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 TECHNICAL DATA ............................................................................................. 10
4.1 Welding torch .....................................................................................................10
4.1.1 Voltage rating ...................................................................................................10
4.1.2 Cooling circuit limits ......................................................................................... 10
4.2 Torch mount ....................................................................................................... 11
4.2.1 Torch mounts for standard RT system ............................................................. 11
4.2.1.1 KS-2 safety-off mechanism ............................................................................ 12
4.2.1.2 FL-1 intermediate flange ................................................................................ 12
4.2.2 Torch mounts for hollow wrist system .............................................................. 12
4.2.2.1 KSC-2 torch mount with safety-off mechanism .............................................. 14
4.2.2.2 FLC-2 rigid torch mount ................................................................................. 15
4.3 Adaptor flanges .................................................................................................. 15
4.4 Cable assemblies ...............................................................................................16
4.4.1 Cable assemblies for standard RT system ..................................................... 16
4.4.2 Cable assemblies for hollow wrist systems ...................................................... 17
5 INSTALLATION................................................................................................... 19
5.1 Preparation ......................................................................................................... 19
5.2 Installing the adapter flange .............................................................................19
5.3 Installing the torch mount ................................................................................. 19
5.3.1 Torch mount in standard RT system ................................................................ 20
5.3.1.1 Direct mounting of KS-2 ................................................................................. 20
5.3.1.2 Mounting via mounting flange ....................................................................... 20
5.3.2 Torch mount in hollow wrist system..................................................................22
5.3.2.1 Mounting of KSC-2 ......................................................................................... 22
5.3.2.2 Mounting of FLC-2 ......................................................................................... 23
5.4 Installing the cable assembly ...........................................................................24
5.4.1 Installing the cable assembly in a standard RT system ...................................25
5.4.2 Installing the cable assembly in a hollow wrist system .................................... 26
5.5 Installing the wire guide .................................................................................... 29
5.5.1 Installing the neck liner..................................................................................... 29
5.5.2 Installing a split wire guide in the cable assembly............................................30
5.6 Installing the torch ............................................................................................. 31
5.6.1 Torch neck equipment ...................................................................................... 31
5.6.2 Aristo RT torch installation ............................................................................... 32
0463 373 101 © ESAB AB 2015
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 OPERATION ....................................................................................................... 42
6.1 Important information for programming (hollow wrist system
only)................................................................................................................. 42
7 SERVICE AND MAINTENANCE ........................................................................ 44
7.1 Mandatory checks and actions.........................................................................44
8 TROUBLESHOOTING ........................................................................................ 46
9 ORDERING SPARE PARTS............................................................................... 48
Rights reserved to alter specifications without notice.
0463 373 101 © ESAB AB 2015
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.
0463 373 101
- 5 -
© ESAB AB 2015
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.
0463 373 101
- 6 -
© ESAB AB 2015
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.
0463 373 101
- 7 -
© ESAB AB 2015
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".
0463 373 101
- 8 -
© ESAB AB 2015
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".
0463 373 101
- 9 -
© ESAB AB 2015
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.
0463 373 101
- 10 -
© ESAB AB 2015
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.
0463 373 101
- 11 -
© ESAB AB 2015
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.
0463 373 101
- 12 -
© ESAB AB 2015
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
0463 373 101
- 13 -
© ESAB AB 2015
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
0463 373 101
- 14 -
© ESAB AB 2015
4 TECHNICAL DATA
Item Description Function
5 Adaptor flange Isolating interface to the robot wrist, must be
selected to fit on the specific robot
6 Index pin For precise alignment to the adaptor flange
7 Connector for control cable Electrical connection for collision signal and nozzle
sense function
8 Micro switch Sensor for collision detection
4.2.2.2 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.
0463 373 101
- 15 -
© ESAB AB 2015
Loading...