ESAB RT Robo Welding Torch System Instruction manual

RT Robo Welding Torch Systems
Instruction manual
0463 373 101 GB 20151222

TABLE OF CONTENTS

1 SAFETY ................................................................................................................ 5
2 WARRANTY.......................................................................................................... 7
2.1 Conditions of intended use.................................................................................7
3 INTRODUCTION................................................................................................... 8
3.1 Overview welding torch systems .......................................................................8
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
5.1 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
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TABLE OF CONTENTS
5.7 Connecting to the wire feeder...........................................................................33
5.7.1 Standard RT system ........................................................................................ 33
5.7.2 Hollow wrist system..........................................................................................34
5.7.2.1 Feeding through the robot arm....................................................................... 34
5.7.2.2 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
6.1 Important information for programming (hollow wrist system
only)................................................................................................................. 42
7.1 Mandatory checks and actions.........................................................................44
Rights reserved to alter specifications without notice.
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1 SAFETY

1 SAFETY
Users of ESAB equipment have the ultimate responsibility for ensuring that anyone who works on or near the equipment observes all the relevant safety precautions. Safety precautions must meet the requirements that apply to this type of equipment. The following recommendations should be observed in addition to the standard regulations that apply to the workplace.
All work must be carried out by trained personnel well-acquainted with the operation of the equipment. 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.
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1 SAFETY
WARNING!
Arc welding and cutting can be injurious to yourself and others. Take precautions when welding and cutting. Ask for your employer's safety practices which should be based on manufacturers' hazard data.
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.
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2 WARRANTY

2 WARRANTY
Before delivery, our products are carefully checked. ESAB verify that each product is free from defects of material and workmanship at the time of delivery and is functioning according to its intended use.
ESAB provides warranty on defects of material and workmanship according to legal requirements. Consumables are exempt from this warranty.
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.
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3 INTRODUCTION

3 INTRODUCTION
The RT welding torch systems are developed for fully automatic MIG/MAG welding using robots. The systems consist of a variety of Aristo RT torch necks designed for robotic use, torch mounts, cable assemblies optimized for robotic use, and safety-off features to prevent the system from damage in case of collision.
The standard RT welding system provides collision protection through the use of KS-2 that is a mechanical spring-loaded safety-off functionality. 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".
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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 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".
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4 TECHNICAL DATA

4 TECHNICAL DATA

4.1 Welding torch

The torch model has to be chosen according to the welding application. The required duty-cycle and capacity, the cooling method, and the wire diameter must be considered. If there are increased requirements, for example caused by preheated work pieces, high heat reflection in corners, etc, these must be taken into account by selecting a welding torch with adequate reserve in power rating.
The RT welding torches are intended for the use with CE-conform welding power sources for the processes of metal inert gas welding (MIG), metal active gas welding (MAG) and metal inert gas soldering with commercial round wires. Do not use the torch for other processes.
For aluminium welding the RT82W water cooled torch must be used.
See the spare parts list for available torch models.
Guiding method By machine only
Temperature ranges Storage -15° to 50°C (5° to 122°F)
Operation 5° to 40°C (41° to 104°F)
Blow-out gas Max. 10 bar, separate gas hose
Total weight with torch and 1 m cable assembly
Approximately 5 kg

4.1.1 Voltage rating

Max. permitted voltage / amperage
Complete welding torch system 141 V (peak value for welding)
KS-2 safety-off control circuit
KS-2 push-button
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
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.
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. 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.
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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.

4.2 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
0.85 kg
system)
FL-1 intermediate flange (for standard
0.35 kg
system)
KSC-2 torch mount (for hollow wrist system) 1.90 kg
FLC-2 rigid torch mount (for hollow wrist
1.22 kg
system)
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.
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4 TECHNICAL DATA
4.2.1.1 KS-2 safety-off mechanism
The KS-2 safety mechanism is a spring supported devise that protects the robot and the torch system in case of a collision.
4.2.1.2 FL-1 intermediate flange
The rigid intermediate flange FL-1 can be used instead of the KS-2 if the robot has an electronic collision detection system.

4.2.2 Torch mounts for hollow wrist system

In the hollow wrist system the Aristo RT welding torches are connected via a quick change system to the torch mount.
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.
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4 TECHNICAL DATA
For hollow wrist systems KSC-2W (alternatively FLC-2W) is recommended. This torch mount can be used with both gas-cooled and water-cooled torches of the Aristo RT series.
KSC-2 FLC-2
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
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, the sensing voltage should be disconnected quickly.
For Infiniturn cable assemblies, the nozzle sense function has limited functionality. Please contact us for a detailed investigation of possible solutions in your application.
Voltage rating The maximum permitted
voltage for the safety off control circuit is 48 V.
4.2.2.1 KSC-2 torch mount with safety-off mechanism
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.
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
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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.
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4 TECHNICAL DATA

4.4 Cable assemblies

The connection to the wire feeder is effected by the cable assembly, the available versions mainly depending on system design and cooling media (gas or water), see the spare parts list.
The ratings are valid for cable lengths from 1 to 5 m.
Standard cable
Infiniturn Helix
assembly
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
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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
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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
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5 INSTALLATION

5 INSTALLATION

5.1 Preparation

WARNING!
For your own safety, make sure that the robot is either in standby or power-less state before doing maintenance work in the moving radius of the robot.
The following assembly instructions must be exactly adhered to. Attention is to be paid during assembly that the cables are not damaged. This can lead to a short circuit, which may damage the electronics of the robot or the welding torch.
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.
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5 INSTALLATION

5.3.1 Torch mount in standard RT system

5.3.1.1 Direct mounting of KS-2
1. If necessary, carefully press the cylindrical pins (1) into the corresponding holes in the bracket. Avoid the formation of burrs. The pins should protrude by approximately 5 mm (0.2 inch).
2. Position the mount on the safety-off mechanism KS-2 and carefully insert the cylindrical pins (1) into the holes provided. In doing so, take the later position of the torch into account. 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.
1. Cylindrical pins Ø4×20
2. Cylinder screw with hexagon socket M6 DIN 912 (length of the screw depending on the torch mount)
Side view
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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5 INSTALLATION
1. Cylindrical pins Ø4×14
2. Cylinder screw with hexagon socket M6×16
3. Washer Ø9 mm
4. Axial cylinder screw with hexagon socket M8×16
Top view
5. Place the torch mount (5) onto the journal (6) of the mounting flange, paying attention while doing so to the exact alignment of the feather key (7) and the corresponding groove (7a).
6. 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. Then fix the clamping mandrel from the opposite side using the M6 cylinder screw with hexagon socket (10) and the Ø22 mm washer (11).
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5 INSTALLATION
8. Finally, screw the axial cylinder screw (4) with the Ø9 mm washer (3) into the mounting flange and tighten firmly.
3. Washer Ø9 mm
4. Axial cylinder screw with hexagon socket M8×16
5. Torch mount
6. Mounting flange journal
7. Feather key; 7a. Groove for feather key
8. Clamping mandrel
9. Mating surface of mounting flange; 9a. Mating surfaces of clamping mandrel
10. Cylinder screw with hexagon socket M6×30
11. Washer Ø22×6.4 mm

5.3.2 Torch mount in hollow wrist system

5.3.2.1 Mounting of KSC-2
Remove the three screws (2) from the front cover (3) of the torch mount and carefully pull the cover off the main body (5). Take care not to damage the micro switches installed inside the assembly.
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1. Hexagon wrench 4 mm
2. 3× M5×12 screws
3. KSC-2 front cover
4. Rubber boot
5. KSC-2 main body
Pull off the rubber boot (4) from the main body (5) to the front.
Now position the main body (5) on the adapter flange (7) so that the index pin is correctly seated. Attach with the screws (6) enclosed.
Fastening torque max. 2.2 Nm (19.5 lbf in).
Reinstall the rubber boot (4) on the KSC-2 main body (5) and make sure it is correctly located in the grooves on the front and back flange.
1. Hexagon wrench 4 mm
4. Rubber boot
6. 3× M5×12 hexagon socket screws
7. Adapter flange
5.3.2.2 Mounting of FLC-2
Remove the three M5 screws (2) from the front cover (3) of the FLC-2 torch mount and carefully pull the cover off the main body (4).
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1. Hexagon wrench 4 mm
2. 3× M5×12 screws
3. FLC-2 front cover
4. FLC-2 main body
Now position the FLC-2 main body (4) on the adapter flange (6) so that the index pin is correctly seated. Attach with the screws (5) enclosed.
Fastening torque max. 2.2 Nm (19.5 lbf in).
1. Hexagon wrench 4 mm
4. FLC-2 main body
5. 3× M5×12 hexagon socket screws
6. Adapter flange

5.4 Installing the cable assembly

The cable assembly must be aligned to the intended use in length and design. 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.

5.4.1 Installing the cable assembly in a standard RT system

The front part of the cable assembly is directly clamped into the torch mount (see illustration below).
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 (4a) 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.
1. Cylinder screws
2. Torch mount top section
3. Neck support flange
4. Feather key; 4a. Groove for feather key
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5.4.2 Installing the cable assembly in a hollow wrist system

In a hollow wrist system the recommended order of installation is to feed the cable assembly through the robot arm before connecting the cables to the torch mount, see description "Feeding through the robot arm" under section "Connecting to the wire feeder".
When the cable assembly is correctly installed in the hollow wrist, continue the installation according to the procedure described below.
NOTE!
For some robots, it may be possible to deviate from this order, and first connect the cable assembly to the KSC-2 and FLC-2, then thread the cable from the front through the robot arm. If in doubt, please follow the suggested order.
1. Loosen the three screws (7) with the associated washers and remove them from the KSC-2 or 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”) 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. KSC-2 / FLC-2 cover
2. Coupling
3. KSC-2 / FLC-2 main body
4. 3× O-ring for water cooled systems; 4a. O-ring for gas cooled systems
5. Index hole
6. Index pin
7. 3× M5×35 screws
11. Control cable connector
5. Insert the three screws (7) with the associated washers (8) and tighten gently with the enclosed hexagonal wrench, see below illustration.
Do not use excessive force! (approximately 2 Nm (18 lbf in))
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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
8. Washer
10. Control cable plug
11. Control cable connector
12. 2× Micro switch
13. Index pin
7. Gently push back the cable assembly into the robot arm and carefully seat the KSC-2 or FLC-2 cover (1) in place. Observe the index pin (13) to be in the correct position. Make sure the two micro switches (12) are not damaged if present.
8. Insert the three M5 screws (14) and tighten without excessive force.
13. Index pin
14. 3× M5×12 screws
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5.5 Installing the wire guide

Choose the wire guide or liner depending on the filler wire material and diameter to be used, see the spare parts list. Accurate performance of the system can only be guaranteed when using original ESAB wire guides.
The recommended wire guide is the split wire guide, which consists of the neck liner and a separate guide in the cable assembly. 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):

5.5.1 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.
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.
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7. Insert the neck liner again. It will be stopped by the contact tip. Measure the excess liner sticking out of the neck.
8. Remove the liner again and shorten the front end by the measured length. Carefully deburr the edge and make sure that the inner hole is not blocked.
9. Reinstall the neck liner and tighten the guide nipple in the neck.

5.5.2 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).
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 KSC-2 / 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.
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5. Remove the wire guide again and shorten the front end by the measured length.
Steel liner: grind down the burred edges if needed. Plastic liner: make a clean cut and chamfer the edges (e.g. with a pencil sharpener)
NOTE!
Make sure the inner opening of the liner is not obstructed by the cut wire end.
6. Reinstall the wire guide and attach the sleeve nut (2).
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 Installing the torch

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

5.6.1 Torch neck equipment

The torch neck, see (1) in the illustration below, must always be equipped to suit the wire diameter and material.
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.
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1. Torch neck
2. Tip holder
3. Gas diffuser
4. Contact tip
5. Gas nozzle

5.6.2 Aristo RT torch installation

NOTE!
Check the O-rings on the flange of the torch neck before mounting. Replace the O-rings if damaged or lost. Missing or faulty O-rings will lead to leaks of shielding gas and coolant.
1. 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 KSC-2 or 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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3. The correct seating of the torch can be checked by means of the window (1). If the torch has been correctly mounted, no gap should be seen through the window (1).

5.7 Connecting to the wire feeder

5.7.1 Standard RT system

In order to be able to create the connection, the cable assembly must be mounted as described in the "Installing the cable assembly" section and equipped following "Installing the wire guide" section. Only then can the central and media connection take place. 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. Control cable 5. Return of heated water (red cap)
2. EURO central connector 6. Main drive / feeder
3. Air blow-out 7. Water cooling system
4. Cooling water (blue cap)
2. Connect the water hoses to the cooling circuit (7) in water cooled systems. 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 control line plug (1) to the feeder. See section "Electrical connections".
NOTE!
All hoses and the control line must be installed such that they cannot bend or be damaged!

5.7.2 Hollow wrist system

5.7.2.1 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 inch) 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!
Important! Axis 6 must be in 0° position.
5.7.2.2 Connections to the feeder cabinet
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. Refer to the instruction of the feeder manufacturer.
2. Now adjust the position of the wire feeder to suit the length of the Infiniturn or Helix cable, as indicated with "A" in the illustration below.
CAUTION!
When adjusting the position of the feeder cabinet, make sure that the cable assembly is not under stress when the robot arm is in stretched-out position. 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 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.
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.
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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").

5.8 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. Please see the manufacturer's documentation for details. The link to the robot control is then implemented via the power source controller.

5.8.1 Standard RT system

5.8.1.1 Connecting the safety-off mechanism KS-2
The switch for the safety-off functionality KS-2 is connected through the control cable, see (3) in the illustration below. This connects to the 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
1. Push-button for wire run-in 6. Switch for KS-2 push-button (brown/white)
2. Control cable (1-wire) for nozzle sense
function
7. Switch for KS-2 safety-off mechanism
(blue/black))
3. Control cable (4-wire) 8. Circuit for nozzle sense function (black)
4. Control cable plug 9. Power source / robot control
5. KS-2 connector for control cable plug
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5.8.1.2 Connecting the nozzle sense function
If the robot control provides a control circuit for nozzle sense functionality, this can be applied for both KS-2 and FL-1. The connection is accomplished with a 1-wire connection, see (8) in the previous illustration.
Rating of the control circuit: max 50 V / 5 A.
DANGER!
If the nozzle sense function is not being used, the open end of the control cable on the power source connection side must be properly isolated in order to avoid short circuits. 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)

5.8.2 Hollow wrist system with Infiniturn cable assembly

5.8.2.1 Connecting the safety-off mechanism KSC-2
The switch for the safety-off functionality KSC-2 is connected through the control cable, see (3) in the illustration below. This connects to the 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 4. Switch for KSC-2 safety-off mechanism
(black/black)
2. EURO central connector 5. Power source / robot control
3. Control cable
5.8.2.2 Connecting the nozzle sense function
If the robot control provides a control circuit for nozzle sense functionality, this function can be implemented for both KSC-2 and FLC-2.
The connection is accomplished with a 2-wire connection (black/black) to the nozzle sense circuit in the robot control (5), see illustration below.
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Usually, the control cable will be directly connected to the wire feeder. See the manufacturer's documentation for details. The link to the robot control is then implemented via the power source robot interface.
Rating of the control circuit: max. 50 V / 5 A.
DANGER!
If the nozzle sense function is not being used, the open end of the control cable on the power source connection side must be properly isolated in order to avoid short circuits. 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)
1. Control cable plug 4. Connection to FLC-2 or KSC-2
(by-passing the switch)
2. EURO central connector 5. Power source / robot control for nozzle
sense function
3. Control cable

5.8.3 Hollow wrist system with Helix cable assembly

5.8.3.1 Connecting the safety-off mechanism KSC-2
The switch for the safety-off functionality KSC-2 is connected through the control cable, see (2) in the illustration below. This connects to the 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
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1. Control cable plug 4. Switch for KSC-2 safety-off mechanism
(normally closed)
2. Control cable 5. Power source / robot control
3. EURO central connector
5.8.3.2 Connecting the nozzle sense function
If the robot control provides a control circuit for nozzle sense functionality, this function can be implemented for both KSC-2 and FLC-2.
The connection is accomplished with a 1-wire connection (green) to the nozzle sense circuit in the robot control (5), see illustration below.
Usually, the control cable will be directly connected to the wire feeder. See the manufacturer's documentation for details. The link to the robot control is then implemented via the power source robot interface.
Rating of the control circuit: max. 50 V / 5 A.
DANGER!
If the nozzle sense function is not being used, the open end of the control cable on the power source connection side must be properly isolated in order to avoid short circuits. 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)
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1. Control cable plug 4. Connection to FLC-2 or KSC-2
(by-passing the switch)
2. Control cable 5. Power source / robot control with nozzle
sense function
3. EURO central connector
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6 OPERATION

6 OPERATION
CAUTION!
Before starting the system, check the whole installation according to the manufacturer's instructions and applicable safety regulations.
Please check the following to make sure that the system has been installed correctly:
1. Are all parts securely attached (torch, torch mount, flanges, safety-off device, cable assembly, and wire feeder cabinet)?
2. Are all media hoses connected correctly and protected from damage?
3. 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 (KSC-2 and 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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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

7 SERVICE AND MAINTENANCE
WARNING!
Before performing maintenance on the system, the main power of the installation must be turned off. Please note the safety regulations at the beginning of this manual.
Damaged torches or cable assemblies must not be used any more! Known defects must be repaired by qualified personnel prior to the next use of the equipment.
WARNING!
Risk of burn injuries! Gas nozzle and torch head get very hot during welding. Let the torch cool down prior to doing maintenance work.
WARNING!
In order to prevent personal injuries or damage to your installation, the following instructions must be followed:
1. Repair of the KSC-2 or FLC-2 torch mount, the 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 KSC-2 or 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 down-time 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:
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:
Change wire liners.
Change neck liners.
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Weekly or as needed depending on use:
Remove the wire guide and check for wear and dirt deposits. Exchange if needed.
Monthly or more often at heavy use (i.e. more than 8 hours/day):
Blow out the wire guide channel with compressed air (remove contact tip and wire guide).
Make sure that all screws are tightened.
Inspect all connections and hoses for damages.
Damage of the electrical isolation must be repaired by trained personnel before the system can safely be operated. When in doubt, exchange the whole cable assembly and send it in for inspection and repair by ESAB.
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8 TROUBLESHOOTING

8 TROUBLESHOOTING
Fault Possible cause Action
Cannot feed in the wire
Torch is getting too hot
The welding wire has not been straightened before feeding 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 are 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 wire guide (cable assembly and torch neck) and the contact tip.
Pull out the wire guide a little from the Euro-connector. 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, blow out 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 it out. If
needed exchange it.
Consumables used are not suitable
Check with 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 section "Installing the cable assembly").
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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, 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

9 ORDERING SPARE PARTS
CAUTION!
Repair and electrical work should be performed by an authorised ESAB service technician. Use only ESAB original spare and wear parts.
The ESAB RT torches, torch mounts, and cable assemblies are designed and tested in accordance with the international and European standards IEC-/ EN 60974-7. It is the obligation of the service unit which has carried out the service or repair work to make sure that the product still conforms to the said standard.
Spare parts may 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 subsidiaries and representative offices
Europe
AUSTRIA
ESAB Ges.m.b.H Vienna-Liesing Tel: +43 1 888 25 11 Fax: +43 1 888 25 11 85
BELGIUM
S.A. ESAB N.V. Heist-op-den-Berg Tel: +32 15 25 79 30 Fax: +32 15 25 79 44
BULGARIA
ESAB Kft Representative Office Sofia Tel: +359 2 974 42 88 Fax: +359 2 974 42 88
THE CZECH REPUBLIC
ESAB VAMBERK s.r.o. Vamberk Tel: +420 2 819 40 885 Fax: +420 2 819 40 120
DENMARK
Aktieselskabet ESAB Herlev Tel: +45 36 30 01 11 Fax: +45 36 30 40 03
FINLAND
ESAB Oy Helsinki Tel: +358 9 547 761 Fax: +358 9 547 77 71
GREAT BRITAIN
ESAB Group (UK) Ltd Waltham Cross Tel: +44 1992 76 85 15 Fax: +44 1992 71 58 03
ESAB Automation Ltd Andover Tel: +44 1264 33 22 33 Fax: +44 1264 33 20 74
FRANCE
ESAB France S.A. Cergy Pontoise Tel: +33 1 30 75 55 00 Fax: +33 1 30 75 55 24
GERMANY
ESAB GmbH Solingen Tel: +49 212 298 0 Fax: +49 212 298 218
HUNGARY
ESAB Kft Budapest Tel: +36 1 20 44 182 Fax: +36 1 20 44 186
ITALY
ESAB Saldatura S.p.A. Bareggio (Mi) Tel: +39 02 97 96 8.1 Fax: +39 02 97 96 87 01
THE NETHERLANDS
ESAB Nederland B.V. Amersfoort Tel: +31 33 422 35 55 Fax: +31 33 422 35 44
NORWAY
AS ESAB Larvik Tel: +47 33 12 10 00 Fax: +47 33 11 52 03
POLAND
ESAB Sp.zo.o. Katowice Tel: +48 32 351 11 00 Fax: +48 32 351 11 20
PORTUGAL
ESAB Lda Lisbon Tel: +351 8 310 960 Fax: +351 1 859 1277
ROMANIA
ESAB Romania Trading SRL Bucharest Tel: +40 316 900 600 Fax: +40 316 900 601
RUSSIA
LLC ESAB Moscow Tel: +7 (495) 663 20 08 Fax: +7 (495) 663 20 09
SLOVAKIA
ESAB Slovakia s.r.o. Bratislava Tel: +421 7 44 88 24 26 Fax: +421 7 44 88 87 41
SPAIN
ESAB Ibérica S.A. Alcalá de Henares (MADRID) Tel: +34 91 878 3600 Fax: +34 91 802 3461
SWEDEN
ESAB Sverige AB Gothenburg Tel: +46 31 50 95 00 Fax: +46 31 50 92 22
ESAB International AB Gothenburg Tel: +46 31 50 90 00 Fax: +46 31 50 93 60
SWITZERLAND
ESAB AG Dietikon Tel: +41 1 741 25 25 Fax: +41 1 740 30 55
UKRAINE
ESAB Ukraine LLC Kiev Tel: +38 (044) 501 23 24 Fax: +38 (044) 575 21 88
North and South America
ARGENTINA
CONARCO Buenos Aires Tel: +54 11 4 753 4039 Fax: +54 11 4 753 6313
BRAZIL
ESAB S.A. Contagem-MG Tel: +55 31 2191 4333 Fax: +55 31 2191 4440
CANADA
ESAB Group Canada Inc. Missisauga, Ontario Tel: +1 905 670 02 20 Fax: +1 905 670 48 79
MEXICO
ESAB Mexico S.A. Monterrey Tel: +52 8 350 5959 Fax: +52 8 350 7554
USA
ESAB Welding & Cutting Products Florence, SC Tel: +1 843 669 44 11 Fax: +1 843 664 57 48
Asia/Pacific
AUSTRALIA
ESAB South Pacific Archerfield BC QLD 4108 Tel: +61 1300 372 228 Fax: +61 7 3711 2328
CHINA
Shanghai ESAB A/P Shanghai Tel: +86 21 2326 3000 Fax: +86 21 6566 6622
INDIA
ESAB India Ltd Calcutta Tel: +91 33 478 45 17 Fax: +91 33 468 18 80
INDONESIA
P.T. ESABindo Pratama Jakarta Tel: +62 21 460 0188 Fax: +62 21 461 2929
JAPAN
ESAB Japan Tokyo Tel: +81 45 670 7073 Fax: +81 45 670 7001
MALAYSIA
ESAB (Malaysia) Snd Bhd USJ Tel: +603 8023 7835 Fax: +603 8023 0225
SINGAPORE
ESAB Asia/Pacific Pte Ltd Singapore Tel: +65 6861 43 22 Fax: +65 6861 31 95
SOUTH KOREA
ESAB SeAH Corporation Kyungnam Tel: +82 55 269 8170 Fax: +82 55 289 8864
UNITED ARAB EMIRATES
ESAB Middle East FZE Dubai Tel: +971 4 887 21 11 Fax: +971 4 887 22 63
Africa
EGYPT
ESAB Egypt Dokki-Cairo Tel: +20 2 390 96 69 Fax: +20 2 393 32 13
SOUTH AFRICA
ESAB Africa Welding & Cutting Ltd Durbanvill 7570 - Cape Town Tel: +27 (0)21 975 8924
Distributors
For addresses and phone numbers to our distributors in other countries, please visit our home page
www.esab.com
www.esab.com
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