ESAB RT Robo Welding Torch System Instruction manual

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RT Robo Welding Torch System

RTKS-2, RTFL-2, KSC-2, FLC-2, RT42, RT52, RT62, RT72, RT82, RT42-NG, RT82WNG

Instruction manual

0463 373 101 US 20181227

SAFETY ....................................................................................................... 5

1.1 Meaning of symbols ............................................................................... 5

1.2 Safety precautions ................................................................................. 5

WARRANTY................................................................................................. 8

2.1 Conditions of intended use ................................................................... 8

INTRODUCTION.......................................................................................... 9

3.1 Overview of welding torch systems ..................................................... 9

TECHNICAL DATA ...................................................................................... 11

4.1 Welding torch neck ................................................................................ 11

4.2 Voltage rating.......................................................................................... 12

4.2.1 Cooling circuit limits.............................................................................. 12

4.3 Torch mount............................................................................................ 13

4.3.1 Torch mounts for standard RT system.................................................. 13

4.3.1.1 RTKS-2 safety-off mechanism.......................................................... 14

4.3.1.2 RTFL-2 intermediate flange .............................................................. 14

4.3.2 Torch mounts for hollow wrist system................................................... 14

4.3.2.1 RTKSC-2 G/W torch mount with safety-off mechanism ................... 16

4.3.2.2 RTFLC-2 G/W rigid torch mount ....................................................... 17

4.4 adapter flanges....................................................................................... 18

4.5 Cable assemblies ................................................................................... 18

4.5.1 Cable assemblies for standard RT system........................................... 18

4.5.2 Cable assemblies for hollow wrist systems .......................................... 19

INSTALLATION............................................................................................ 21

5.1 RTKS-2 standard arm installation........................................................ 21

5.1.1 RTKS-2 safety-off mechanism............................................................. 21

5.1.1.1 Torch installation with adjustable mount............................................ 22

5.1.2 Standard arm cable assembly for KS-2 and FL-2 ................................ 24

5.1.3 RTKS-2 wire feeder connection........................................................... 25

5.1.4 RTKS-2 electrical connections ............................................................ 26

5.1.4.1 RTKS-2 safety-off mechanism connection ....................................... 26

5.1.5 RTKS-2 Torch installation .................................................................... 27

5.2 RTFL-2 standard arm installation ........................................................ 28

5.2.1 RTFL-2 rigid mount.............................................................................. 28

5.2.2 RTFL-2 torch installation ..................................................................... 30

5.3 RTKSC-2 hollow wrist system installation.......................................... 30

5.3.1 RTKSC-2 mount with safety off mechanism ........................................ 30

5.3.2 Mounting the cable assembly ............................................................... 31

5.3.2.1 RTKSC-2 feeder cabinet connections .............................................. 32

5.3.3 RTKSC-2 cable assembly ................................................................... 34

5.3.3.1 RTKSC-2 cable assembly installation .............................................. 34

5.3.3.2 RTKSC-2 electrical connections ....................................................... 37

0463 373 101 © ESAB AB 2018

TABLE OF CONTENTS

5.3.4 RTKSC-2 torch installation .................................................................. 38

5.4 RTFLC-2 installation.............................................................................. 39

5.4.1 RTFLC-2 mount ................................................................................... 39

5.4.2 RTFLC-2 wire feeder connection......................................................... 39

5.4.2.1 Feeding through the robot arm .......................................................... 39

5.4.2.2 RTFLC-2 feeder cabinet connections ............................................... 40

5.4.3 RTFLC-2 cable assembly .................................................................... 42

5.4.3.1 RTFLC-2 cable assembly installation ............................................... 42

5.4.4 RTFLC-2 electrical connections .......................................................... 45

5.4.4.1 RTFLC-2 hollow wrist system with Infiniturn cable assembly........... 45

5.4.4.2 RTFLC-2 hollow wrist system with Helix cable assembly................. 46

5.5 Torch installation.................................................................................... 46

5.5.1 Torch neck equipment .......................................................................... 46

5.5.2 Aristo RT torch neck installation ........................................................... 47

5.6 Installing the wire guide for standard and hollow Wrist arm ............. 48

5.6.1 Installing the neck liner ......................................................................... 48

5.6.2 Installing a split wire guide in the cable assembly ................................ 49

5.6.3 Installing a continuous wire guide in the cable assembly ..................... 51

5.7 Adjust the narrow gap contact tip ........................................................ 52

OPERATION ................................................................................................ 55

6.1 Important information for programming (hollow wrist system only) 55

SERVICE AND MAINTENANCE ................................................................. 57

7.1 Mandatory checks and actions ............................................................. 57

TROUBLESHOOTING ................................................................................. 59

ORDERING SPARE PARTS ........................................................................ 61

Rights reserved to alter specifications without notice.

0463 373 101 © ESAB AB 2018

1 SAFETY

1.1 Meaning of symbols

As used throughout this manual: Means Attention! Be Alert!

DANGER! Means immediate hazards which, if not avoided, will result in immediate,

serious personal injury or loss of life.

WARNING! Means potential hazards which could result in personal injury or loss of life.

CAUTION! Means hazards which could result in minor personal injury.

WARNING!

Before use, read and understand the instruction manual and follow all labels, employer's safety practices and Safety Data Sheets (SDSs).

1.2 Safety precautions

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

1. Anyone who uses the equipment must be familiar with: ○ its operation ○ the location of emergency stops ○ its function ○ the relevant safety precautions ○ welding and cutting or other applicable operation of the equipment

2. The operator must ensure that: ○ no unauthorized person is 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

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1 SAFETY

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

WARNING!

Arc welding and cutting may cause injury to yourself and others. Take precautions when welding and cutting.

ELECTRIC SHOCK - Can kill

• Install and ground the unit in accordance with instruction manual.

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

• Insulate yourself from work and ground.

• Ensure your working position is safe

ELECTRIC AND MAGNETIC FIELDS - Pose health risks

• Welders with pacemakers fitted should consult their doctor before welding. EMF may interfere with some pacemakers.

• Exposure to EMF may have other health effects which are unknown.

• Welders should use the following procedures to minimize exposure to EMF:

○ Route the electrode and work cables together on the same side of

your body. Secure them with tape when possible. Do not place your body between the torch and work cables. Never coil the torch or work cable around your body. Keep the welding power source and cables as far away from your body as possible.

○ Connect the work cable to the workpiece as close as possible to the

area being welded.

FUMES AND GASES - Can be dangerous to your 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.

0463 373 101

NOISE - Excessive noise can damage hearing

Protect your ears. Use ear defenders or other hearing protection.

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1 SAFETY

MOVING PARTS - Can cause injuries

• Keep all doors, panels and covers closed and securely in place. Have only qualified people remove covers for maintenance and troubleshooting as necessary. Reinstall panels or covers and close doors when service is finished and before starting engine.

• Stop engine before installing or connecting unit.

• Keep hands, hair, loose clothing and tools away from moving parts.

FIRE HAZARD

• Sparks (spatter) can cause a fire. Make sure there are no inflammable materials nearby.

• Do not use on closed containers.

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

PROTECT YOURSELF AND OTHERS!

CAUTION!

This product is solely intended for arc welding.

WARNING!

Do not use the power source for thawing frozen pipes.

CAUTION!

Class A equipment is not intended for use in residential locations where the electrical power is provided by the public low-voltage supply system. There may be potential difficulties in ensuring electromagnetic compatibility of class A equipment in such locations, due to conducted as well as radiated disturbances.

NOTE! Dispose of electronic equipment at a recycling

facility!

To conform with the European Directive 2012/19/EC on Waste Electrical and Electronic Equipment and its implementation in accordance with national law, electrical and/or electronic equipment that has reached the end of its life must be disposed of at a recycling facility.

As the person responsible for the equipment, it is your responsibility to obtain information on approved collection stations.

For further information contact the nearest ESAB dealer.

ESAB has an assortment of welding accessories and personal protection equipment for purchase. For ordering information, contact your local ESAB dealer or visit us on our website.

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2 WARRANTY

Before delivery, our products are carefully checked. ESAB verifies 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 Aristo® RT Robotic 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 Aristo® RT Robotic 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 Aristo® RT Robotic 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 Aristo® RT Robotic 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 RT KS-2 and RT KSC-2 are only to be used as emergency stop mechanisms within their technical specifications and in combination with a RT standard arm cable assembly (KS-2), Infiniturn or Helix (KSC-2), ESAB adapter flange, including RT torch mounts (KS-2) 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 protect 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 ranging 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.

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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 RTKS-2 which is a mechanical spring-loaded safety-off functionality. This can optionally be replaced by RTFL-2 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.

RTKSC-2 and RT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 RTKSC-2 torch mount allows for large elastic deflection of the torch in case of collision. The Infiniturn and Helix cable assemblies are 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.

The instruction manual is 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 of welding torch systems

Standard RT system

For a detailed description refer to the corresponding section in the TECHNICAL DATA chapter:

1. Torch neck See "Welding torch".

2. Cable assembly See "Cable assemblies for standard RT system".

3. Torch mount See "Torch mounts for standard RT system".

4. RTKS-2 safety-off mechanism See "RTKS-2 safety-off mechanism".

5. RTFL-2 intermediate flange See "RTFL-2 intermediate flange".

6. Adapter flange (if required) See "Adapter flanges".

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3 INTRODUCTION

Hollow wrist system

For a detailed description refer to the corresponding section in the TECHNICAL DATA chapter:

1. Torch neck See "Welding torch".

2. Torch mount RTKSC-2 See "RTKSC-2 torch mount with safety-off mechanism".

3. Torch mount RTFLC-2 See "RTFLC-2 rigid torch mount".

4. Adapter flange See "Adapter flanges".

5. Cable assembly Helix or Infiniturn See "Cable assemblies for hollow wrist systems".

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4 TECHNICAL DATA

4.1 Welding torch neck

Choose your torch model 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 or high heat reflection in corners, take these into account by selecting a welding torch with adequate reserve in its power rating.

RT welding torches are intended for the use with CE-conformant welding power sources for the processes of Metal Inert Gas welding (MIG), Metal Active Gas welding (MAG) and MIG Brazing with commercial round wires. Do not use the torch for other processes.

For pulsed arc welding of steel or aluminum welding, the RT82W water cooled torch must be used.

See the available torch models below.

Torch model Cooling method Shielding gas Rating

RT42G Gas cooled CO

Gas cooled 300A / 100%

Gas cooled Mix 350A / 60%

Gas cooled 250A / 100%

RT42W Water cooled CO

Water cooled 420A / 100%

Water cooled Mix 350A / 60%

Water cooled 350A / 100%

RT52G Gas cooled CO

Gas cooled 300A / 100%

Gas cooled Mix 350A / 60%

Gas cooled 250A / 100%

RT52W Water cooled CO

Water cooled 470A / 100%

Water cooled Mix 400A / 60%

Water cooled 400A / 100%

RT62G Gas cooled CO

Gas cooled 340A / 100%

420A / 60%

470A / 60%

500A / 60%

Gas cooled Mix 420A / 60%

Gas cooled 290A / 100%

RT62W Water cooled CO

Water cooled 530A / 100%

Water cooled Mix 450A / 60%

Water cooled 450A / 100%

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530A / 60%

4 TECHNICAL DATA

Torch model Cooling method Shielding gas Rating

RT72G Gas cooled CO

480A /60%

Gas cooled 320A / 100%

Gas cooled Mix 400A / 60%

Gas cooled 270A / 100%

RT72W Water cooled CO

480A / 60%

Water cooled 430A / 100%

Water cooled Mix 480A / 60%

Water cooled 430A / 100%

RT82W Water cooled CO

600A / 60%

Water cooled 600A / 100%

Water cooled Mix 550A / 60%

Water cooled 550A / 100%

The values for torch rating and duty cycle are valid for a ten-minute cycle.

The technical data is valid for a standardized application utilizing the standard wear/spare parts. The torch rating is reduced when using pulsed arc metal transfer mode.

Temperature ranges Storage: -15–50°C (5–122°F)

Operation: 5–40°C (41–104°F)

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

Total weight (torch neck, safety-off

Approximately 5 kg mechanism, torch mount and 1-m cable assembly)

4.2 Voltage rating

Max. permitted voltage / amperage

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

RTKS-2 safety-off control circuit

RTKS-2 push-button

RT KSC-2 safety off control circuit 48 V

Using nozzle sense functionality with a standard cable assembly

Using nozzle sense functionality with Helix or Infiniturn cable assemblies

24 V / 1 A

48 V / 0.1 A

50 V / 5 A

(Allowed load max. 1 minute at the rated

nominal current)

50 V / 5 A

(Allowed load max. 1 minute at the rated

nominal current)

The indicated ratings refer to a standardized case of use.

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

4.2.1 Cooling circuit limits

Valid for water cooled version only.

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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.

4.3 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 the section "Overview welding torch systems".

Component Approximate weight

Torch mount (for standard system) 1102.3lb (0.43 kg)

RTKS-2 safety-off mechanism (for standard

1102.3lb (0.85 kg)

system)

RTFL-2 intermediate flange (for standard

1102.3lb (0.35 kg)

system)

RTKSC-2 torch mount (for hollow wrist

1102.3lb (1.90 kg)

system)

RTFLC-2 rigid torch mount (for hollow wrist

1102.3lb (1.22 kg)

system)

Robot welding torch 1102.3lb (0.66 kg)

4.3.1 Torch mounts for standard RT system

For standard RT systems the torch mount is installed on the RTKS-2 safety-off mechanism (alternatively on the RTFL-2 intermediate flange), clamping the cable assembly and the connected torch neck.

Select the torch mount 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.

Torch mount for standard arm robots

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4 TECHNICAL DATA

4.3.1.1 RTKS-2 safety-off mechanism

The RTKS-2 safety mechanism is a spring supported device that protects the robot and the torch system in case of a collision.

NOTE!

Do not disassemble the RTKS-2.

4.3.1.2 RTFL-2 intermediate flange

The rigid intermediate flange RTFL-2 can be used instead of the RTKS-2 if the robot has an electronic collision detection system.

4.3.2 Torch mounts for hollow wrist system

In the hollow wrist system the Aristo RT welding torch necks are connected to the torch mount KSC-2 or FLC-2.

The torch mount RTKSC-2 allows for elastic deflection of the torch in case of a collision. At the same time, an electrical contact is opened, signaling 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 RTFLC-2 has no built-in safety-off function.

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4 TECHNICAL DATA

For hollow wrist systems RTKSC-2 G/W (alternatively RTFLC-2 G/W) is recommended. This torch mount can be used with both gas-cooled and water-cooled torches in the Aristo RT series.

RTKSC-2 G/W RTFLC-2 G/W

Functional principle of the

Mechanical Not applicable (rigid mount)

safety-off mechanism

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

Release torque on transverse

669lb-ft (24 Nm) Not applicable (rigid mount)

axis (Mx)

Reset after release Automatic Not applicable (rigid mount)

Repeatability Lateral ± 0.1 mm at the TCP

Not applicable (rigid mount)

of a standard Aristo RT torch

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

Safety switch Normally closed

Not applicable (rigid mount)

Electrical load max. 48 V / 1A

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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, quickly disconnect the sensing voltage.

• For Infiniturn cable assemblies, the nozzle

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, quickly disconnect the

sensing voltage. sense function has limited functionality. Contact ESAB for a detailed investigation of possible solutions in your application.

Voltage rating Maximum permitted voltage

for the safety off control circuit: 48 V.

4.3.2.1 RTKSC-2 G/W torch mount with safety-off mechanism

Item Description Function

1 Torch neck support Aristo RT torch interface

2 RTKSC-2 cover Assembly with cable and torch interfaces

58.3/3Rubber boot Protection for safety-off mechanism

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4 TECHNICAL DATA

Item Description Function

58.3/4RTKSC-2 main body Allows for mechanical deflection during a collision

58.3/5Adapter flange Isolating interface to robot wrist (must fit the specific robot)

58.3/6Index pin For precise alignment to the adapter flange

58.3/7Connector for control cable Electrical connection for collision signal and nozzle sense function

58.3/8Micro switch Sensor for collision detection

4.3.2.2 RTFLC-2 G/W rigid torch mount

Item Description Function

1 Torch neck support Aristo RT torch interface

2 RTFLC-2 cover Assembly with cable and torch interfaces

58.3/3RTFLC-2 main body Allows for mechanical deflection during a collision

58.3/4Index pin For precise alignment to the adapter flange

58.3/5Adapter flange Isolating interface to robot wrist (must fit the specific

robot)

58.3/6Connector for control cable

(3-pole)

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Electrical connection for the nozzle sense function (if applicable)

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4 TECHNICAL DATA

4.4 adapter flanges

Choose the adapter flange required for installation on the robot arm depending on the robot type. Adapter flanges for all suitable standard and hollow wrist systems are available. See the spare parts list.

4.5 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

Infiniturn Helix

assembly

Rating (10 min. cycle)

Gas cooled (mixed gas)

Rating (10 min. cycle)

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. 320 A / 100 % duty cycle

Max. 550 A / 100 % duty cycle

Max. 400 A / 60 % duty cycle

Max. 320 A / 100 % duty cycle

Max. 550 A / 100 % duty cycle

Rotational range Limited rotatability Endlessly rotatable ± 270° from neutral

position

Weight

Gas cooled

Weight

Water cooled

1.2 m long:

1102.3lb (2.35 kg)

1.2 m long:

1102.3lb (2.35 kg)

1.0 m long:

1102.3lb (2.0 kg)

1.0 m long:

1102.3lb (2.0 kg)

1.0 m long:

1102.3lb (2.0 kg)

1.0 m long:

1102.3lb (2.0 kg)

4.5.1 Cable assemblies for standard RT system

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4 TECHNICAL DATA

Burndy connector pins

A. Touch sense Gas Nozzle

C. Collision sensor

D. Collision sensor

F. 0V

G. + Motor voltage

H. - Motor voltage

E. Inching

Item Description Function

1 Neck support flange Torch interface

2 Protective cover Protects cable assembly from damage

58.3/3Burndy connector, 12-pole Electrical connection between safety-off and wire

feeder

58.3/4Control cable For KS-2 (safety-off and push button)

58.3/5EURO connector Wire feeder connection

58.3/6Blow-out hose (black cap) For cleaning the torch with compressed air after

cleaning cycle

58.3/7Water inlet (blue cap)

Water inlet for torch cooling

58.3/8Water return (red cap)

58.3/9Control cable plug for safety-off

mechanism

Only water cooled torch systems

Water return of heated water from the torch

Electrical connection with RTKS-2 for the safety-off signal and nozzle sense function

4.5.2 Cable assemblies for hollow wrist systems

The Infiniturn cable assembly allows endless rotation of the torch in both directions. At the same time, cooling fluid, shielding gas, blow-out air, 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. It can be used for 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.

NOTE!

Do not connect a Helix cable assembly operated with a gas cooled torch neck to a water cooling system.

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4 TECHNICAL DATA

Item Description Function

1 Flange Torch mount RTKSC-2 / RTFLC-2 interface

2 Index pin Secures correct coupling orientation

58.3/3Control cable plug Electrical connection to RTKSC-2 for safety-off

signal and nozzle sense function (if applicable)

58.3/4EURO connector Wire feeder connection

58.3/5Control cable Electrical connection for the safety-off signal (from

RTKSC-2) and nozzle sense function (nozzle sense is standard for Helix, not for Infiniturn)

58.3/6Water return (red cap) Water return of heated water from the torch

58.3/7Water inlet (blue cap) Water inlet for torch cooling

58.3/8Blow out hose (black cap) For cleaning the torch with compressed air after

welding

58.3/9Media coupling Endlessly rotatable coupling with media transfer

58.3/

Protective cover Protects cable assembly from damage

10

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5 INSTALLATION

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.

Follow the assembly instructions exactly. Pay attention during assembly that the cables are not damaged. Damaged cables 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 the correct functioning of the whole welding torch system can be guaranteed.

5.1 RTKS-2 standard arm installation

5.1.1 RTKS-2 safety-off mechanism

1. Dismount the insulation flange (10) from the RTKS-2 (11) by removing the screws (12).

2. Position the insulation flange (10) with the index pin on the robot arm and fix it with the screws (20) included. The insulation flange (10) is directly compatible with robots with tool flange according to DIN ISO 9409-1-A40 (diameter 40mm, 4×M6). If the insulation flange (10) does not fit, use an adapter flange (21).

NOTE!

Ensure that the index pin is located correctly. The maximum torque of 1.2Nm (10.5in.lb) must be observed for the fastening of the adapter flange screws. Prevent self-loosening of the screws by using suitable thread locking measures.

3. Mount the RTKS-2 the back on the insulation flange (10).

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4. Position the mount on the RTKS-2 and carefully insert the cylindrical pins (14) into the holes provided. Take the position of the torch into account. Two mounting positions may be potentially possible.

5. Screw the mount evenly using the enclosed cylinder screws with hexagon socket (12).

NOTE!

The maximum tightening torque for the cylinder screw (5) is 6Nm (53in.lb) and the property class category is 8.8.

12 - Cylinder screw with hexagon socket M6DIN912 (length of the screw depending on the torch mount)

14 - Cylindrical pins Ø4×20

5.1.1.1 Torch installation with adjustable mount

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. The pins should protrude by approximately 5 mm (0.2 in.).

2. Position the mount on the safety-off mechanism RT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 in.lb) and the property class category is 8.8.

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4. Unscrew the axial cylinder screw with hexagon socket (4) out of the mounting flange together with the washer (3).

1 - Cylindrical pins Ø4×14 3 - Washer Ø9 mm

2 - Cylinder screw with hexagon socket

M6×16

4 - Axial cylinder screw with hexagon

socket M8×16

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. Insert the clamping mandrel (8) into the lateral hole (see illustration) and position it so that the mating surfaces (9a) of the clamping mandrel rest on the mating surface (9) of the journal.

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7. Fix the clamping mandrel from the opposite side using the M6 cylinder screw with hexagon socket (10) and the Ø22 mm washer (11).

8. Screw the axial cylinder screw (4) with the Ø9 mm washer (3) into the mounting flange and tighten firmly.

3 - Washer Ø9 mm 8 - Clamping mandrel

4 - Axial cylinder screw with hexagon

9 - Mating surface of mounting flange

socket M8×16

5 - Torch mount 9a - Mating surfaces of clamping mandrel

6 - Mounting flange journal 10 - Cylinder screw with hexagon socket

M6×30

7 Feather key 11 - Washer Ø22×6.4 mm

7a - Groove for feather key

5.1.2 Standard arm cable assembly for KS-2 and FL-2

The cable assembly must be aligned to the intended use in length and design. The type of cooling for the torch and the cable assembly must be the same (either gas or water cooled respectively). In order to prevent damage to the torch system and other components, it is imperative to observe the following instructions.

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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.

• Chafing on the robot or other objects must be excluded.

1. Unscrew the cylinder screws (1) and lift off the top section (2) of the torch mount.

2. Insert the feather key (4) into the recess of the neck support flange (3) from below.

3. Align the neck support flange (3) including the feather key (4) to the groove (5) of the torch mount and push into the groove right up to the stop of the flange.

4. Hold the cable assembly in this position and simultaneously place the top section (2) back onto the torch mount. First screw both cylinder screws (1) loosely in to about the same length, then tighten alternately. The top section (2) of the mount should have an even gap to the bottom section. The front part of the cable assembly is directly clamped into the torch mount (see illustration below).

1 - Cylinder screws 4 - Feather key

2 - Torch mount top section 5 - Groove for feather key

3 - Neck support flange

5.1.3 RTKS-2 wire feeder connection

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. Proceed as described below:

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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 - Burndy Connector 4 - Return of heated water (red cap)

2 - EURO central connector 5 - Return of heated water (red cap)

3 - Air blow-out 6 - Main Wire feeder

2. For water cooled systems. Connect the water hoses to the cooling circuit. The end of the hose marked blue (4) is connected to the water outlet, and the end marked red (5) is connected to the water return.

3. Connect the blow-out line (3) to the corresponding connection of the feeder.

4. Connect the Burndy Connector to the wire feeder. (1) to the feeder. See section "Electrical connections".

NOTE!

All hoses and the control line must be installed so they can not bend or get damaged!

5.1.4 RTKS-2 electrical connections

5.1.4.1 RTKS-2 safety-off mechanism connection

The switch for the safety-off functionality RTKS-2 is connected through the control cable, see (3) in the illustration below. This connects to the RTKS-2 unit via the 4-pole plug (4) that contains circuits for the push-button (6) and the safety-off signal (7).

If a collision is detected, the control circuit for the safety-off signal (7), which is normally closed, will be interrupted.

Rating of the control circuit: max. 48 V / 1 A

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2 - Burndy connector 5 - RTKS-2 connector for control cable plug

4 - Control cable plug

Burndy connector pins

A. Touch sense Gas Nozzle

C. Collision sensor

D. Collision sensor

F. 0V

G. + Motor voltage

H. - Motor voltage

E. Inching

If the robot control provides a control circuit for nozzle sense functionality, the connection is accomplished with a 1-wire connection.

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. During certain problems on the torch head, the full welding potential may be present on this cable.

CAUTION!

After detection of contact (gas nozzle on work piece), quickly reduce or cut off the maximum current in the nozzle sense circuit in order to avoid overloading of the system.

Allowed load max. 1 minute at the rated nominal current.

5.1.5 RTKS-2 Torch installation

Continue according to section "Torch installation".

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5.2 RTFL-2 standard arm installation

5.2.1 RTFL-2 rigid mount

1. Position the RT FL-2 (2) with the index pin on the robot arm and fix it with the hexagon socket screw included. The FL-2 is directly compatible with robots with tool flange according to DIN ISO 9409-1-A40 (diameter 40mm, 4×M6). If the rigid mount does not fit, use an adapter flange (3).

NOTE!

2. Install torch mount (1). Only torch mounts having a hole pattern equivalent with the mounting surface may be attached. If necessary, carefully press the cylindrical pins (4) into the corresponding holes in the bracket. The pins should protrude by approximately 5mm (0.2in.). Position the torch mount on the RTFL-2 (2) and carefully insert the cylindrical pins (4) into the holes provided. Take the position of the torch into account. Two mounting positions may be potentially possible.

3. Screw the mount evenly using the enclosed cylinder screws with hexagon socket (5).

NOTE!

The maximum tightening torque for the cylinder screw (5) is 6Nm (53in.lb) and the property class category is 8.8.

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4 - Cylindrical pins Ø4×20

5 - Cylinder screw with hexagon socket M6 DIN 912 (length of the screw depending on the torch mount)

Side view

Torch installation with adjustable mount

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 in.).

2. Position the mount on the RTFL-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 in.lb) 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).

1 - Cylindrical pins Ø4×14 3 - Washer Ø9 mm

2 - Cylinder screw with hexagon socket

M6×16

4 - Axial cylinder screw with hexagon

socket M8×16

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).

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6. Insert the clamping mandrel (8) into the lateral hole (see illustration) and position it so that the mating surfaces (9a) of the clamping mandrel rest on the mating surface (9) of the journal.

7. Fix the clamping mandrel from the opposite side using the M6 cylinder screw with hexagon socket (10) and the Ø22 mm washer (11).

8. Screw the axial cylinder screw (4) with the Ø9 mm washer (3) into the mounting flange and tighten firmly.

3 - Washer Ø9 mm 8 - Clamping mandrel

4 - Axial cylinder screw with hexagon

9 - Mating surface of mounting flange

socket M8×16

5 - Torch mount 9a - Mating surfaces of clamping mandrel

6 - Mounting flange journal 10 - Cylinder screw with hexagon socket

M6×30

7 - Feather key 11 - Washer Ø22×6.4 mm

7a - Groove for feather key

5.2.2 RTFL-2 torch installation

Continue according to section "Torch installation".

5.3 RTKSC-2 hollow wrist system installation

5.3.1 RTKSC-2 mount with safety off mechanism

CAUTION!

For hollow wrist systems make sure that the clear space around the robot is at least Ø45 mm (1.8 in.) around the wrist and 50 mm (2.0 in.) near the wire feeder.

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1. Remove the three screws (2) from the front cover (3) of the torch mount and carefully pull the cover off the RTKSC-2 main body (5). Take care not to damage the micro switches installed inside the assembly.

1 - Hexagon wrench 4 mm 4 - Rubber boot

2 - 3× M5×12 screws 5 - RT KSC-2 main body

3 - RT KSC-2 front cover

1. Pull off the rubber boot (4) from the RTKSC-2 main body (5) to the front.

2. Now position the RTKSC-2 main body (5) on the adapter flange (7) so that the index pin is correctly seated. Attach with the screws (6) enclosed.

3. Reinstall the rubber boot (4) on the RTKSC-2 main body (5) and make sure it is correctly located in the grooves on the front and back flange.

4. Istall the adapter flange (7) on the robot.

Fastening torque max. 2.2 Nm (19.5 in.lb).

1 - Hexagon wrench 4 mm 3 - 3× M5×12 hexagon socket screws

2 - Rubber boot 4 - Adapter flange

5.3.2 Mounting the cable assembly

NOTE!

In order to adjust the wire feeder position to the cable assembly length, it must be mounted on an adjustable support with a possible movement of ±2-3cm (±1in.) to the back and to the front. The length of the cable assembly must be determined from the centred mounting position of the wire feeder.

1. Move the robot arm into a completely straight position, see illustration below. Make sure that (1) axis 6 (rotation around the torch axis) is in 0° position.

2. Move the feeder (3) completely to the back in order to create space for inserting the cable assembly. If it is not possible to move the feeder sufficiently, it should be removed from the robot.

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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!

Axis 6 must be in 0° position.

5.3.2.1 RTKSC-2 feeder cabinet connections

When installed for the first time, the position of the wire feeder cabinet must be adjusted to the length of the cable assembly. First, the robot arm must be fully extended (straight).

CAUTION!

As long as the correct position of the feeder corresponding to the length of the cable assembly has not been determined, be careful when moving the robot arm and avoid overstretching the cable. It is helpful to loosen the positioning screws of the feeder before moving the robot arm to allow the feeder to follow the cable assembly.

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1. Loosen the sliding mechanism of the wire feeder and connect the cable assembly.

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. It is normal for the cable assembly to sag slightly, it should never be taut.

3. Before securing the wire feeder in its permanent position, ensure that the Euro connectors are tightly connected. Then turn the torch mount down and up again (rotating on the axis 5), in order not to tighten the cable assembly too much against the feeder (see illustration above). Once this is done, tighten the feeder in that position.

4. For water cooled systems, connect the water lines to the cooling circuit. See section "Cable assemblies for hollow wrist systems" in the TECHNICAL DATA chapter for indications. The hose with the blue rubber cap is for cooling water to the torch, the hose with the red rubber cap returns the heated water. Make sure the hoses will not kink or get otherwise blocked.

NOTE!

A Helix cable assembly used for a gas cooled system must not be connected to a cooling circuit. As the water connections are not needed, they may be cut off.

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. Install the necessary plug on the control cable and connect it to the safety off circuit interface of the wire feeder (see section "Electrical connections").

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5.3.3 RTKSC-2 cable assembly

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.

• Chafing on the robot or other objects must be excluded.

5.3.3.1 RTKSC-2 cable assembly installation

NOTE!

For some robots, it may be possible to deviate from this order, and first connect the cable assembly to the RTKSC-2, then thread the cable from the front through the robot arm. If in doubt, follow the suggested order.

1. Loosen the three screws (7) with the associated washers and remove them from the RTKSC-2 cover (1). See illustration below.

2. Install the supplied O-rings (4) into the grooves in the cover (1).

3. Pull the cable assembly approximately 15 cm (6 in.) from the main body (3).

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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!

Make sure that the position of the O-rings are not shifted by the index pin during the assembly.

1 - RTKSC-2 cover 5 - Index hole

2 - Coupling 6 - Index pin

3 - RTKSC-2 main body 7 - 3× M5×35 screws

4 - 3× O-ring for water cooled systems 11 - Control cable connector

5. Insert the three screws (7) with the associated washers (8) and tighten gently with the enclosed hexagonal wrench, see below illustration.

Fastening torque approximately 2 Nm (18 in.lb).

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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 11 - Control cable connector

8 - Washer 12 - 2× Micro switch

10 - Control cable plug 13 - Index pin

7. Gently push back the cable assembly into the robot arm and carefully seat the RTKSC-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. Insert the three M5 screws (14) and tighten without excessive force.

13. Index pin

14. 3× M5×12 screws

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5.3.3.2 RTKSC-2 electrical connections

NOTE!

After connecting the control cable, secure the cable in order to protect it from getting caught while the robot is moving.

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 controller.

RTKSC-2 safety-off mechanism connection

The switch for the safety-off functionality RTKSC-2 is connected through the control cable, see (3) in the illustration below. This connects to the RTKSC-2 unit via the control cable plug (1).

The safety-off signal requires a 2-wire connection (black/black) to the safety-off circuit in the robot control (5).

If a collision is detected, the control circuit (normally closed) will be interrupted (4).

Rating of the control circuit: max. 48 V / 1 A.

1 - Control cable plug 3 - Burndy connector VVV

2 - EURO central connector

Burndy connector pins

A. Touch sense Gas Nozzle

C. Collision sensor

D. Collision sensor

F. 0V

G. + Motor voltage

H. - Motor voltage

E. Inching

RTKSC-2 nozzle sense function connection

If the robot control provides a control circuit for nozzle sense functionality.

The connection is accomplished with a 2-wire connection (black/black) to the nozzle sense circuit in the robot control (5), see illustration below.

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Rating of the control circuit: max. 50 V / 5 A.

DANGER!

CAUTION!

After detection of contact (gas nozzle on work piece), quickly reduce or cut off the maximum current in the nozzle sense circuit in order to avoid overloading of the system.

Allowed load max. 1 minute at the rated nominal current.

1 - Control cable plug 3 - Control cable

2 - EURO central connector

5.3.4 RTKSC-2 torch installation

Continue according to section "Torch installation".

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5.4 RTFLC-2 installation

5.4.1 RTFLC-2 mount

1. Remove the three M5 screws (2) from the front cover (3) of the RT FLC-2 torch mount and carefully pull the cover off the main body (4).

1 - Hexagon wrench 4 mm 3 - RT FLC-2 front cover

2 - 3× M5×12 screws 4 - RT FLC-2 main body

2. Now position the RT 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 in.lb).

1 - Hexagon wrench 4 mm 5 - 3× M5×12 hexagon socket screws

4 - RT FLC-2 main body 6 - Adapter flange

5.4.2 RTFLC-2 wire feeder connection

5.4.2.1 Feeding through the robot arm

NOTE!

In order to adjust the wire feeder position to the cable assembly length, it must be mounted on an adjustable support with a possible movement of ± 2-3 cm (± 1 in.) to the back and to the front. The length of the cable assembly must be determined from the centred mounting position of the wire feeder.

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1. Move the robot arm into a completely straight position, see illustration below. Make sure that (1) axis 6 (rotation around the torch axis) is in 0° position.

2. Move the feeder (3) completely to the back in order to create space for inserting the cable assembly. If it is not possible to move the feeder sufficiently, it should be removed from the robot.

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.

5.4.2.2 RTFLC-2 feeder cabinet connections

When installed for the first time, the position of the wire feeder cabinet must be adjusted to the length of the cable assembly. First, the robot arm must be fully extended (straight).

CAUTION!

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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!

3. Before securing the wire feeder in its permanent position, ensure that the Euro connections are tightly connected. Then turn the torch mount down and up again (rotating on the axis 5), in order not to tighten the cable assembly too much against the feeder (see illustration above). Once this is done, tighten the feeder in that position.

NOTE!

A Helix cable assembly used for a gas cooled system must not be connected to a cooling circuit. As the water connections are not needed, they may be cut off.

5. Connect the blow-out hose (black rubber cap) to the corresponding outlet of the wire feeder.

NOTE!

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6. Install the necessary plug on the control cable and connect it to the safety off circuit interface of the wire feeder (see section "Electrical connections").

5.4.3 RTFLC-2 cable assembly

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.

• Chafing on the robot or other objects must be excluded.

5.4.3.1 RTFLC-2 cable assembly installation

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.

When the cable assembly is correctly installed in the hollow wrist, continue the installation according to the procedure described below.

NOTE!

For some robots, it may be possible to deviate from this order, and first connect the cable assembly to the RTKSC-2 and RTFLC-2, then thread the cable from the front through the robot arm. If in doubt, follow the suggested order.

1. Loosen the three screws (7) with the associated washers and remove them from the RTFLC-2 cover (1). See illustration below.

2. Install the supplied O-rings (4) into the grooves in the cover (1). For gas cooled systems, only one O-ring (4a) is needed, for water cooled systems all three O-rings are needed.

3. Pull the cable assembly approximately 15 cm (6 in.) from the main body (3).

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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 - RT FLC-2 cover 5 - Index hole

2 - Coupling 6 - Index pin

3 - RT FLC-2 main body 7 - 3× M5×35 screws

4 - 3× O-ring for water cooled systems 11 - Control cable connector

5. Insert the three screws (7) with the associated washers (8) and tighten gently with the enclosed hexagonal wrench, see below illustration.

Fastening torque approximately 2 Nm (18 in.lb).

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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 11 - Control cable connector

8 - Washer 12 - 2× Micro switch

10 - Control cable plug 13 - Index pin

7. Gently push back the cable assembly into the robot arm and carefully seat the RT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. Insert the three M5 screws (14) and tighten without excessive force.

13 - Index pin 14 - 3x M5x12 screws

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5.4.4 RTFLC-2 electrical connections

NOTE!

After connecting the control cable, secure the cable in order to protect it from getting caught while the robot is moving.

Usually, the control cable will be directly connected to the wire feeder. See the documentation of the manufacturer for details. The link to the robot control is then implemented via the power source controller.

5.4.4.1 RTFLC-2 hollow wrist system with Infiniturn cable assembly

Connecting the nozzle sense function

If the robot control provides a control circuit for nozzle sense functionality.

The connection is accomplished with a 2-wire connection (black/black) to the nozzle sense circuit in the robot control (5), see illustration below.

Rating of the control circuit: max. 50 V / 5 A.

DANGER!

CAUTION!

After detection of contact (gas nozzle on work piece), quickly reduce or cut off the maximum current in the nozzle sense circuit in order to avoid overloading of the system.

Allowed load max. 1 minute at the rated nominal current.

1 - Control cable plug 3 - Control cable

2 - EURO central connector

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5.4.4.2 RTFLC-2 hollow wrist system with Helix cable assembly

Connecting the nozzle sense function

If the robot control provides a control circuit for nozzle sense functionality.

The connection is accomplished with a 1-wire connection (green) to the nozzle sense circuit in the robot control (5), see illustration below.

Rating of the control circuit: max. 50 V / 5 A.

DANGER!

CAUTION!

After detection of contact (gas nozzle on work piece), quickly reduce or cut off the maximum current in the nozzle sense circuit in order to avoid overloading of the system.

Allowed load max. 1 minute at the rated nominal current.

1 - Control cable plug 3 - EURO central connector

2 - Control cable 4 - Burndy connector

5.5 Torch installation

Be sure to use the correct version of the torch mount and cable assembly (water or gas cooled).

5.5.1 Torch neck equipment

The torch neck, see (1) in the illustration below, must always be equipped to suit the wire diameter and material.

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1. Select the correct wire guide, contact tip (4), tip holder (2), gas nozzle (5), and gas diffuser/spatter protection (3). You will find an exact overview and possible alternative equipment elements for various torch models in the spare parts list. Only use original ESAB parts; only then is the fitting accuracy ensured.

2. Firmly tighten the tip holder and the contact tip using a suitable tool for example the enclosed monkey wrench.

3. When using a split wire guide, remove the installed guide nipple including the o-ring from the torch flange upon delivery if necessary (see section "Installing the neck liner").

CAUTION!

The torch must be completely equipped before welding, especially the gas diffuser and/or spatter protection and all necessary insulators have to be installed according to the spare parts list. Welding without these items may cause immediate destruction of the torch.

1 - Torch neck 4 - Contact tip

2 - Tip holder 5 - Contact tip

3 - Gas diffuser

5.5.2 Aristo RT torch neck 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. For hollow wrist systems, insert the torch into the torch mount in the correct orientation, so that the locator pin fits into the slot of the RTKSC-2 or RTFLC-2 interface, see (A) in the illustration below. For standard systems, attach the torch to the RT flange of the cable assembly, (B) in the illustration below. Installation is only possible in the correct orientation.

2. Tighten the locking nut of the torch neck.

NOTE!

Only tighten by hand, never use tools or excessive force.

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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).

5.6 Installing the wire guide for standard and hollow Wrist arm

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. The front part of the wire guide, which is most stressed, can be exchanged easily and independently of the cable assembly wire guide.

For correct installation, the following steps must be followed (example for Euro central connector).

5.6.1 Installing the neck liner

The neck liner must be selected to fit the material and diameter of the welding wire, see the spare parts list.

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5 INSTALLATION

1. If present, remove the central guide nipple (1), from the torch neck using a hexagon wrench (size 6 mm) or a large flat-blade screwdriver.

NOTE!

The guide nipple (1) can only be used with one-piece liners and must not be used with the standard RT or hollow wrist system.

2. When replacing the neck liner: Unfasten the sleeve nut and remove the torch neck. Unfasten the liner nipple using a hexagon wrench (size 6 mm) and remove nipple and liner from the torch neck.

3. Remove the gas nozzle and the contact tip.

4. Insert the new neck liner (2) into the torch. Carefully tighten the guide nipple using a suitable tool, e.g. a hex-wrench (size 6 mm) or a large flat-blade screwdriver.

5. Cut the neck liner flush with the tip holder and remove the neck liner from the torch.

6. Install the contact tip.

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.

5.6.2 Installing a split wire guide in the cable assembly

The correct liner must be inserted to suit the filler material and the wire diameter, see the spare parts list.

The wire guide is inserted through the cable assembly from the rear, reaching the guide nipple that is installed in the flange where the torch neck will be attached. The following worksteps must be followed in order to correctly determine the wire guide length. (Example for Euro central connector).

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5 INSTALLATION

1. For standard RT system: Install the guide nipple (1) in the center hole of the neck support flange, see illustration A below. For hollow wrist system: Install the guide nipple (1) into the torch interface of the RTKSC-2 / RTFLC-2 cover, see illustration B below.

2. Remove the sleeve nut (2) from the central connector, and remove the old wire guide.

3. Insert the wire guide through the central connection and push forwards as far as it will go into the guide nipple (1), applying light pressure.

CAUTION!

Ensure that the wire guide has advanced right up to the stop at the front, rotating and pushing forward gently.

4. Measure the excess length that needs to be cut from the wire guide.

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.

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5 INSTALLATION

6. Reinstall the wire guide and attach the sleeve nut (2).

NOTE!

For hollow wrist systems where Infiniturn and Helix cable assemblies are used, wire guides should be installed without tension so that the ends of the liners may rotate freely.

Important note when using a plastic liner:

The wire channel between the drive rolls of the feeder and the central connector of the torch must be fitted with a plastic liner. Depending on the design of the feeder, a piece of plastic liner inserted into a brass guide tube can be used.

During wire run-in, make sure that the wire is fed correctly into the plastic liner of the torch. If necessary, remove the cable assembly from the feeder and insert the wire, then reattach.

5.6.3 Installing a continuous wire guide in the cable assembly

Installing a steel liner

The wire guide is inserted through the cable assembly from the rear and reaches to the contact tip. The following worksteps must be followed for the correct calculation of the length (example for Euro central connector):

1. Install the torch (see section "Torch neck equipment").

2. Remove the gas nozzle and contact tip from the torch.

3. Remove the sleeve nut (D) from the Euro connector.

4. Push in the liner through the central connector and fix with the sleeve nut.

5. Cut off the liner flush with the nozzle holder. To determine the thread projection of the contact tip, pull the liner backwards and screw in the contact tip.

6. Push the liner forwards as far as it will go to the contact tip applying light pressure on the liner and measure the length to be shortened at the rear.

7. Now remove the liner again and cut the excess length measured off it’s front end. If needed, grind down the burred edges. Make sure the inner opening of the liner is not obstructed by the cut wire end.

8. The insulation of the liner must be removed after cutting off in the front area, such that the insulation protrudes out of the RM2 flange by approx. 5 cm. For this, briefly remove the torch neck.

9. Push the liner back in again and fix with the sleeve nut (D), see above. Re-install the gas nozzle.

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5 INSTALLATION

Installing a plastic liner

1. Mount the torch neck (see section "Torch neck equipment") and equip it with a gas nozzle and contact tip.

2. Remove the sleeve nut (D) from the Euro connector.

3. Cleanly cut off the liner, slightly break the outer edges, point slightly (e.g. with a pencil sharpener).

4. Insert the liner through the central connector into the cable assembly with fitted torch. If it gets stuck, rotate the liner to free it and facilitate installation.

NOTE!

Make sure the liner is completely inserted by rotating it and slightly pushing it forward, until you can feel it has reached its stop.

5. Mount the nipple (B) and the O-Ring (C), move it to the right position and fix it with the sleeve nut (D) of the Euro central connector.

6. Measure the required overlap needed inside the wire feeder cabinet and cut the liner accordingly.

5.7 Adjust the narrow gap contact tip

The adjusting tool RT42-NG is designed for the narrow gap torch necks RT42W-NG, RT42G-NG and RT 82W-0°NG, torches with curved narrow gap contact tip. It facilitates the precisely repeatable and fast changing of the curved contact tip.

NOTE!

The adjusting tool must be securely fastened to a stable base, in order to prevent the position of the device in relation to the robot cannot change unintentionally. If the exact orientation of the device is lost, the alignment of the contact tip used for the elaboration of the welding programs can no longer be reproduced with precision.

Select a position within the operating range of the robot for orientation (alignment) of the contact tip to the torch. Fasten the adjusting tool firmly to a base using the fastening grooves provided for this purpose. Fastening material is not included with the adjusting tool. Select fastening material (screws) to suit the existing conditions.

Save all motion sequences and stop positions required to change or align the wearing parts to a separate robot program.

Before programming the welding tasks: plan at which orientation the contact tip is to stand in relation to the torch. The torch must then be positioned in the desired rotational position and the contact tip aligned using the adjusting device. Only then may the welding task be programmed. If different orientations of the contact tip are required for various welding tasks, the contact tip has to be aligned to the new position when the welding task is changed.

WARNING!

The gas nozzle and the torch head become very hot during welding. Always allow the torch to cool down before replacing wearing parts or adjusting the contact tip.

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5 INSTALLATION

Adjust the contact tip

Move the robot torch to a position parallel to the opening of the adjusting tool (2). Maintain a sufficient distance to the work table to be able to comfortably remove the gas nozzle. Define this position in your robot program as the wearing parts change position (stop position 1).

Remove the gas nozzle by pulling it downwards. Remove the welding wire in the contact tip if necessary.

Loosen the counter nut (4) of the contact tip while counter-holding the nozzle holder at the wrench flat (3).

Unscrew the contact tip including the counter nut from the nozzle holder and replace the nozzle holder if necessary.

Completely screw the counter nut (4) onto the new contact tip. Screw the contact tip including the counter nut into the nozzle holder.

Align the contact tip until it is parallel to the opening of the adjusting tool. If necessary, slightly unscrew the contact tip so that it can be easily turned in both directions.

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5 INSTALLATION

NOTE!

The contact tip must be able to be easily moved by hand in both directions in order to enable the threading of the adjusting tool.

Place the robot torch or contact tip directly in front of the opening of the adjusting tool (2) (stop position 2).

Insert it slowly from the front until it is completely inserted into the device (stop position 3).

The contact tip was aligned exactly in the device during insertion. Now cautiously tighten the counter nut (4) in this position, while counter holding the nozzle holder at the wrench flat.

Slowly move the robot torch out of the adjusting gauge, return to stop position 1 and push on the gas nozzle as far as it will go.

Allow the welding wire to run into the contact tip and bring the robot arm into welding position.

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6 OPERATION

CAUTION!

Before starting the system, check the whole installation according to the manufacturer's instructions and applicable safety regulations.

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. Is the EURO central connector or direct connector fastened tightly?

4. Is the cable assembly length correct and suitable for the installation and can the cable rotate freely? The cable must not be bent sharply. Any risk of the cable getting caught on another object must be eliminated.

5. Is the control cable of the safety-off circuit connected and functioning? Move torch by hand to test (RTKSC-2 and RTKS-2 only).

6. Is the torch firmly attached and is it completely equipped?

7. Is the wire guide installed according to the manual?

8. Are all lines and tubes arranged so that they cannot be damaged or bent?

The wire run-in can now be started, either via the wire run-in pushbutton or via the wire run-in at the feeder.

6.1 Important information for programming (hollow wrist system only)

Fast rotation of axis 6 of the robot will significantly stress the cable assembly. In certain cases, this can lead to damage or destruction of the cable. In order to maximize the lifetime of the cable, we strongly suggest respecting the following limitations when programming the robot.

Position of axis 5 Max. rotational speed of axis 6

0 – 60° 100 % (no limitations)

60° – 80° 300°/sec (approximately 50 % of max. robot speed)

> 80° 120°/sec (approximately 20 % of max. robot speed)

NOTE!

The above values are only indications. For information on the exact rotational speed limits, refer to the individual robot manual or contact the robot supplier.

To reposition the torch quickly, the robot arm may have to be slightly extended first to achieve a bending angle of max. 60° of axis 5. In this position, the maximum available rotation speed of axis 6 can be used.

When using the ESAB Helix cable assembly, the max. rotation of ±270° from the neutral position must not be exceeded.

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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.

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7 SERVICE AND MAINTENANCE

WARNING!

Before performing maintenance on the system, the main power of the installation must be turned off. Note the safety regulations at the beginning of this manual.

Damaged torches or cable assemblies must not be used! 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. Let the torch cool down prior to maintenance work.

WARNING!

In order to prevent personal injuries or damage to your installation, follow these instructions:

1. Repair of the RTKSC-2 or RTFLC-2 torch mount, the RTKS-2 safety-off mechanism, the cable assembly, or the Infiniturn media coupling must only be carried out by ESAB service support.

2. The Infiniturn media coupling must never be opened. It contains no user-serviceable parts and will be destroyed by disassembly.

3. Never disassemble the RTKSC-2 or RTKS-2. This is a spring loaded mechanism. Improper manipulation can lead to severe injury.

7.1 Mandatory checks and actions

Before every use:

• Check torch, contact tip, gas nozzle, neck liner, cables, and overall equipment for general damage.

NOTE!

To minimize downtime, it is recommended to alternate between two torch necks, always having a freshly equipped torch neck at hand and ready for use.

Every 8 hours of use (depending on application):

• Change contact tip.

Daily:

• Do a functional check by hand of the safety-off mechanism.

• Do a visual inspection for damage - e.g. bends or cracks.

• Verify the correct position of the wire feeder. The cable assembly must not be too tense or sagging.

• Inspect the media connections and the Infiniturn media coupling for leakage.

• Perform cleaning and maintenance of the torch according to the torch manual.

Every 40 hours of use (depending on application):

• Change wire liners.

• Change neck liners.

Weekly or as needed depending on use:

• Remove the wire guide and check for wear and dirt deposits. Exchange if needed.

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7 SERVICE AND MAINTENANCE

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.

• Exchange after all 250 kg welded wire.

Damage of the electrical isolation must be repaired by trained personnel before the system can safely be operated.

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8 TROUBLESHOOTING

Fault Possible cause Action

Cannot feed wire

Torch is getting too hot

The welding wire has not been straightened before feeding it into the cable assembly

The torch and the cable assembly are not equipped correctly for the wire diameter and wire material

The wire guide is not correctly inserted into the cable assembly

The contact tip blocked is blocked with wire debris The wire guide is worn The wire feed is impeded by dirt and debris in the torch

Contact tip or tip holder is not tightened correctly

If necessary, pull the welding wire out again, cut off and deburr the end, and straighten the first 10 cm of the wire. Then thread back into the cable assembly.

Check the guide (cable assembly and torch neck) and contact tip.

Pull out the wire guide from the EURO connector a little. When inserting the wire guide, you should feel the last centimeters slip into the guide nipple in the torch interface. Otherwise the wire guide may be too short and not fully inserted.

Replace the contact tip and/or wire guide and blow out the torch neck, wire guide conduit and wire guide with compressed air.

Use a suitable tool for tightening hand-tight.

Wire feeding problems

Cooling system is not working well Check water flow, filling level and

cleanliness.

Cooling system is not correctly connected

Check connections (water inlet and return).

Torch overstrained Observe technical data. If needed,

choose a different type.

Cable assembly defective Check cables, tubes and

connections.

Contact tip is worn Exchange contact tip.

Liner is worn / dirty Check the liner; blow out. Exchange

if needed.

Consumables used are not suitable

Check spare part list.

for the wire diameter or material

Wire feeder not set-up properly Check the wire feeding rolls, the

contact pressure and the spool brake.

Cable assembly is bent or laid out in too small radii

Check the cable assembly for damages. Can the liner be inserted easily? Install as instructed. See the section "Installing the cable assembly".

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Wire is contaminated Use a cleaning felt.

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8 TROUBLESHOOTING

Fault Possible cause Action

Wire feed stops during welding

Welding process is stopping

Pores in the seam

Wire spool is empty 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, and clean or replace the contact tip if required.

Wire burn back into the contact tip

Replace the contact tip.

or worn contact tip

Safety-off mechanism has triggered. Search for collision points and

prevent them. Check control line for a loose contact.

Gas swirl caused by spatter adherence

Too small or extremely high gas flow in the torch

Clean the torch head, use gas diffuser / spatter protection.

Check flow rate with measurement tool.

Gas supply defective Check flow rate and possible

leakage.

Moisture or contamination on the wire or on the work piece

Check the wire and the work piece. Use less or different anti-spatter liquid.

Arc is not stable Contact tip is worn Exchange contact tip.

Wrong welding parameters Check the set-up of the welding

equipment.

Insufficient electrical connections in the circuit

Check all electrical connections (incl. ground cable) between the power source torch or work piece for firm seating.

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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 RTKS-2, RTFL-2, RT-KSC-2, RT-FLC-2, RT42, RT52, RT62, RT72, RT82, RT42-NG, and RT82WNG are designed and tested in accordance with international and European standards IEC/EN 60974-7. It is the obligation of the service unit that carried out the service or repair work to make sure that the product still conforms to said standard.

Spare parts and wear parts can be ordered through your nearest ESAB dealer, see the back cover of this document. When ordering, please state product type, serial number, designation and spare part number in accordance with the spare parts list. This facilitates dispatch and ensures correct delivery.

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ESAB AB, Lindholmsallén 9, Box 8004, 402 77 Gothenburg, Sweden, Phone +46 (0) 31 50 90 00

http://manuals.esab.com

For contact information visit esab.com

ESAB RT Robo Welding Torch System Instruction manual

Specifications and Main Features

Frequently Asked Questions

User Manual

TABLE OF CONTENTS

1 SAFETY

1.1 Meaning of symbols

1.2 Safety precautions

2 WARRANTY

2.1 Conditions of intended use

3 INTRODUCTION

3.1 Overview of welding torch systems

4 TECHNICAL DATA

4.1 Welding torch neck

4.2 Voltage rating

4.2.1 Cooling circuit limits

4.3 Torch mount

4.3.1 Torch mounts for standard RT system

4.3.2 Torch mounts for hollow wrist system

4.4 adapter flanges

4.5 Cable assemblies

4.5.1 Cable assemblies for standard RT system

4.5.2 Cable assemblies for hollow wrist systems

5 INSTALLATION

5.1.1.1 Torch installation with adjustable mount

5.1.2 Standard arm cable assembly for KS-2 and FL-2

5.3.2 Mounting the cable assembly

5.4.2.1 Feeding through the robot arm

Connecting the nozzle sense function

Connecting the nozzle sense function

5.5 Torch installation

5.5.1 Torch neck equipment

5.5.2 Aristo RT torch neck installation

5.6 Installing the wire guide for standard and hollow Wrist arm

5.6.1 Installing the neck liner

5.6.2 Installing a split wire guide in the cable assembly

5.6.3 Installing a continuous wire guide in the cable assembly

5.7 Adjust the narrow gap contact tip

6 OPERATION

6.1 Important information for programming (hollow wrist system only)

7 SERVICE AND MAINTENANCE

7.1 Mandatory checks and actions

8 TROUBLESHOOTING

9 ORDERING SPARE PARTS