 3 9 - 3 3 8 C o u p l e r 1 20PM (NITTO KOHKI CO., LTD.)
7 - Hexagon socket head bolt 2 M6x10
8 4 8 1 3 - 0 4 9 S o l e n o i d v a l v e 1 VX232AFXB (SMC)
9 - M a l e c o n n e c t o r 1 KQ2H06-02S (SMC)
NCS-142-AD
10 1 0 0 - 0 4 2 0 A d a p t e r 1
(Nanaboshi Electric Mfg. CO,Ltd.)
Fig.5.7 Exploded diagram for the air regulator assembly (L11701E00)
Table 5.8 Parts list for the flow switch assembly (For NB6) (L11701F00)
1 L 1 1 7 0 1 F 0 2 B r a c k e t 1
2 1 0 0 - 2 7 7 5 F l o w s w i t c h 1 PFMB7201S-02-AN (SMC)
4 1 0 0 - 2 7 7 6 S i l e n c e r 1 AN15-02 (SMC)
6 - C a b l e t i e 3 SKB-2MC / FOR FIXING CABLE
Fig.5.8 Exploded diagram for the flow switch assembly (For NB6) (L11701F00)
－60－
Table 5.9 Parts list for the flow switch assembly (For NV type) (L11702F00)
1 L 1 1 7 0 2 F 0 2 B r a c k e t 1 FOR NV TYPE ROBOT
2 1 0 0 - 2 7 7 5 F l o w s w i t c h 1 PFMB7201S-02-AN (SMC)
4 1 0 0 - 2 7 7 6 S i l e n c e r 1 AN15-02 (SMC)
6 - C a b l e t i e 3 SKB-2MC / FOR FIXING CABLE
Fig.5.9 Exploded diagram for the flow switch assembly (For NV type) (L11702F00)
Table 5.10 Parts list for air hose assembly (L11741G00)

1 1 0 0 - 2 7 8 2 S p u t t e r t u b e 10M TE-06-AF-LB (CHIYODA MC Co., LTD.)
2 - S p u t t e r t u b e 2M TE-06-AF-LB (CHIYODA MC Co., LTD.)
3 1 0 0 - 2 0 8 0 H o s e e l b o w 2 M-5HL-6-X112 (SMC)
4 1 0 0 - 2 8 4 7 M a l e c o n n e c t o r 1 KQ2H06-03AS (SMC)
5 1 0 0 - 2 8 4 8 Different diameter straight 1 KQ2H06-08A (SMC)
Fig.5.10 Exploded diagram for the air hose assembly (L11741G00)
－61－
Table 5.11 Parts list for air solenoid valve assembly (For NB6) (L11800B00)
1 - S o l e n o i d v a l v e 1 VX3344-02-5GS1-B
2 L 1 1 8 0 0 B 0 1 S O L p l a t e 1 For NB6
3 - M a i l e l b o w 3 KQ2L06-02AS (SMC)
4 - Cross hole with he x bol t 4 M5x8
Fig.5.11 Exploded diagram for the air hose assembly (L11741G00)
Table 5.12 Parts list for air solenoid valve assembly (L11799B00)
1 - S o l e n o i d v a l v e 1 VX3344-02-5GS1-B
2 L 1 1 7 9 9 B 0 1 S O L p l a t e 1 For NV type
3 - M a i l e l b o w 3 KQ2L06-02AS (SMC)
4 - Cross hole with he x bol t 4 M5x8
Fig.5.12 Exploded diagram for the air hose assembly (L11799B00)
－62－
Table 5.13 Parts list for the power supply unit for air control (L23230A00)
1 1 0 0 - 2 8 0 9 P o w e r s u p p l y 1 DC24V
2 - B o l t 4 M4X8 (For fixing mounting plate)
3 - B o l t 4 M3x6
4 - S p a c e r 4 M3, HEXAGON, H=24mm
5 N B 1 0 4 7 2 L a b e l 1
②
③④
①
⑤
Fig.5.13 Exploded diagram for the power supply unit for air control (L23230A00)
Table 5.14 Parts list for the air control cable AL

1 L 2 3 3 5 1 B 0 0 Air control cable AL 1 CABLE LENGTH : 8M
2 L 2 3 3 5 1 C 0 0 Air control cable AL (1) OPTION (CABLE LENGTH : 13M)
3 L 2 3 3 5 1 D 0 0 Air control cable (1)
AL OPTION (CABLE LENGTH : 18M)
*) required when connect to NV6S / NV20 manipulator.
Fig.5.14 Exploded diagram for the air control cable AL
－63－
Table 5.15 Parts list for the air control cable AL (robot controller)
Ai r control ca ble AL
1 L 2 3 3 5 0 B 0 0 1 CABLE LENGTH : 5M
( r o b o t c o n t r o l l e r )
2 L 2 3 3 5 0 C 0 0 (1) OPTION (CABLE LENGTH : 10M)
3 L 2 3 3 5 0 D 0 0
(1) OPTION (CABLE LENGTH : 15M)
*) required when connect to NB6 / NV8 / NV25 manipulator.
Fig.5.15 Exploded diagram for the air control cable (robot controller)
Table 5.16 Parts list for the adapter cable AL

1 L 2 3 3 5 2 B 0 0 A d a p t e r c a b l e A L 1
Fig.5.16 Exploded diagram for the adapter cable AL
Table 5.17 Parts list for the air control cable AL (FL / SV relay cable)
Air control cable AL
1 L 2 2 7 7 9 J 0 0 1
(FL / SV relay cable)
Fig.5.17 Exploded diagram for the air control cable AL (FL / SV relay cable)
－64－
6. Tool Parameter
Table 6.1 tool constants of AC servo pull feeder (for NB6)

Reference
Torch Model Length Angle Center of G Weight Moment of inertia Radius
drawing
X Y Z Rx Ry Rz Gx Gy Gz Mass Ix Iy Iz r
[mm] [mm] [mm] [deg] [deg] [deg] [mm] [mm] [mm] [kg] [kgm^2] [kgm^2] [kgm^2] [mm]
RTA2500H -140.0 0.0 510.0 180.0 -45.0 0.0 -27.1 3.8 202.7 2.8 0.168 0.173 0.007 0.0 Fig. 6.1
Table 6.2 tool constants of AC servo pull feeder

(for NV6S / NV8 / NV20S / NV20A / NV25)
Reference
Torch Model Length Angle Center of G Weight Moment of inertia Radius
drawing
X Y Z Rx Ry Rz Gx Gy Gz Mass Ix Iy Iz r
[mm] [mm] [mm] [deg] [deg] [deg] [mm] [mm] [mm] [kg] [kgm^2] [kgm^2] [kgm^2] [mm]
RTA2500H -140.0 0.0 450.0 180.0 -45.0 0.0 95.9 -0.5 132.1 3.3 0.106 0.143 0.039 0.0 Fig. 6.3
(Unit ：mm )
Fig. 6.1 Installation of torch Fig. 6.2 Installation of torch
for NB6 for NV type
－65－
7. Electrical connection diagram
AC servo push feeder
Wire feeding controller
Motor/Encoder
Red Red
Blue Blue
Yellow Yellow
White White
Gray
Black
Green/Yellow
Shield
Gray FG(Shield clamp)
Inching SW
Black
Red Red
White White
Black Black
Green
X key
Green Shield
FG(Earth terminal) FG(Shield clamp)
Upper arm side

Inside of the manipulator Wire buffer
Encoder
Blue Red
Blue Blue
Blue Yellow
Blue White
Shield
Green Green
/Yellow /Yellow
Red Red Blue Red Blue Red

Blue Blue Blue Blue Blue Blue
Motor/Encoder
Yellow Yellow Blue Yellow Blue Yellow
White White Blue White Blue White
Green Blue Green Shield
Orange Blue Orange Green Green
/Yellow Green/Yellow /Yellow
Green Green
Green /Yellow /Yellow
Orange Green Green Shield
Shield
/Yellow /Yellow
FG(Shield clamp)
Red Red Black Red Red

White White Black White White
Black Black Black Black Black
Y key Green Green/Yellow Green Green

Yellow
Shield Blue Shield
Green
FG(Earth terminal) FG(Shield clamp) Shield
Fig.7.1 Electrical connection diagram (For NB6 / NV8 / NV25) (1/2)
－66－
*1 CNSW short circuit connector of the relay unit, please use in the default setting (NPN) .
2. If connect to the Arc I / F board, please use the jumper wire attached L23230D00.
3. These are the connection examples were set as follows:
[The feeder cooling ON/OFF] → OUT1 or OUT97
[Air blow switching] → OUT2 or OUT98
[Feeder cooling confirmation] → IN1 or IN97
Fig.7.2 Electrical connection diagram (For NB6 / NV8 / NV25) (2/2)
－67－
AC servo wire feed control unit Wire buffer
Encorder
Red Red
Blue Blue
Yellow Yellow
White White
Shield
Green/Yellow
FG(Shield clamp)
AC servo push feeder

Motor/Encorder
Red Red
Blue Blue
Yellow Yellow
White White
Gray
Black
Green/Yellow
Shield
Gray
FG(Shield clamp)
Inching SW
Black
Red Red
White White
Black Black
Green
X key
Green Shield

Motor/Encorder
Upper arm side
Red Red Red

Blue Blue Blue
Yellow Yellow Yellow
White White White
Shield Shield
Green/Yellow Green/Yellow Green/Yellow

FG(Shield clamp)
Red Red Red

White White White
Black Black Black
Y key Green Green

E
Shield Shield
Green
Fig. 7.3 Electrical connection diagram (For NV6S / NV20 type) (1/2)
－68－
*1 CNSW short circuit connector of the relay unit, please use in the default setting (NPN) .
2. If connect to the Arc I / F board, please use the jumper wire attached L23230D00.
3. These are the connection examples were set as follows:
[The feeder cooling ON/OFF] → OUT1 or OUT97
[Air blow switching] → OUT2 or OUT98
[Feeder cooling confirmation] → IN1 or IN97
Fig. 7.4 Electrical connection diagram (For NV6S / NV20 type) (2/2)
－69－
Instruction Manual for AC Servo Pull Feeder
AFAPS-2503/L-11707/L-11743
No.3L11804-E-1 May. ,2017 1st edition 1st copy

No.3L11804-E-2 Feb. ,2018 2nd edition 1st copy
No.3L11804-E-3 Mar. ,2018 3rd edition 1st copy
DAIHEN Corporation
4-1, Koyocho-nishi, Higashinada-ku, Kobe, Hyogo 658-0033, Japan
Phone: +81-78-275-2006, Fax: +81-78-845-8159
DAIHEN Inc.
1400 Blauser Drive Tipp City, Ohio 45371, USA
Phone: +1-937-667-0800, Fax: +1-937-667-0885
OTC DAIHEN EUROPE GmbH

Krefelder Strasse 677, D-41066 Mönchengladbach, Germany
Phone: +49-2161-6949710, Fax: +49-2161-6949711
OTC Industrial (Shanghai) Co.,Ltd.

6F, Building B,ORIENTO Plaza, 388 North Fuquan Road,
Changning District,Shanghai, China 200335
Phone: +86-21-5882-8633, Fax: +86-21-5882-8846
OTC (Taiwan) Co.,Ltd.

2F No.153, Huanbei Rd., Chung Li City, Taoyuan Hsien, Taiwan
Phone: +886-3-461-3962, Fax: +886-3-434-2394
OTC DAIHEN Asia Co.,Ltd.

23/43, 16th F1.Sorachai Building, 23 Soi 63 Sukhumvit Road,
Klongtonnua, Wattana, Bangkok 10110, Thailand
Phone: +66-2-714-3201, Fax: +66-2-714-3204
OTC DAIHEN INDIA Pvt.Ltd.

V. M. TOWER, Plot No. 54A, Ground Floor Unit-1,
Sector-18, Gurgaon-122015 Haryana, India
Phone:+91 124-4239368, Fax:+91 124-4239364
PT.OTC DAIHEN INDONESIA

Blok G1A-20, Jl. Kenari ll, Dalta Silicon V,
Lippo Cikarang Industrial Park, Bekasi 17550 Indonesia
Phone:+6221-2957-7566, Fax:+6221-2957-7567
DAIHEN Korea Co., Ltd.

85, Hyeongoksandan-ro, Cheongbuk-myeon, Pyeongtaek-city, Gyeonggi-do, Korea.
Phone: +82-31-686-7445, Fax: +82-31-686-7464
Upon contact, advise MODEL and MANUAL NO.

160727

3L11804-E-3 AC Servo Pull Feeder

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

3L11804-E-3 AC Servo Pull Feeder

Uploaded by

Copyright:

Available Formats

For MIG AC Servo Pull Feeder

Thoroughly read this Contents

Symbol Signal Description

Mishandling may cause seriously dangerous

Mishandling may cause a dangerous situation that

Mishandling may cause a dangerous situation that

Material damage ： Damage to property, and direct and incidental / consequential

Ref.: IMPORTANT : The sign “IMPORTANT” indicates special instructions

● Observe the following notices to prevent a serious

2.2 Observe the following to prevent electric shock.

WARNING ● Do not touch live electrical parts.

● Touching live electrical parts can cause fatal shock or severe

● Install a lightproof wall where arc is generated.

● Arc rays may cause inflammation of eyes and burns on skin

● DO NOT inhale fumes and gases generated by welding.

● Fumes and gases generated by welding have a harmful effect

1) KEEP YOUR HEAD out of fumes and DO NOT inhale any.

PRINCIPAL SAFETY STANDARDS

Safety and Health Standards, OSHA 29 CFR 1910, from Superintendent of

Recommended Practices for Plasma Arc Cutting, American Welding Society

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, from

Rated duty cycle

CAUTION ●To prevent burns, comply with the following cautions.

●Do not disassemble the shock sensor. If disassembled, gas leak

3.4 Cable hose

3.5 Shock sensor

● Do not alter or remodel our products.

1.1 AC servo pull feeder

Air flow (Note 6) 50 L/min (1.77 cfm) or more

Table1.2 List of adapter for pull feeder

1.3 Applicable torch

Table1.3 List of applicable torch

Table1.4 Specifications of welding torch

Table1.6 Synchro feed welding components (For NB6)

Table1.8 Synchro feed welding components (For NV8 / NV25)

○ Wire feeding independent from robot motion

1.5 Prepared by Users

This set is required when using the product with a rated

Be sure to keep the air dry by installing equipment such as a

Fig.1.4 Outline drawing of the AC servo pull feeder

Insulating flange ···································································· 1 piece

Table 2.3 List of Applicable manipulator

L-11702G NV6S / NV8 / NV20A / NV20S / NV25

Fig.2.4 Checking the contents of package (High duty cycle kit)

L-11799 NV6S / NV8 / NV20A / NV20S / NV25

Air solenoid valve assembly ············································ 1 piese

Air solenoid valve assembly ············································ 1 piese

Mounting bolt (M8x12) ················································ 2 pieces

Insulating flange Power shaft

AC servo pull feeder

Power shaft Hexagon socket head screw

Lock nut Insulating flange

AC servo pull feeder

2.2.3 Installing of the power shaft

＜Power shaft (L11609C10)＞

Lock nut contact

③ Tighten the power shaft to the housing until it no longer turns.

④Tighten the lock nut with specified torque.

Lock nut Tightening torque ：30 N・m

Bracket Hexagon socket head cap screw

Tightening torque：3.0 N・m

Power cable cover

AC servo pull feeder

Hexagon socket head cap screw