ESAB RT Robo Welding Torch System User manual

Type
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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© ESAB AB 2015
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 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. ± 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
contact us for a detailed
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
2.35 kg
1.0 m long:
2.0 kg
2.0 kg
1.0 m long:
2.0 kg
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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