RT Robo Welding Torch Systems Instruction manual 0463 373 101 GB 20151222
TABLE OF CONTENTS 1 SAFETY ................................................................................................................ 5 2 WARRANTY.......................................................................................................... 7 2.1 3 INTRODUCTION ................................................................................................... 8 3.1 4 Conditions of intended use .................................................................................
TABLE OF CONTENTS 5.7 Connecting to the wire feeder...........................................................................33 5.7.1 Standard RT system ........................................................................................ 33 5.7.2 Hollow wrist system.......................................................................................... 34 5.7.2.1 Feeding through the robot arm....................................................................... 34 5.7.2.
1 SAFETY 1 SAFETY Users of ESAB equipment have the ultimate responsibility for ensuring that anyone who works on or near the equipment observes all the relevant safety precautions. Safety precautions must meet the requirements that apply to this type of equipment. The following recommendations should be observed in addition to the standard regulations that apply to the workplace. All work must be carried out by trained personnel well-acquainted with the operation of the equipment.
1 SAFETY WARNING! Arc welding and cutting can be injurious to yourself and others. Take precautions when welding and cutting. Ask for your employer's safety practices which should be based on manufacturers' hazard data.
2 WARRANTY 2 WARRANTY Before delivery, our products are carefully checked. ESAB verify that each product is free from defects of material and workmanship at the time of delivery and is functioning according to its intended use. ESAB provides warranty on defects of material and workmanship according to legal requirements. Consumables are exempt from this warranty.
3 INTRODUCTION 3 INTRODUCTION The RT welding torch systems are developed for fully automatic MIG/MAG welding using robots. The systems consist of a variety of Aristo RT torch necks designed for robotic use, torch mounts, cable assemblies optimized for robotic use, and safety-off features to prevent the system from damage in case of collision. The standard RT welding system provides collision protection through the use of KS-2 that is a mechanical spring-loaded safety-off functionality.
3 INTRODUCTION Hollow wrist system For a detailed description refer to the corresponding section in the TECHNICAL DATA chapter: 1. Torch See "Welding torch". 2. Torch mount KSC-2 See "KSC-2 torch mount with safety-off mechanism". 3. Torch mount FLC-2 See "FLC-2 rigid torch mount". 4. Adapter flange See "Adapter flanges". 5. Cable assembly Helix or Infiniturn See "Cable assemblies for hollow wrist systems".
4 TECHNICAL DATA 4 TECHNICAL DATA 4.1 Welding torch The torch model has to be chosen according to the welding application. The required duty-cycle and capacity, the cooling method, and the wire diameter must be considered. If there are increased requirements, for example caused by preheated work pieces, high heat reflection in corners, etc, these must be taken into account by selecting a welding torch with adequate reserve in power rating.
4 TECHNICAL DATA Min. water flow rate: 1.0 l/min / 1.1 quarts/min Min. water pressure: 2.5 bar / 36.3 PSI Max. water pressure: 3.5 bar / 50.8 PSI Inlet temperature: Max. 40 °C / 104 °F Return temperature: Max. 60 °C / 140 °F Cooling capacity: Min. 1000 W, depending on application CAUTION! Return temperatures above 60 °C / 140 °F may cause damage or destroy the cable assembly. 4.
4 TECHNICAL DATA 4.2.1.1 KS-2 safety-off mechanism The KS-2 safety mechanism is a spring supported devise that protects the robot and the torch system in case of a collision. 4.2.1.2 FL-1 intermediate flange The rigid intermediate flange FL-1 can be used instead of the KS-2 if the robot has an electronic collision detection system. 4.2.2 Torch mounts for hollow wrist system In the hollow wrist system the Aristo RT welding torches are connected via a quick change system to the torch mount.
4 TECHNICAL DATA For hollow wrist systems KSC-2W (alternatively FLC-2W) is recommended. This torch mount can be used with both gas-cooled and water-cooled torches of the Aristo RT series.
4 TECHNICAL DATA Electrical control circuit for nozzle sense function Rating: • For Helix cable assemblies: max. 50 V DC / 5 A, max. 1 minute After detection of contact, the sensing voltage should be disconnected quickly. • For Infiniturn cable assemblies, the nozzle sense function has limited functionality. Please contact us for a detailed investigation of possible solutions in your application. Voltage rating The maximum permitted voltage for the safety off control circuit is 48 V. 4.2.2.
4 TECHNICAL DATA Item Description Function 5 Adaptor flange Isolating interface to the robot wrist, must be selected to fit on the specific robot 6 Index pin For precise alignment to the adaptor flange 7 Connector for control cable Electrical connection for collision signal and nozzle sense function 8 Micro switch Sensor for collision detection 4.2.2.
4 TECHNICAL DATA 4.4 Cable assemblies The connection to the wire feeder is effected by the cable assembly, the available versions mainly depending on system design and cooling media (gas or water), see the spare parts list. The ratings are valid for cable lengths from 1 to 5 m. Standard cable assembly Infiniturn Helix Rating (10 min. cycle) • Gas cooled (mixed • gas) • Water cooled • Max. 500 A / 60 % • duty cycle Max. 350 A / 100 % duty cycle Max. 600 A / 100 • % duty cycle Max.
4 TECHNICAL DATA Item Description Function 8 Water return (red cap) Water return of heated water from the torch 9 Control cable plug for safety-off mechanism Electrical connection with the KS-2 for the safety-off signal and nozzle sense function (if applicable) 4.4.2 Cable assemblies for hollow wrist systems The Infiniturn cable assembly allows for endless rotation of the torch in both directions.
4 TECHNICAL DATA Item Description Function 8 Blow out hose (black cap) For cleaning the torch with compressed air after welding 9 Media coupling Endlessly rotatable coupling with media transfer 10 Protective cover Protects the cable assembly from damage 0463 373 101 - 18 - © ESAB AB 2015
5 INSTALLATION 5 INSTALLATION 5.1 Preparation WARNING! For your own safety, make sure that the robot is either in standby or power-less state before doing maintenance work in the moving radius of the robot. The following assembly instructions must be exactly adhered to. Attention is to be paid during assembly that the cables are not damaged. This can lead to a short circuit, which may damage the electronics of the robot or the welding torch.
5 INSTALLATION 5.3.1 Torch mount in standard RT system 5.3.1.1 Direct mounting of KS-2 1. If necessary, carefully press the cylindrical pins (1) into the corresponding holes in the bracket. Avoid the formation of burrs. The pins should protrude by approximately 5 mm (0.2 inch). 2. Position the mount on the safety-off mechanism KS-2 and carefully insert the cylindrical pins (1) into the holes provided. In doing so, take the later position of the torch into account.
5 INSTALLATION 1. Cylindrical pins Ø4×14 2. Cylinder screw with hexagon socket M6×16 3. Washer Ø9 mm 4. Axial cylinder screw with hexagon socket M8×16 Top view 5. Place the torch mount (5) onto the journal (6) of the mounting flange, paying attention while doing so to the exact alignment of the feather key (7) and the corresponding groove (7a). 6.
5 INSTALLATION 8. Finally, screw the axial cylinder screw (4) with the Ø9 mm washer (3) into the mounting flange and tighten firmly. 3. Washer Ø9 mm 4. Axial cylinder screw with hexagon socket M8×16 5. Torch mount 6. Mounting flange journal 7. Feather key; 7a. Groove for feather key 8. Clamping mandrel 9. Mating surface of mounting flange; 9a. Mating surfaces of clamping mandrel 10. Cylinder screw with hexagon socket M6×30 11. Washer Ø22×6.4 mm 5.3.2 Torch mount in hollow wrist system 5.3.2.
5 INSTALLATION 1. 2. 3. 4. 5. Hexagon wrench 4 mm 3× M5×12 screws KSC-2 front cover Rubber boot KSC-2 main body Pull off the rubber boot (4) from the main body (5) to the front. Now position the main body (5) on the adapter flange (7) so that the index pin is correctly seated. Attach with the screws (6) enclosed. Fastening torque max. 2.2 Nm (19.5 lbf in). Reinstall the rubber boot (4) on the KSC-2 main body (5) and make sure it is correctly located in the grooves on the front and back flange. 1.
5 INSTALLATION 1. 2. 3. 4. Hexagon wrench 4 mm 3× M5×12 screws FLC-2 front cover FLC-2 main body Now position the FLC-2 main body (4) on the adapter flange (6) so that the index pin is correctly seated. Attach with the screws (5) enclosed. Fastening torque max. 2.2 Nm (19.5 lbf in). 1. Hexagon wrench 4 mm 4. FLC-2 main body 5. 3× M5×12 hexagon socket screws 6. Adapter flange 5.4 Installing the cable assembly The cable assembly must be aligned to the intended use in length and design.
5 INSTALLATION CAUTION! • Coordinate the length and design of the cable assembly to suit the range of action of the robot. • Do not bend, compress or overstretch the cable assembly. • Fix the cable assembly such that is can be moved freely and cannot become entangled. • Any additional holding devices possibly installed, for example a balancer, must not crush or bend the cable assembly. • Extreme turning movements must be avoided in which the cable assembly may become twisted.
5 INSTALLATION 5.4.2 Installing the cable assembly in a hollow wrist system In a hollow wrist system the recommended order of installation is to feed the cable assembly through the robot arm before connecting the cables to the torch mount, see description "Feeding through the robot arm" under section "Connecting to the wire feeder". When the cable assembly is correctly installed in the hollow wrist, continue the installation according to the procedure described below.
5 INSTALLATION 4. Insert the coupling (2) into the socket of the cover (1) as shown. Align the index pin (6) with the index hole (5) in the main body and insert completely. NOTE! Take great care that the position of the O-rings is not shifted by the index pin during the assembly. 1. KSC-2 / FLC-2 cover 2. Coupling 3. KSC-2 / FLC-2 main body 4. 3× O-ring for water cooled systems; 4a. O-ring for gas cooled systems 5. Index hole 6. Index pin 7. 3× M5×35 screws 11. Control cable connector 5.
5 INSTALLATION 6. If present insert the control cable plug (10) into the connector (11) and make sure it is firmly seated. 7. 3× M5×35 screw 8. Washer 10. Control cable plug 11. Control cable connector 12. 2× Micro switch 13. Index pin 7. Gently push back the cable assembly into the robot arm and carefully seat the KSC-2 or FLC-2 cover (1) in place. Observe the index pin (13) to be in the correct position. Make sure the two micro switches (12) are not damaged if present. 8.
5 INSTALLATION 5.5 Installing the wire guide Choose the wire guide or liner depending on the filler wire material and diameter to be used, see the spare parts list. Accurate performance of the system can only be guaranteed when using original ESAB wire guides. The recommended wire guide is the split wire guide, which consists of the neck liner and a separate guide in the cable assembly.
5 INSTALLATION 7. Insert the neck liner again. It will be stopped by the contact tip. Measure the excess liner sticking out of the neck. 8. Remove the liner again and shorten the front end by the measured length. Carefully deburr the edge and make sure that the inner hole is not blocked. 9. Reinstall the neck liner and tighten the guide nipple in the neck. 5.5.
5 INSTALLATION 5. Remove the wire guide again and shorten the front end by the measured length. Steel liner: grind down the burred edges if needed. Plastic liner: make a clean cut and chamfer the edges (e.g. with a pencil sharpener) NOTE! Make sure the inner opening of the liner is not obstructed by the cut wire end. 6. Reinstall the wire guide and attach the sleeve nut (2).
5 INSTALLATION 1. 2. 3. 4. 5. Torch neck Tip holder Gas diffuser Contact tip Gas nozzle 5.6.2 Aristo RT torch installation NOTE! Check the O-rings on the flange of the torch neck before mounting. Replace the O-rings if damaged or lost. Missing or faulty O-rings will lead to leaks of shielding gas and coolant. 1.
5 INSTALLATION 3. The correct seating of the torch can be checked by means of the window (1). If the torch has been correctly mounted, no gap should be seen through the window (1). 5.7 Connecting to the wire feeder 5.7.1 Standard RT system In order to be able to create the connection, the cable assembly must be mounted as described in the "Installing the cable assembly" section and equipped following "Installing the wire guide" section. Only then can the central and media connection take place.
5 INSTALLATION 1. Connect the central connector of the cable assembly (2) to the wire feeder cabinet socket. Tighten the central connector sleeve nut fingertight. Do not use tools! 1. Control cable 5. Return of heated water (red cap) 2. EURO central connector 6. Main drive / feeder 3. Air blow-out 7. Water cooling system 4. Cooling water (blue cap) 2. Connect the water hoses to the cooling circuit (7) in water cooled systems.
5 INSTALLATION 3. Insert the cable assembly with the coupling (2) first into the robot arm and feed it through the robot wrist. 4. The feeder should only be installed again after the correct mounting position with respect to the cable length has been determined. (See section "Installing the cable assembly"). CAUTION! Important! Axis 6 must be in 0° position. 5.7.2.
5 INSTALLATION 1. Loosen the sliding mechanism of the wire feeder and connect the cable assembly. Refer to the instruction of the feeder manufacturer. 2. Now adjust the position of the wire feeder to suit the length of the Infiniturn or Helix cable, as indicated with "A" in the illustration below. CAUTION! When adjusting the position of the feeder cabinet, make sure that the cable assembly is not under stress when the robot arm is in stretched-out position.
5 INSTALLATION 5. Connect the blow-out hose (black rubber cap) to the corresponding outlet of the wire feeder. NOTE! If the blow-out function is not used, the blow-out hose must be sealed with the rubber cap enclosed. With Infiniturn systems, the blow-out air must be supplied to the corresponding connection hose, if it is not permitted to connect blow-out air to the shield gas connection! 6.
5 INSTALLATION 5.8.1.2 Connecting the nozzle sense function If the robot control provides a control circuit for nozzle sense functionality, this can be applied for both KS-2 and FL-1. The connection is accomplished with a 1-wire connection, see (8) in the previous illustration. Rating of the control circuit: max 50 V / 5 A. DANGER! If the nozzle sense function is not being used, the open end of the control cable on the power source connection side must be properly isolated in order to avoid short circuits.
5 INSTALLATION Usually, the control cable will be directly connected to the wire feeder. See the manufacturer's documentation for details. The link to the robot control is then implemented via the power source robot interface. Rating of the control circuit: max. 50 V / 5 A. DANGER! If the nozzle sense function is not being used, the open end of the control cable on the power source connection side must be properly isolated in order to avoid short circuits.
5 INSTALLATION 1. Control cable plug 4. Switch for KSC-2 safety-off mechanism (normally closed) 5. Power source / robot control 2. Control cable 3. EURO central connector 5.8.3.2 Connecting the nozzle sense function If the robot control provides a control circuit for nozzle sense functionality, this function can be implemented for both KSC-2 and FLC-2. The connection is accomplished with a 1-wire connection (green) to the nozzle sense circuit in the robot control (5), see illustration below.
5 INSTALLATION 1. Control cable plug 2. Control cable 4. Connection to FLC-2 or KSC-2 (by-passing the switch) 5. Power source / robot control with nozzle sense function 3.
6 OPERATION 6 OPERATION CAUTION! Before starting the system, check the whole installation according to the manufacturer's instructions and applicable safety regulations. Please check the following to make sure that the system has been installed correctly: 1. Are all parts securely attached (torch, torch mount, flanges, safety-off device, cable assembly, and wire feeder cabinet)? 2. Are all media hoses connected correctly and protected from damage? 3.
6 OPERATION CAUTION! While axis 5 is bent more than 60°, the rotational speed of the torch around axis 6 must be limited, see table above. Otherwise, the cable assembly may be damaged.
7 SERVICE AND MAINTENANCE 7 SERVICE AND MAINTENANCE WARNING! Before performing maintenance on the system, the main power of the installation must be turned off. Please note the safety regulations at the beginning of this manual. Damaged torches or cable assemblies must not be used any more! Known defects must be repaired by qualified personnel prior to the next use of the equipment. WARNING! Risk of burn injuries! Gas nozzle and torch head get very hot during welding.
7 SERVICE AND MAINTENANCE Weekly or as needed depending on use: • Remove the wire guide and check for wear and dirt deposits. Exchange if needed. Monthly or more often at heavy use (i.e. more than 8 hours/day): • • • Blow out the wire guide channel with compressed air (remove contact tip and wire guide). Make sure that all screws are tightened. Inspect all connections and hoses for damages.
8 TROUBLESHOOTING 8 TROUBLESHOOTING Fault Possible cause Action Cannot feed in the wire The welding wire has not been If necessary, pull the welding wire straightened before feeding into the out again, cut off and deburr the cable assembly end and straighten the first 10 cm of the wire. Then thread back into the cable assembly. The torch and the cable assembly are not equipped correctly for the wire diameter and wire material Check wire guide (cable assembly and torch neck) and the contact tip.
8 TROUBLESHOOTING Fault Possible cause Action Wire feed stops Wire spool is empty during welding Check the quantity of the welding wire on the spool in the wire feeder. Wire blockage in the cable assembly Check wire feed (possibly too fast), check the contact tip for contamination/clogging, clean or replace the contact tip if required. Wire burn back into the contact tip or worn contact tip. Replace the contact tip. Welding process is stopping Safety-off mechanism has triggered.
9 ORDERING SPARE PARTS 9 ORDERING SPARE PARTS CAUTION! Repair and electrical work should be performed by an authorised ESAB service technician. Use only ESAB original spare and wear parts. The ESAB RT torches, torch mounts, and cable assemblies are designed and tested in accordance with the international and European standards IEC-/ EN 60974-7. It is the obligation of the service unit which has carried out the service or repair work to make sure that the product still conforms to the said standard.
9 ORDERING SPARE PARTS 0463 373 101 - 49 - © ESAB AB 2015
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