ESAB RT Robo Welding Torch System User manual

Instruction manual

0463 373 101 GB 20151222

RT Robo Welding Torch

Systems

TABLE OF CONTENTS

0463 373 101 © ESAB AB 2015

1 SAFETY ................................................................................................................ 5

2 WARRANTY.......................................................................................................... 7

2.1 Conditions of intended use.................................................................................7

3 INTRODUCTION................................................................................................... 8

3.1 Overview welding torch systems .......................................................................8

4 TECHNICAL DATA ............................................................................................. 10

4.1 Welding torch ..................................................................................................... 10

4.1.1 Voltage rating ...................................................................................................10

4.1.2 Cooling circuit limits ......................................................................................... 10

4.2 Torch mount ....................................................................................................... 11

4.2.1 Torch mounts for standard RT system ............................................................. 11

4.2.1.1 KS-2 safety-off mechanism ............................................................................ 12

4.2.1.2 FL-1 intermediate flange ................................................................................ 12

4.2.2 Torch mounts for hollow wrist system ..............................................................12

4.2.2.1 KSC-2 torch mount with safety-off mechanism .............................................. 14

4.2.2.2 FLC-2 rigid torch mount ................................................................................. 15

4.3 Adaptor flanges..................................................................................................15

4.4 Cable assemblies ............................................................................................... 16

4.4.1 Cable assemblies for standard RT system .....................................................16

4.4.2 Cable assemblies for hollow wrist systems......................................................17

5 INSTALLATION................................................................................................... 19

5.1 Preparation ......................................................................................................... 19

5.2 Installing the adapter flange .............................................................................19

5.3 Installing the torch mount .................................................................................19

5.3.1 Torch mount in standard RT system ................................................................ 20

5.3.1.1 Direct mounting of KS-2 ................................................................................. 20

5.3.1.2 Mounting via mounting flange ....................................................................... 20

5.3.2 Torch mount in hollow wrist system.................................................................. 22

5.3.2.1 Mounting of KSC-2......................................................................................... 22

5.3.2.2 Mounting of FLC-2 ......................................................................................... 23

5.4 Installing the cable assembly ...........................................................................24

5.4.1 Installing the cable assembly in a standard RT system ...................................25

5.4.2 Installing the cable assembly in a hollow wrist system ....................................26

5.5 Installing the wire guide ....................................................................................29

5.5.1 Installing the neck liner..................................................................................... 29

5.5.2 Installing a split wire guide in the cable assembly............................................30

5.6 Installing the torch .............................................................................................31

5.6.1 Torch neck equipment ...................................................................................... 31

5.6.2 Aristo RT torch installation ............................................................................... 32

TABLE OF CONTENTS

0463 373 101 © ESAB AB 2015

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

5.7.2.2 Connections to the feeder cabinet ................................................................. 35

5.8 Electrical connections ....................................................................................... 37

5.8.1 Standard RT system ........................................................................................37

5.8.1.1 Connecting the safety-off mechanism KS-2................................................... 37

5.8.1.2 Connecting the nozzle sense function ........................................................... 38

5.8.2 Hollow wrist system with Infiniturn cable assembly.......................................... 38

5.8.2.1 Connecting the safety-off mechanism KSC-2 ................................................ 38

5.8.2.2 Connecting the nozzle sense function ........................................................... 38

5.8.3 Hollow wrist system with Helix cable assembly ...............................................39

5.8.3.1 Connecting the safety-off mechanism KSC-2 ................................................ 39

5.8.3.2 Connecting the nozzle sense function ........................................................... 40

6 OPERATION ....................................................................................................... 42

6.1 Important information for programming (hollow wrist system

only)................................................................................................................. 42

7 SERVICE AND MAINTENANCE ........................................................................ 44

7.1 Mandatory checks and actions.........................................................................44

8 TROUBLESHOOTING ........................................................................................ 46

9 ORDERING SPARE PARTS ............................................................................... 48

Rights reserved to alter specifications without notice.

1 SAFETY

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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. Incorrect operation of the equipment may lead to hazardous situations which can

result in injury to the operator and damage to the equipment.

1. Anyone who uses the equipment must be familiar with:

○ its operation

○ location of emergency stops

○ its function

○ relevant safety precautions

○ welding and cutting or other applicable operation of the equipment

2. The operator must ensure that:

○ no unauthorised person is stationed within the working area of the equipment when it

is started up

○ no-one is unprotected when the arc is struck or work is started with the equipment

3. The workplace must:

○ be suitable for the purpose

○ be free from drafts

4. Personal safety equipment:

○ Always wear recommended personal safety equipment, such as safety glasses,

flame-proof clothing, safety gloves

○ Do not wear loose-fitting items, such as scarves, bracelets, rings, etc., which could

become trapped or cause burns

5. General precautions:

○ Make sure the return cable is connected securely

○ Work on high voltage equipment may only be carried out by a qualified electrician

○ Appropriate fire extinguishing equipment must be clearly marked and close at hand

○ Lubrication and maintenance must not be carried out on the equipment during

operation

CAUTION!

Read and understand the instruction manual before

installing or operating.

1 SAFETY

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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.

ELECTRIC SHOCK - Can kill

• Install and earth the unit in accordance with applicable standards

• Do not touch live electrical parts or electrodes with bare skin, wet gloves or

wet clothing

• Insulate yourself from earth and the workpiece

• Ensure your working stance is safe

FUMES AND GASES - Can be dangerous to health

• Keep your head out of the fumes

• Use ventilation, extraction at the arc, or both, to take fumes and gases away

from your breathing zone and the general area

ARC RAYS - Can injure eyes and burn skin

• Protect your eyes and body. Use the correct welding screen and filter lens and

wear protective clothing

• Protect bystanders with suitable screens or curtains

FIRE HAZARD

• Sparks (spatter) can cause fire. Make sure therefore that there are no

inflammable materials nearby

NOISE - Excessive noise can damage hearing

• Protect your ears. Use earmuffs or other hearing protection.

• Warn bystanders of the risk

MALFUNCTION - Call for expert assistance in the event of malfunction.

Read and understand the instruction manual before installing or operating.

PROTECT YOURSELF AND OTHERS!

ESAB can provide you with all necessary welding protection and accessories.

2 WARRANTY

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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.

The warranty does not cover any damages or functional defects resulting from:

• overloading, abusing or diverting from intended use of the product

• collisions or accidents

• non compliance with instructions stated in these operating instructions

• improper installation or assembly

• insufficient maintenance

• modifying the product from its original state

• chemical influences

• normal wear and tear

ESAB assumes no liability other than for replacement or repair of faulty parts.

2.1 Conditions of intended use

1. The product is intended for industrial and commercial use and must only be utilized by

trained personnel. The manufacturer is not liable for any damage or accidents resulting

from improper usage.

2. The ESAB RT Robo welding system is designed and produced at the state of the art and

is safe and reliable in operation when handled, installed and maintained by trained

personnel. The instructions for installation, operation and maintenance described in this

document must be followed.

3. The ESAB RT Robo welding system may only be installed, operated and serviced by

trained personnel. The installation, operation, and maintenance regulations detailed in

this manual are to be followed.

4. The ESAB RT Robo welding system may solely be used for the purpose intended by the

manufacturer within the framework of its technical data and with automated handling

systems. The type of torch must be selected to suit the welding task.

5. The ESAB RT Robo welding system was designed for use as a complete system. The

incorporation of components from other manufacturers into the system is not permissible.

6. The torch mount KSC-2 is only to be used as an emergency stop mechanism within its

technical specifications and in combination with an Infiniturn or Helix cable assembly,

ESAB adapter flange and an Aristo RT welding torch.

7. No oil or anti-spatter fluid should be added to the blow-out gas. ESAB does not

guarantee chemical resistance to those substances. ESAB recommends using the ESAB

spraying unit to apply the minimum amount of anti-spatter fluid to the torch and therefore

protecting the environment.

8. The product must be kept dry and protected from humidity when transported, stored or

used.

9. The system is designed for environmental temperatures range from 5 °C to 40 °C (41 °F

to 104 °F). In case these limits are exceeded, specific action is needed. In case of frost

risk, use a suitable coolant.

3 INTRODUCTION

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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. This can optionally be replaced by FL-1 to

take advantage of the collision detection function of the robot control system. The standard

RT welding system can be used with a variety of cable assembly types.

KSC-2 and FLC-2 torch mounts with Infiniturn or Helix cable assemblies are intended for use

in hollow wrist robot welding systems designed for advanced welding applications. The

safety-off mechanism in the KSC-2 torch mount allows for large elastic deflection of the torch

in case of collision. The Infiniturn and Helix cable assemblies are light-weight and simple to

install, providing a highly reliable system with precise maneuvering capabilities.

In combination with the well established Aristo RT robot welding torches, these constituents

create a highly reliable and long lasting system which needs only a minimum of

maintenance.

Consumption wear parts and instruction manual are included on delivery of torch mounts and

cable assemblies.

The ESAB ordering numbers, available accessories, spare parts, and wear parts are

found in the Spare parts list.

3.1 Overview welding torch systems

Standard RT system

For a detailed description refer to the

corresponding section in the TECHNICAL

DATA chapter:

1. Torch

See "Welding torch".

2. Cable assembly

See "Cable assemblies for standard RT

system".

3. Torch mount

See "Torch mounts for standard RT

system".

4. KS-2 safety-off mechanism

See "KS-2 safety-off mechanism".

5. FL-1 intermediate flange

See "FL-1 intermediate flange".

6. Adapter flange

See "Adapter flanges".

3 INTRODUCTION

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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

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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.

The RT welding torches are intended for the use with CE-conform welding power sources for

the processes of metal inert gas welding (MIG), metal active gas welding (MAG) and metal

inert gas soldering with commercial round wires. Do not use the torch for other processes.

For aluminium welding the RT82W water cooled torch must be used.

See the spare parts list for available torch models.

Guiding method By machine only

Temperature ranges Storage -15° to 50°C (5° to 122°F)

Operation 5° to 40°C (41° to 104°F)

Blow-out gas Max. 10 bar, separate gas hose

Total weight with torch and 1 m cable

assembly

Approximately 5 kg

4.1.1 Voltage rating

Max. permitted voltage / amperage

Complete welding torch system 141 V (peak value for welding)

KS-2 safety-off control circuit

KS-2 push-button

24 V / 1 A

48 V / 0.1 A

KSC-2 safety off control circuit 48 V

Using nozzle sense functionality with a

standard cable assembly

50 V / 5 A

(Allowed load max. 1 minute at the rated

nominal current)

Using nozzle sense functionality with Helix or

Infiniturn cable assemblies

50 V / 5 A

(Allowed load max. 1 minute at the rated

nominal current)

For detailed information regarding the rating and technical specifications of your torch please

see the spare parts list included with the torch. The values for torch rating and duty cycle are

valid for a 10 min. cycle.

The indicated ratings refer to a standardized case of use. In special cases, e.g. in case of an

especially high heat reflection on the torch, the torch may overheat at lower currents than

indicated. In this case, please use a more powerful model or reduce the duty cycle.

The rating will be notably reduced with the use of pulsed arc power sources.

For cable assembly ratings, see section "Cable assemblies".

4.1.2 Cooling circuit limits

Valid for water cooled version only.

4 TECHNICAL DATA

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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.

4.2 Torch mount

The type of torch mount required depends on the RT welding torch system design and on the

choice of safety-off devices, see section "Overview welding torch systems" in the

INTRODUCTION chapter.

Component Approximate weight

Torch mount (for standard system) 0.43 kg

KS-2 safety-off mechanism (for standard

system)

0.85 kg

FL-1 intermediate flange (for standard

system)

0.35 kg

KSC-2 torch mount (for hollow wrist system) 1.90 kg

FLC-2 rigid torch mount (for hollow wrist

system)

1.22 kg

Robot welding torch 0.66 kg

4.2.1 Torch mounts for standard RT system

For standard RT systems the torch mount is installed on the KS-2 safety-off mechanism

(alternatively on the FL-1 intermediate flange), clamping the cable assembly and the

connected torch neck.

The torch mount must be selected in accordance with the type of torch and its geometry.

Various mount types may be used. See the spare parts list for available torch mounts for

standard RT system.

4 TECHNICAL DATA

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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.

The torch mount KSC-2 allows for elastic deflection of the torch in case of a collision. At the

same time, an electrical contact is opened, signalling the robot control to stop. After resetting

the error, the initial geometry and Tool Center Point (TCP) of the torch will be reached with

high precision. The system functions purely mechanically and is spring loaded.

The torch mount FLC-2 has no built-in safety-off function. It is a rigid mount that is connected

to the electronic collision detection system in the robot.

4 TECHNICAL DATA

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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.

KSC-2 FLC-2

Functional principle of the

safety-off mechanism

Mechanical Not applicable (rigid mount)

Axial release force (Fz) 650 N Not applicable (rigid mount)

Release torque on transverse

axis (Mx)

24 Nm Not applicable (rigid mount)

Reset after release Automatic Not applicable (rigid mount)

Repeatability Lateral ± 0.1 mm at the TCP

of a standard Aristo RT torch

Not applicable (rigid mount)

Max. deflection Approx. ± 8° Not applicable (rigid mount)

Safety switch Normally closed

Electrical load max. 48 V / 1A

Not applicable (rigid mount)

4 TECHNICAL DATA

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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

investigation of possible

solutions in your

application.

Rating:

• For Helix cable

assemblies: max. 50 V DC

/ 5 A, max. 1 minute

• For Infiniturn cable

assemblies: max. 50 V DC

/ 1 A, max. 1 minute

After detection of contact, the

sensing voltage should be

disconnected quickly.

Voltage rating The maximum permitted

voltage for the safety off

control circuit is 48 V.

4.2.2.1 KSC-2 torch mount with safety-off mechanism

Item Description Function

1 Torch neck support Interface to Aristo RT torch

2 KSC-2 cover Assembly with interfaces to cable and torch

3 Rubber boot Protection for safety-off mechanism

4 KSC-2 main body Allows for mechanical deflection during a collision

4 TECHNICAL DATA

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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

4.2.2.2 FLC-2 rigid torch mount

Item Description Function

1 Torch neck support Interface to RoboMIG RT torch

2 FLC-2 cover Assembly with interfaces to cable and torch

3 FLC-2 main body Allows for mechanical deflection during a collision

4 Index pin For precise alignment to the adaptor flange

5 Adaptor flange Isolating interface to the robot wrist, must be

selected to fit on the specific robot

6 Connector for control cable

(3-pole)

Electrical connection of the nozzle sense function (if

applicable)

4.3 Adaptor flanges

The adaptor flange needed for installation on the robot arm must be chosen with regard of

the robot type. Adaptor flanges for all suitable standard and hollow wrist systems are

available, see the spare parts list.

4 TECHNICAL DATA

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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. 400 A / 60 %

duty cycle

Max. 330 A / 100

% duty cycle

• Max. 550 A / 100

% duty cycle



• Max. 400 A / 60 %

duty cycle

Max. 330 A / 100

% duty cycle

• Max. 550 A / 100

% duty cycle

Rotational range Not rotatable Endlessly rotatable ± 270° from neutral

position

Weight

• Gas cooled

• Water cooled

1.2 m long:

• 2.35 kg

1.0 m long:

• 2.0 kg

1.0 m long:

• 2.0 kg

4.4.1 Cable assemblies for standard RT system

Item Description Function

1 Neck support flange Interface to torch

2 Protective cover Protects the cable assembly from

damage

3 Control cable, 4-pole Electrical connection for safety-off

function (blue/black) and for push-button

(brown/white)

4 Connection for nozzle sense function

(optional)

5 EURO central connector Connection to the wire feeder

6 Blow-out hose (black cap) For cleaning the torch with cmpressed air

after welding

7 Water inlet (blue cap) Water inlet for cooling of the torch

4 TECHNICAL DATA

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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. At the

same time, cooling fluid, shield gas, blow out air, the welding power and the signal of the

safety-off mechanism are transferred.

The Helix cable assembly is designed for a rotational range of ±270° from the neutral

position and can be used for simple welding tasks that do not require endless rotation.

The Infiniturn cable assemblies are available in gas and water cooled versions, the Helix

cable assemblies can be universally used for gas or water cooled applications. A Helix cable

assembly operated with a gas cooled torch must not be connected to a water cooling

system.

Item Description Function

1 Flange Interface to the torch mount KSC-2 / FLC-2

2 Index pin Secures the correct orientation of the coupling

3 Control cable plug Electrical connection with the KSC-2 for the

safety-off signal and nozzle sense function (if

applicable)

4 EURO central connector Connection to the wire feeder

5 Control cable Electrical connection for the safety-off signal (from

KSC-2) and nozzle sense function (if applicable)

6 Water return (red cap) Water return of heated water from the torch

7 Water inlet (blue cap) Water inlet for cooling of the torch

4 TECHNICAL DATA

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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

5 INSTALLATION

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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.

Use only original ESAB components that have been specially developed for this purpose.

Only then can the correct functioning of the whole welding torch system be guaranteed.

Below, the different steps of installation are described in the preferred order, recommended

by ESAB.

CAUTION!

For hollow wrist systems make sure that the clear space around the robot is at

least Ø45 mm (1.8 inch) around the wrist and 50 mm (2.0 inch) near the wire

feeder.

5.2 Installing the adapter flange

1. Position the model-specific adapter flange (2) with the index pin on the robot arm and fix

it with the hexagon socket screws (1) included. The number and type of screws and

index pin may vary depending on the robot model.

NOTE!

Ensure that the index pin is located correctly! The maximum torque of 1.2 Nm

(10.5 lbf in) must be observed for the fastening of the adapter flange screws.

Prevent self-loosening of the screws by using suitable thread locking measures.

5.3 Installing the torch mount

The installation procedure of the torch mount depends on the design of the system together

with the choice of torch mount and safety-off mechanism.

Only torch mounts having a hole pattern coinciding with that of the mounting surface may be

attached.

5 INSTALLATION

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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. Two mounting positions may be potentially possible.

3. Then screw down the mount evenly using the enclosed cylinder screws with hexagon

socket (2).

NOTE!

The maximum tightening torque for the cylinder screw (2) is 6 Nm (53 lbf in)

and the property class category is 8.8.

Side view

1. Cylindrical pins Ø4×20

2. Cylinder screw with hexagon socket M6

DIN 912 (length of the screw depending

on the torch mount)

5.3.1.2 Mounting via mounting flange

Torch mounts with a central clamping assembly can only be fastened on the journal of the

mounting flange. For this, the mounting flange must be fastened first.

1. If applicable, carefully press the cylindrical pins (1) into the corresponding holes in the

mounting flange. Avoid the formation of burrs. The pins should protrude by

approximately 5 mm (0.2”).

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. Two mounting positions may be potentially possible.

3. Then screw down the mounting flange evenly using the enclosed cylinder screws with

hexagon socket (2).

NOTE!

The maximum tightening torque for the cylinder screw (2) is 7.1 Nm (62.8 lbf

in) and the property class category is 8.8.

4. Unscrew the axial cylinder screw with hexagon socket (4) out of the mounting flange

together with the washer (3).

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ESAB RT Robo Welding Torch System User manual

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