Tweco RDM-2000 User Manual

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RDM-2000

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ROBOTIC

DEFLECTION MOUNT

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Installation and Operation

Guide

Version No: AA.01 Issue Date: July 1, 2006 Manual No: SM-RDM-2000

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PHASE

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WE APPRECIATE YOUR BUSINESS!

Congratulations on your new Tweco® Robotics product. We are proud to have you as our customer and will strive to provide you with the best service and reliability in the industry. This product is backed by our extensive warranty and world-wide service network. To locate your nearest distributor or service agency, please contact a representative at the address and phone number in your area listed on the inside back cover of this manual, or visit us on the web at www.tweco.com.

This Operating Manual has been designed to instruct you on the correct use and operation of your Tweco® Robotics product. Your satisfaction with this product and its safe operation is our ultimate concern. Therefore, please take the time to read the entire manual, especially the Safety Precautions. They will help you to avoid potential hazards that may exist when working with this product.

YOU ARE IN GOOD COMPANY!

The Brand of Choice for Contractors and Fabricators Worldwide.

Tweco® Robotics is a Global Brand of Arc Welding Products for Thermadyne Industries Inc. We manufacture and supply to major welding industry sectors worldwide including; Manufacturing, Construction, Mining, Automotive, Aerospace, Engineering, Rural and DIY/Hobbyist.

We distinguish ourselves from our competition through market-leading, dependable products that have stood the test of time. We pride ourselves on technical innovation, competitive prices, excellent delivery, superior customer service and technical support, together with excellence in sales and marketing expertise.

Above all, we are committed to develop technologically advanced products to achieve a safer working environment within the welding industry.

WARNING

READ AND UNDERSTAND THIS ENTIRE MANUAL AND YOUR EMPLOYER’S SAFETY PRACTICES BEFORE INSTALLING, OPERATING, OR SERVICING THE EQUIPMENT.

WHILE THE INFORMATION CONTAINED IN THIS MANUAL REPRESENTS THE MANUFACTURER’S BEST JUDGMENT, THE MANUFACTURER ASSUMES NO LIABILITY FOR ITS USE.

Robotic Deﬂection Mount Installation and Operation Guide Instruction Manual Number SM-RDM-2000

Published by: Tweco® Products Inc. 2800 Airport Road Denton, TX 76208 (940) 566-2000

www.tweco.com

Reproduction of this work, in whole or in part, without written permission of the publisher is prohibited.

The publisher does not assume and hereby disclaims any liability to any party for any loss or damage caused by any error or omission in this Manual, whether such error results from negligence, accident, or any other cause.

Publication Date: July 1, 2006

Record the following information for Warranty purposes:

Where Purchased: ________________________

Purchase Date: ________________________

Equipment Serial #: ________________________

Robotic Deflection Mount

SECTION 1: SAFETY INSTRUCTIONS AND WARNINGS .......................................... 1-1

1.01 Welding Hazards .......................................................................................1-1

1.02 Principal Safety Standards ........................................................................1-3

1.03 Safety and Health ......................................................................................1-3

SECTION 2: INTRODUCTION AND DESCRIPTION ................................................. 2-4

2.01 How to Use this Manual ............................................................................2-4

2.02 Receipt of Equipment ................................................................................2-4

2.03 Introduction ..............................................................................................2-4

SECTION 3: INSTALLATION AND OPERATION ..................................................... 3-6

3.01 Installation ................................................................................................3-6

3.02 Air Assist Feature ...................................................................................... 3-8

3.03 Wiring Diagram .........................................................................................3-9

3.04 Maintenance ..............................................................................................3-9

Table of Contents

SECTION 4: REPLACEMENT PARTS ................................................................

STATEMENT OF WARRANTY ........................................................................

WARRANTY SCHEDULE .............................................................................

GLOBAL CUSTOMER SERVICE CONTACT INFORMATION .......................................

4-10

5-15

5-16

5-17

SM-RDM-2000

Robotic Deflection Mount

SECTION 1:

SAFETY INSTRUCTIONS AND WARNINGS

WARNING

SERIOUS INJURY OR DEATH MAY RESULT IF WELDING AND CUTTING EQUIPMENT IS NOT PROPERLY INSTALLED, USED AND MAINTAINED. MISUSE OF THIS EQUIPMENT AND OTHER UNSAFE PRACTICES CAN BE HAZARDOUS. THE OPERATOR, SUPERVISOR AND HELPER MUST READ AND UNDERSTAND THE FOLLOWING SAFETY WARNINGS AND INSTRUCTIONS BEFORE INSTALLING OR USING ANY WELDING OR CUTTING EQUIPMENT.

THE WELDING AND CUTTING PROCESS IS USED IN MANY POTENTIALLY DANGEROUS ENVIRONMENTS SUCH AS ELEVATED HEIGHTS, AREAS OF LIMITED VENTILATION, CLOSE QUARTERS, AROUND WATER, IN HOSTILE ENVIRONMENTS, ETC., AND IT IS IMPORTANT THAT THE OPERATOR(S) ARE AWARE OF THE DANGERS ASSOCIATED WITH WORKING IN THESE TYPES OF CONDITIONS. BE CERTAIN THAT THE OPERATOR(S) ARE TRAINED IN SAFE PRACTICES FOR ENVIRONMENTS IN WHICH THEY ARE EXPECTED TO WORK AND UNDER COMPETENT SUPERVISION.

IT IS ESSENTIAL THAT THE OPERATOR, SUPERVISOR AND ALL OTHER PERSONNEL IN THE WORK AREA ARE AWARE OF THE DANGERS OF THE WELDING OR CUTTING PROCESS. TRAINING AND PROPER SUPERVISION ARE IMPORTANT FOR A SAFE WORK PLACE. KEEP THESE INSTRUCTIONS FOR FUTURE USE. ADDITIONAL RECOMMENDED SAFETY AND OPERATING INFORMATION IS REFERENCED IN EACH SECTION.

1.01 Welding Hazards

WARNING

ELECTRIC SHOCK CAN CAUSE INJURY OR DEATH.

INSTALL AND MAINTAIN EQUIPMENT IN ACCORDANCE WITH THE NATIONAL ELECTRICAL CODE (NFPA 70) AND LOCAL CODES. DO NOT SERVICE OR REPAIR EQUIPMENT WITH POWER ON. DO NOT OPERATE EQUIPMENT WITH PROTECTIVE INSULATORS OR COVERS REMOVED. SERVICE OR REPAIR TO EQUIPMENT MUST BE DONE BY A QUALIFIED REPAIR TECHNICIAN, OR TRAINED PERSONNEL ONLY.

1. Do not touch live electrical parts.

2. Do not touch an electrode with bare skin and electrical

ground at the same time.

3. Always keep welding gloves dry and in good condition.

5. All ground connections must be checked periodically to determine that they are mechanically strong and electrically adequate for the required current.

6. When engaged in alternating current, welding, or cutting under wet conditions or warm surroundings where perspiration is a factor, the use of reliable automatic controls for reducing the no-load voltage is recommended to reduce shock hazard.

7. When the welding or cutting process requires values of open circuit voltages in alternating current machines higher than 80 volts, and direct current machines higher than 100 volts, means must be provided to prevent the operator from making accidental contact with the high voltage by adequate insulation or other means.

8. When welding is to be suspended for any substantial length of time, such as during lunch or overnight, all electrodes should be removed from the electrode holder and the electrode holder carefully located so that accidental contact cannot occur.

9. The holder must be disconnected from the power source when not in use.

Never immerse Mig-Guns, electrode holders, tig

10. torches, plasma torches, or electrodes in water.

NOTE

Aluminized protective clothing can become part of the electrical path.

4. Keep oxygen cylinders, chains, wire ropes, cranes, hoists, and elevators away from any part of the electrical path.

SM-RDM-20000

SMOKE, FUMES, AND GASES CAN BE DANGEROUS TO YOUR HEALTH.

1-1

WARNING

SAFETY INSTRUCTIONS AND WARNINGS

Robotic Deflection Mount

11. Keep smoke, fumes, and gases from the breathing area.

12. Fumes from the welding or cutting process are of various types and strengths, depending on the kind of base metal being worked on. To ensure your safety, do not breathe these fumes.

13. Ventilation must be adequate to remove smoke, fumes, and gases during the operation to protect operators and other personnel in the area.

14. Vapors of chlorinated solvents can form the toxic gas “Phosgene” when exposed to ultraviolet radiation from an electric arc. All solvents, degreasers, and potential sources of these vapors must be removed from the work area.

15. Fumes produced by welding or cutting, particularly in conﬁned places, can cause discomfort and physical harm if inhaled over an extended period of time.

16. Provide adequate ventilation in the welding or cutting area. Use air-supplied respirators if ventilation is not adequate to remove all fumes and gases. Never ventilate with oxygen. Oxygen supports and vigorously accelerates ﬁre.

WARNING

ARC RAYS, HOT SLAG AND SPARKS CAN INJURE EYES AND BURN SKIN .

17. The welding and cutting processes produces extreme localized heat and strong ultraviolet rays.

18. Never attempt to weld or cut without a welding helmet with the proper lens. Ensure that the lens complies with federal guidelines. A number 12 to 14 shade ﬁlter lens provides the best protection against arc radiation. When in a conﬁned area, prevent the reﬂected arc rays from entering around the helmet.

19. Ensure all personnel in the work area are protected from arc rays and sparks. Approved shielding curtains and appropriate goggles should be used to provide protection to staff in the surrounding area and operators of nearby equipment.

20. Unprotected skin should also be covered from arc rays, heat and molten metal. Always wear protective gloves and clothing that does not allow skin to become exposed. All pockets should be closed and cuffs sewn shut. Leather aprons, sleeves, leggings, etc., should be worn for out-ofposition welding and cutting or for heavy operations using large electrodes. High top work shoes provide adequate protection from foot burns. For added protection use leather spats.

21. Flammable hair preparations should not be used when welding or cutting. Wear ear plugs to protect ears from sparks.

22. Where the work area permits, the operator should be enclosed in an individual booth painted with a ﬁnish of low reﬂectivity such as zinc oxide. This is an important factor for absorbing ultraviolet radiations, and lamp black. The operator should be enclosed with non-combustible screens similarly painted.

WARNING

WELDING SPARKS CAN CAUSE FIRES AND EXPLOSIONS.

23. Causes of ﬁre and explosion are: combustibles reached by the arc, ﬂame, ﬂying sparks, hot slag, or heated material. Remove combustibles from the work area and/or provide a ﬁre watch.

. Avoid oily or greasy clothing as sparks may ignite them. Have

a ﬁre extinguisher nearby, and know how to use it.

25.

Be alert to the danger of conduction or radiation. For example, if welding or cutting is to be done on a metal wall, partition, ceiling, or roof, precautions must be taken to prevent ignition of combustibles on the other side.

26. Do not w

eld or cut containers that have held combustibles. All hollow spaces, cavities and containers should be vented prior to welding or cutting to permit the escape of air or gases. Purging with inert gas is recommended.

27. Never use oxygen in a welding torch. Use only inert

gases or inert gas mixes as required by the process. Use of combustible compressed gases can cause explosions resulting in personal injury or death. Arcing against any compressed gas cylinder can cause cylinder damage or explosion.

WARNING

NOISE CAN DAMAGE HEARING.

28. Noise from the air carbon-arc process can damage your hearing. Wear protective hearing devices to ensure protection when noise levels exceed OSHA standards. Adequate hearing protection devices must be worn by operators and surrounding personnel to ensure personal protection against noise.

SM-RDM-2000

SAFETY INSTRUCTIONS AND WARNINGS

1-2

1.02 Principal Safety Standards

SAFETY AND OPERATING REFERENCES

1. Code of Federal Regulations. (OSHA) Section 29 Part 1910.95, 132, 133, 134, 139, 251, 252, 253, 254 and 1000. U.S. Government Printing Ofﬁce, Washington, DC. 20402.

2. ANSl Z49.1 “Safety In Welding and Cutting”.

3. ANSI Z87.1 “Practice for Occupational and Educational Eye and Face Protection”.

4. ANSl Z88.2 “Standard Practice for Respiratory Protection”. American National Standards Institute, 1430 Broadway, New York, NY. 10018.

5. AWS F4.1 “Recommended Safe Practices for Welding and Cutting Containers”.

6. AWS C5.3 “Recommended Practices for Air Carbon-Arc Gouging and Cutting”. The American Welding Society, 550 NW Lejeune RD., P.O.Box 351040, Miami FL. 33135.

7. NFPA 51B “Fire Prevention in Cutting and Welding Processes”.

8. NFPA-7 “National Electrical Code”. National Fire Protection Association, Battery Park, Quincy, MA. 02269.

9. CSA W117.2, “Safety in Welding, Cutting and Allied Processes”. Canadian Standards Association, 178 Rexdale Blvd., Rexdale, Ontario, Canada M9W 1R3.

1.03 Safety and Health

Robotic Deflection Mount

NOTE

Be sure to read and fully comprehend the safety instuctions and warnings contained within section 1 of this manual before performing any welding or cutting operations.

SERIOUS INJURY OR DEATH MAY RESULT IF WELDING AND CUTTING EQUIPMENT IS NOT PROPERLY INSTALLED, USED AND MAINTAINED. MISUSE OF THIS EQUIPMENT, OR OTHER UNSAFE PRACTICES, CAN BE HAZARDOUS.

Electric shock can cause injury or death.

• Smoke, fumes, and gases can be dangerous to your

• health. Arc rays, hot slag, and sparks can injure or burn

• unprotected eyes and skin. Welding sparks can cause ﬁres and explosions.

• Excessive noise can damage your hearing.

•

SM-RDM-20000

WARNING

1-3

DO NOT ATTEMPT TO OPEN THE ROBOT MOUNT. THE POWERFUL COMPRESSED SPRING CONTAINED WITHIN CAN CAUSE INJURY IF DISASSEMBLED IMPROPERLY. IT IS RECOMMENDED THAT THE RDM MOUNTS BE RETURNED TO THE FACTORY FOR REPAIRS.

WARNING

SAFETY INSTRUCTIONS AND WARNINGS

Robotic Deflection Mount

INTRODUCTION AND DESCRIPTION

SECTION 2:

2.01 How to Use this Manual

To ensure safe operation, read the entire manual, including the chapters on safety instructions and warnings.

Throughout this manual, the words WARNING, CAUTION, and NOTE may appear. Pay particular attention to the information provided under these headings. These special annotations are easily recognized as follows:

WARNING

A WARNING GIVES INFORMATION REGARDING POSSIBLE PERSONAL INJURY.

CAUTION

A CAUTION refers to possible equipment damage.

NOTE

A NOTE offers helpful information concerning certain operating procedures.

2.03 Introduction

The Tweco® Robotics Robotic Deﬂection Mount – “RDM2000” series — is a safety device designed to act as a switch between the conductor tube and the robot arm. The internal switch mechanism is activated when a collision is detected in any direction.

How the Deﬂection Mount Works

When there is a collision between the conductor tube and ﬁxture/part, the conductor tube will move in the direction with the deﬂection mount shaft. When this happens, one or more of the three switches located inside of the mount assembly will be activated. This activates the E-Stop circuit, which is normally in the closed position, thus stopping the travel of the robot arm.

The deﬂection mount detects motion in any direction, whether it is in the Z-axis (head on), a side load, or a torsional load.

2.02 Receipt of Equipment

When you receive the equipment, check it against the invoice to make sure it is complete and inspect the equipment for possible damage due to shipping. If there is any damage, notify the carrier immediately to ﬁle a claim. Furnish complete information concerning damage claims or shipping errors to the location in your area listed in the inside back cover of this manual. Include a full description of the parts in error.

If you want additional or replacement copies of this CD, please contact Tweco® Robotics at the address and phone number in your area listed on the inside back cover of this manual. Include the Manual number (from page i) and CD part number: 64-2601.

The RDM-2000 series deﬂection mounts are offered in three models, allowing you to choose the best spring rate depending upon the speciﬁc application requirements. In addition to the three spring rates, the mounts come standard with an air assist feature. This allows the robot technician to increase the break - away pressure for any of the forces. Refer to Tables 1 through 3 for more detail, located on in Section 3, page 3-8.

Part No. Stock No. Description

RDM-2000-S 3500-1155 Light Duty RDM-2000-M 3500-1156 Medium Duty RDM-2000-H 3500-1157 Heavy Duty

Part No. Fz Mx/My Mz

RDM-2000-S 267 N

(60#)

RDM-2000-M 444 N

(100#)

RDM-2000-H 662 N

(140#)

18 Nm (160 In-lbs)

27 Nm (245 In-lbs)

28 Nm (250 In-lbs)

Ca. 15Nm (130 In-lbs)

Ca. 25 Nm (220 In-lbs)

Ca. 26 Nm (230 In-lbs)

SM-RDM-2000

INTRODUCTION AND DESCRIPTION

2-4

Robotic Deflection Mount

The RDM-2000 series deﬂection mounts come standard with the items shown in Figure 1. Before starting the installation, please read and understand the installation procedure outlined in this manual.

NOTE

RDM adapter plate used to adapt the RDM mount to the robot arm are sold separately. Refer to Section 4, pages 10-14, to ensure the RDM adapter plate is correct for your speciﬁc robot.

Figure 1: Packaged RDM-2000 Mount

Item No. Description Qty.

1 RDM-2000 Deﬂection Mount Assembly 1 2 E-Stop Cable Assembly 1 3 Rear Adapter Plate (Aluminum) 1 4 M6 x 1 x 16mm Flat Head Socket Cap Screw 5 5 4mm Hex Wrench 1 6 3 mm Hex Wrench 1 7 3/16” x 3/16” x ½” Long Keystock 1 8 Air Fitting (Accepts 5/32” tubing) 1 9 M4 x 60mm Socket Head Cap Screws 6

SM-RDM-20000

2-5

INTRODUCTION AND DESCRIPTION

Robotic Deflection Mount

SECTION 3:

INSTALLATION AND OPERATION

3.01 Installation

1. Remove the RDM mount and the other accessories from the carton. Check to ensure all the items shown in Figure 1 are located and identiﬁed. If any of the component parts are missing, please notify the Welding Distributor or Tweco Products customer service department (1-800-426-1888).

2. Identify and set the “HOME

3. Located on the outer diameter of the RDM adapter plate is a machined line indicating “HOME” position. Position this line to the “HOME” position on the robot arm. Using a 5mm allen wrench, insert and tighten the socket head cap screws furnished with the RDM adapter plate. Refer to Figure 2.

” position on the robot.

7. Locate the engraved arrows on the side of the mount.

Align the arrows with the “HOME” line on the rear adapter plate and place the mount against the plate. The brass locating pin protruding out from the rear mounting plate should help locate and position the RDM mount into the correct position. Refer to Figure 4.

HOME POSITION

Figure 4: Arrows On RDM Mount

ALIGN WITH “HOME“ POSITION ON ROBOT ARM

RDM ADAPTER PLATE

SOCKET HEAD CAP SCREWS

Figure 2: RDM Adapter To Robot Arm

4. Position and secure the aluminum rear adapter plate to the RDM adapter plate using the M6 x 1 x 16mm ﬂat head cap screws. This plate also has a machined line indicating “HOME” position. Align this to the RDM adapter plate machined line. Refer to Figure 3.

SEE DETAIL B

RDM ADAPTER PLATE

REAR MOUNTING PLATE

FLAT HEAD CAP SCREWS

ALIGN

LOCATING PIN

DETAIL B

Figure 3: Rear Mounting Plate

8. Using the 3mm Allen wrench, supplied from the factory, tighten the M4 x 60mm socket head cap screw to the rear adapter plate. Refer to Figure 5.

RDM ADAPTER PLATE

REAR ADAPTER PLATE

RDM-2000 DEFLECTION MOUNT

M4 X 60MM SOCKET HEAD CAP SCREWS

Figure 5: Mounting of RDM Mount

9. Slide the black protective cover back over the mount shaft and place the 3/16” key stock into the machined slot on the mount shaft. Refer to Figure 6.

10. If the air assist feature will be used, remove the 1/8” NPT plug from the side of the mount. Refer to Figure 7.

5. Remove the 7/16”-20 socket head cap screw and ﬂat washer from the mount shaft on the RDM mount and set aside.

6. Slide the black protective cover away from the RDM mount. Insert the M4 x 60mm socket head cap screws into the holes on the front cover plate.

key

rdm deflection mount

Figure 6: Key Stock Location

SM-RDM-2000

INSTALLATION AND OPERATION

3-6

Robotic Deflection Mount

RDM MOUNTING ARM

AIR ASSIST PORT (1/8 NPT)

Figure 7: Air Assist Port

11. Thread the air ﬁtting supplied from the factory, into the RDM mount and tighten. The ﬁtting will accept 5/32” tubing, (not supplied), from a compressed air regulator. Refer to Figure 8.

AIR FITTING

Figure 8: Installation of Air Fitting

12. To provide the air assist, a 5/32” (3,97mm) tubing coming out of the air ﬁtting should be extended back to the feeder or robot base where it is attached to an adjustable air line regulator. Refer to Section 3.02 page 10 for more detail on the air assist option.

5/16-18 SOCKET HEAD CAP SCREW & WASHER

WEDGE PIN

7/16 FLAT WASHER

7/16-20 SOCKET HEAD CAP SCREW

Figure 10: Exploded View of RDM Mounting Arm &

Mounting Screws

15. Align the machined key slot on the mounting arm with the 3/16” key stock on the RDM mount shaft. Slide the mounting arm over the mount shaft.

16. Tighten the 5/16”-18 socket head cap screw until the wedge pin is drawn into contact against the shaft on the RDM mount. This connection must be wrench tight.

17. Install the 7/16-20 socket head cap screw and 7/16” ﬂat washer removed in Step 5 onto the RDM mount and secure. Refer to Figure 10.

NOTE

The centerline of the RDM mount arm should be inline with the engraved arrows on the RDM mount when in the “HOME” position.

5/32” TUBING

AIR FITTING

Figure 9: Air Tubing To Air Line Regulator

NOTE

It’s recommended that the air assist feature be installed in a manner that a continuous air pressure is supplied to the mount during operation.

13. The RDM mount is now ready for the RDM mounting arm to be secured into position.

14. Loosen the 5/16”-18 socket head cap screw that is threaded into the wedge pin of the mounting hardware of the RDM arm. Refer to Figure 10.

7/16”-20

5/16-18 SOCKET HEAD CAP SCREW & WASHER

SOCKET HEAD CAP SCREW

Figure 11: Mounting Arm Screws Used to Secure Arm

to Mount

18. Attach the E-Stop cable assembly, supplied from the factory, to the RDM mount. Refer to Figure 11.

E-STOP CABLE

MOUNT ARM

RDM DEFLECTION MOUNT

Figure 12: E-stop Cable Connection

SM-RDM-20000

3-7

INSTALLATION AND OPERATION

Robotic Deflection Mount

100

150

200

250

300

350

400

450

500

0 10 20 30 40 50 60 70 80 90 10

Air Pressure (PSI)

Mx,My & Mz ( in-lbs)

100

150

200

250

300

350

400

450

500

Fz (lbs)

100

150

200

250

300

350

400

450

500

0 10 20 30 40 50 60 70 80 90 10

Air Pressure (PSI)

Mx,My & Mz (in-lbs)

100

150

200

250

300

350

400

450

500

Fz (lbs)

100

150

200

250

300

350

400

450

500

0 10 20 30 40 50 60 70 80 90 10

Mx,My & Mz (in-lbs)

100

150

200

250

300

350

400

450

500

Fz (lbs)

19. The installation of the RDM mount arm is now complete and is ready to accept the torch and cable assembly. Follow the outlined procedure found in the Installation Guide provided with the Torch and Cable Assembly.

3.02 Air Assist Feature

The addition of air pressure to the RDM mount during operation will increase the force that would be required to activate the switches within the mount causing the robot arm to stop.Refer to Figure 12 and Tables 1 through 3 for further detail on air pressure versus force (Mx, My, and Mz lb-in) and (Fz – lb).

Figure 12: RDM Mount Motion with Air Assist

Table 1: Light Deﬂection Mount Table 2: Medium Deﬂection Mount

Table 1: Heavy Deﬂection Mount

SM-RDM-2000

INSTALLATION AND OPERATION

3-8

3.03 Wiring Diagram

The RDM-2000 Series deﬂection mount uses a single normally closed, switch to determine the deflection breakaway. Since the circuit is normally closed, the emergency stop relay will be on during operation. If the power is lost, a wire breaks, or if there is a collision, the circuit will break telling the robot to stop. (If a normally open circuit is desired, use the white wire instead of the brown.) Refer to the diagram below.

RDM 2000 SERIES DEFLECTION MOUNT NORMAL OPERATION

ROBOT CONTROL

SHOCK SENSOR CIRCUIT

BROWN

NORMALLY CLOSED

Robotic Deflection Mount

COMMON

OPTIONAL NORMALLY OPEN CIRCUIT

GREEN

WHITE

NORMALLY OPEN

COMMON

3.04 Maintenance

The RDM-2000 Series deﬂection mount is designed to operate in the most rugged industrial environments with a minimum of maintenance. We recommend that the user does not attempt to disassemble the mount other than those steps required to attach the unit to the robot arm.

WARNING

DO NOT ATTEMPT TO OPEN THE RDM DEFLECTION MOUNT. THE POWERFUL COMPRESSED SPRING CONTAINED WITHIN CAN CAUSE INJURY IF DISASSEMBLED IMPROPERLY. IT IS RECOMMENDED THAT THE RDM DEFLECTION MOUNTS BE RETURNED TO THE FACTORY FOR REPAIRS.

Figure 13: Exploded View of Internal Components

SM-RDM-20000

3-9

INSTALLATION AND OPERATION

Robotic Deflection Mount

B°

Ø A

RDM-AP-X

B°

Ø D

RDM-AP-X

YPE A

REPLACEMENT PARTS

SECTION 4:

Replacement Parts for RDM-2000

Item No. Part No. Stock No. Description

1 RDM-2000-B 3500-1197 RDM-2000 Deﬂection Mount Assembly

2 RDM-2000-JC 3044-1842 E-Stop Cable Assembly - 18”

RDM-2000-EC

3 RDM-2000-AP 3500-1174 Rear Adapter Plate (Aluminum)

4 AF532-18NPT-S 3500-1385 Air Fitting (Accepts 5/32” tubing)

Adapter Plates for RDM-2000

(457.2mm)***

3500-1172 E-Stop Cable Assembly – 20’ (6,10m)

*** Standard on all RDM Deﬂection Mounts

Tweco Robotics offers many different adapter plates to use with the RDM-2000 Series deﬂection mount. The adapter plate acts as an additional insulator to protect the robot arm as well as a mechanical breakaway in the event the switching does not stop the robot or peripheral motion. The following table will aid in determining the proper adapter plate required too install the deﬂection mount to your robot arm.

SM-RDM-2000

REPLACEMENT PARTS

4-10

Robotic Deflection Mount

Robot Type Robot

Model No.

AdapterPart

No.

AdapterStock

No. Type Ø A B° C Ø D

ABB IRB-6 RDM-AP-8 3500-1147 A 1.575”

40,01mm

RDM-AP-2 3500-1141 A 1.575”

40,01mm

IRB 1500 RDM-AP-8 3500-1147 A 1.575”

40,01mm

RDM-AP-2 3500-1141 A 1.575”

40,01mm

IRB 2000 RDM-AP-8 3500-1147 A 1.575”

40,01mm

RDM-AP-2 3500-1141 A 1.575”

40,01mm

IRB 1400 RDM-AP-8 3500-1147 A 1.575”

40,01mm

RDM-AP-2 3500-1141 A 1.575”

40,01mm

IRB 2400 RDM-AP-8 3500-1147 A 1.575”

40,01mm

RDM-AP-2 3500-1141 A 1.575”

40,01mm

IRB 240L RDM-AP-8 3500-1147 A 1.575”

40,01mm

RDM-AP-2 3500-1141 A 1.575”

40,01mm

ASEA ALL

MODELS

RDM-AP-8 3500-1147 A 1.575”

40,01mm

RDM-AP-2 3500-1141 A 1.575”

40,01mm

ESAB 1500 RDM-AP-8 3500-1147 A 1.575”

40,01mm

RDM-AP-2 3500-1141 A 1.575”

40,01mm

2000 RDM-AP-8 3500-1147 A 1.575”

40,01mm

RDM-AP-2 3500-1141 A 1.575”

40,01mm

FANUC ARC MATE

100/S6

RDM-AP-8 3500-1147 A 1.575”

40,01mm

RDM-AP-2 3500-1141 A 1.575”

40,01mm

ARC MATE 120

RDM-AP-8 3500-1147 A 1.575”

40,01mm

RDM-AP-2 3500-1141 A 1.575”

40,01mm

45° .650”

16,51mm

22.5° .525” 13,34mm

45 .650”

16,51mm

22.5° .525” 13,34mm

45° .650”

16,51mm

22.5° .525” 13,34mm

45° .650”

16,51mm

22.5° .525” 13,34mm

45° .650”

16,51mm

22.5° .525” 13,34mm

45° .650”

16,51mm

22.5° .525” 13,34mm

45° .650”

16,51mm

22.5° .525” 13,34mm

45° .650”

16,51mm

22.5° .525” 13,34mm

45° .650”

16,51mm

22.5° .525” 13,34mm

45° .650”

16,51mm

22.5° .525”

13,34mm

45° .650”

16,51mm

22.5° .525”

13,34mm

1.937” 49,20mm

SM-RDM-20000

4-11

REPLACEMENT PARTS

Robotic Deflection Mount

Robot

Type

FANUC ARC MATE

Robot Model

No.

120/S/12

AdapterPart

No.

AdapterStock

No. Type Ø A B° C Ø D

RDM-AP-8 3500-1147 A 1.575”

40,01mm

RDM-AP-2 3500-1141 A 1.575”

40,01mm

ARC MATE 100/I

RDM-AP-8 3500-1147 A 1.575”

40,01mm

RDM-AP-2 3500-1141 A 1.575”

40,01mm

ARC MATE JR SR.S-10

ARC MATE JR S/5

LR MATE 100 1

RDM-AP-4 3500-1143 A 1.968”

49,99mm

RDM-AP-4 3500-1143 A 1.968”

49,99mm

RDM-AP-16 3500-1120 A 1.240”

31,50MM

50 iL RDM-AP-24 3500-1181 B 1.240”

31,50mm

Arc Mate 100iB, M-6iB,

RDM-AP-8 3500-1147 A 1.575”

40,01

100ib/6S

HITACHI 5430 RDM-AP-4 3500-1143 A 1.968”

49,99mm

MR 6060 RDM-AP-6 3500-1145 B 1.575”

40,01mm

MR 6100 RDM-AP-6 3500-1145 B 1.575”

40,01mm

KAWASAKI FS010 RDM-AP-25 3500-1118 B 2.480”

62,99mm

FS010L RDM-AP-25 3500-1118 B 2.480”

62,99mm

JS6 RDM-AP-6 3500-1145 B 1.575”

40,01mm

SJ10 RDM-AP-6 3500-1145 B 1.575”

40,01mm

KUKA KR6 RDM-AP-17 3500-1123 B 1.968”

49,99mm

KR150 RDM-AP-17 3500-1123 B 1.968”

49,99mm

KR3015 RDM-AP-17 3500-1123 B 1.968”

49,99mm

MILLER MRV-6 RDM-AP-8 3500-1147 A 1.575”

40,01mm

RDM-AP-2 3500-1141 A 1.575”

40,01mm

MRV-2000 RDM-AP-8 3500-1147 A 1.575”

40,01mm

RDM-AP-2 3500-1141 A 1.575”

40,01mm

MRV-2300 RDM-AP-8 3500-1147 A 1.575”

40,01mm

RDM-AP-2 3500-1141 A 1.575”

40,01mm

45° .650”

16,51mm

22.5° .525” 13,34mm

45° .650”

16,51mm

22.5° .525” 13,34mm

45° .525”

13,34mm

45° .525”

13,34mm

45° .650”

16,51mm

45° .550”

13,97mm

45° .650”

16,51mm

45° .525”

13,34mm

45° .525”

13,34mm

45° .525”

13,34mm

45° .525”

13,34mm

45° .525”

13,34mm

45° .525”

13,34mm

45° .525”

13,34mm

45° .650”

16,51mm

45° .650”

16,51mm

45° .650”

16,51mm

45° .650”

16,51mm

22.5° .525” 13,34mm

45° .650”

16,51mm

22.5° .525” 13,34mm

45° .650”

16,51mm

22.5° .525” 13,34mm

1.937” 49,20mm

1.263” 32,08mm

1.973” 49,20mm

.787” 19,99mm

1.937” 49,20mm

1.263” 32,08mm

.981” 24,92mm

1.571” 39,90mm

.981” 24,92mm

1.236” 31,39mm

1.937” 49,20mm

SM-RDM-2000

REPLACEMENT PARTS

4-12

Robotic Deflection Mount

Robot Type Robot

Model No.

AdapterPart

No.

AdapterStock

No. Type Ø A B° C Ø D

MILLER MR-5 RDM-AP-7 3500-1146 A 1.265”

32,13mm

MR-1000 RDM-AP-7 3500-1146 A 1.265”

32,13mm

MRH RDM-AP-7 3500-1146 A 1.265”

32,13mm

MRK5 RDM-AP-7 3500-1146 A 1.265”

32,13mm

MOTOMAN SV-3 RDM-AP-24 3500-1181 B 1.240”

31,50mm

K5 RDM-AP-8 3500-1147 A 1.575”

40,01mm

RDM-AP-2 3500-1141 A 1.575”

40,01mm

K6 RDM-AP-8 3500-1147 A 1.575”

40,01mm

RDM-AP-2 3500-1141 A 1.575”

40,01mm

K10 RDM-AP-8 3500-1147 A 1.575”

40,01mm

45° .650”

16,51mm

45° .650”

16,51mm

45° .650”

16,51mm

45° .650”

16,51mm

45° .550”

13,97mm

45° .650”

16,51mm

22.5° .525” 13,34mm

45° .650”

16,51mm

22.5° .525” 13,34mm

45° .650”

16,51mm

1.579” 40,11mm

.787” 19,99mm

1.937” 49,20mm

RDM-AP-2 3500-1141 A 1.575”

40,01mm

SK SERIES RDM-AP-8 3500-1147 A 1.575”

40,01mm

RDM-AP-2 3500-1141 A 1.575”

40,01mm

SUPER K RDM-AP-8 3500-1147 A 1.575”

40,01mm

RDM-AP-2 3500-1141 A 1.575”

40,01mm

UP6, UP20,

RDM-AP-27 3500-1191 A 1.575”

40,01mm UP20-6 & UP20M

L SERIES RDM-AP-9 3500-1148 B 2.047”

51,99mm

NACHI SC15 RDM-AP-11 3500-1115 A 1.890”

48,01mm

7603 RDM-AP-10 3500-1149 A 2.047”

51,99mm

SC06 RDM-AP-26 3500-1114 B 1.890”

48,01mm

22.5° .525” 13,34mm

45° .650”

16,51mm

22.5° .525” 13,34mm

45° .650”

16,51mm

22.5° .525” 13,34mm

45° .650”

16,51mm

22.5° .525” 13,34mm

25° .525”

13,34mm

22.5° .525” 13,34mm

30° .525”

13,34mm

1.937” 49,20mm

1.569” 39,85mm

.949” 24,10mm

1.697” 43,10mm

.561” 14,25mm

OTC DIAHEN

SM-RDM-20000

DR 4000 RDM-AP-8 3500-1147 A 1.575”

40,01mm

RDM-AP-2 3500-1141 A 1.575”

40,01mm

4-13

45° .650”

16,51mm

22.5° .525” 13,34mm

1.937” 49,20mm

REPLACEMENT PARTS

Robotic Deflection Mount

Robot Type Robot

Model No.

OTC

DR 500 RDM-AP-8 3500-1147 A 1.575”

DIAHEN

AdapterPart

No.

AdapterStock

No. Type Ø A B° C Ø D

40,01mm

RDM-AP-2 3500-1141 A 1.575”

40,01mm

DR 4200 RDM-AP-8 3500-1147 A 1.575”

40,01mm

RDM-AP-2 3500-1141 A 1.575”

40,01mm

DR 3000 RDM-AP-7 3500-1146 A 1.265”

32,13mm

PANASONIC AW5A RDM-AP-12 3500-1116 B 1.968”

49,99mm

AW6A RDM-AP-12 3500-1116 B 1.968”

49,99mm

AW10A RDM-AP-12 3500-1116 B 1.968”

49,99mm

AW5C RDM-AP-12 3500-1116 B 1.968”

49,99mm

AW6AL RDM-AP-12 3500-1116 B 1.968”

49,99mm

VR 005 RDM-AP-12 3500-1116 B 1.968”

49,99mm

VR 006 RDM-AP-12 3500-1116 B 1.968”

49,99mm

VR 006L RDM-AP-12 3500-1116 B 1.968”

49,99mm

VR 008 RDM-AP-12 3500-1116 B 1.968”

49,99mm

VR 16 RDM-AP-12 3500-1116 B 1.968”

49,99mm

REIS RV6 RDM-AP-17 3500-1123 B 1.968”

49,99mm

RV6L RDM-AP-17 3500-1123 B 1.968”

49,99mm

RV-16 RDM-AP-20 3500-1177 B 2.480”

62,99mm

RH30-16 RDM-AP-20 3500-1177 B 2.480”

62,99mm

STAUBLI RX90 RDM-AP-8 3500-1147 A 1.575”

40,01mm

RDM-AP-2 3500-1141 A 1.575”

40,01mm

45° .650”

16,51mm

22.5° .525” 13,34mm

45° .650”

16,51mm

22.5° .525” 13,34mm

45° .650”

16,51mm

45° .525”

13,34mm

45° .525”

13,34mm

45° .525”

13,34mm

45° .525”

13,34mm

45° .525”

13,34mm

45° .525”

13,34mm

45° .525”

13,34mm

45° .525”

13,34mm

45° .525”

13,34mm

45° .525”

13,34mm

45° .650”

16,51mm

45° .650”

16,51mm

45° .650”

16,51mm

45° .650”

16,51mm

45° .650”

16,51mm

22.5° .525” 13,34mm

1.937” 49,20mm

1.579” 40,11mm

1.571” 39,90mm

1.236” 31,39mm

1.888” 47,96mm

1.937” 49,20mm

SM-RDM-2000

REPLACEMENT PARTS

4-14

Robotic Deflection Mount

STATEMENT OF WARRANTY

LIMITED WARRANTY: THERMADYNE® warrants that its products will be free of defects in workmanship or material. Should any failure to conform to this warranty appear within the time period applicable to the THERMADYNE products as stated below, THERMADYNE shall, upon notiﬁcation thereof and substantiation that the product has been stored, installed, operated, and maintained in accordance with THERMADYNE’s speciﬁcations, instructions, recommendations and recognized standard industry practice, and not subject to misuse, repair, neglect, alteration, or accident, correct such defects by suitable repair or replacement, at THERMADYNE’s sole option, of any components or parts of the product determined by THERMADYNE to be defective.

THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE.

LIMITATION OF LIABILITY:

damages, such as, but not limited to, damage or loss of purchased or replacement goods, or claims of customers of distributor (hereinafter the “Purchaser”) for service interruption. The remedies of the Purchaser set forth herein are exclusive and the liability of THERMADYNE with respect to any contract, or anything done in connection therewith such as the performance or breach thereof, or from the manufacture, sale, delivery, resale, or use of any goods covered by or furnished by THERMADYNE whether arising out of contract, negligence, strict tort, or under any warranty, or otherwise, shall not, except as expressly provided herein, exceed the price of the goods upon which such liability is based.

THIS WARRANTY BECOMES INVALID IF REPLACEMENT PARTS OR ACCESSORIES ARE USED WHICH MAY IMPAIR THE SAFETY OR PERFORMANCE OF ANY THERMADYNE PRODUCT.

THIS WARRANTY IS INVALID IF THE PRODUCT IS SOLD BY NON-AUTHORIZED PERSONS.

This warranty is effective for the time stated in the Warranty Schedule beginning on the date that the authorized distributor delivers the products to the Purchaser.

Warranty repairs or replacement claims under this limited warranty must be submitted by an authorized THERMADYNE repair facility within thirty (30) days of the repair. No transportation costs of any kind will be paid under this warranty. Transportation charges to send products to an authorized warranty repair facility shall be the responsibility of the Purchaser. All returned goods shall be at the Purchaser’s risk and expense. This warranty supersedes all previous THERMADYNE warranties.

THERMADYNE shall not under any circumstances be liable for special or consequential

SM-RDM-20000

5-15

WARRANTY SCHEDULE

The warranty is effective below for the time stated in the Warranty Schedule beginning on the date that the authorized distributor delivers the products to the purchaser. THERMADYNE® reserves the right to request documented evidence of date of purchase.

Engine Driven Welders Parts / Labor

Original Main Power Stators and Inductors 3 years / 3 years Original Main Power Rectiﬁers, Control P.C. Boards 3 years / 3 years All Other Original Circuits and Components Including, but not Limited to, Relays, Switches, Contactors, Solenoids, Fans, Power Switch Semi-Conductors 1 year / 1 year Engines and Associated Components are NOT Warranted by Thermal Arc®, Although Most are Warranted by the Engine Manufacturer. SEE THE ENGINE

MANUFACTURERS’ WARRANTY FOR DETAILS.

Fabricator® 131, 181, 190, 210, 251, 281; Fabstar® 4030; PowerMaster® 350, 350P, 500, 500P; Excel-Arc® 6045; Wire Feeders: Ultrafeed®, Porta-feed®

Original Main Power Transformer and Inductor 5 years / 3 years Original Main Power Rectiﬁers, Control P.C. Boards, Power Switch Semi-Conductors 3 years / 3 years All Other Original Circuits and Components Including, but not Limited to, Relays, Switches, Contactors, Solenoids, Fans, Electric Motors 1 year / 1 year

160TS, 300TS, 400TS, 185AC/DC, 200AC/DC, 300AC/DC, 400GTSW, 400MST, 300MST, 400MSTP

Original Main Power Magnetics 5 years / 3 years Original Main Power Rectiﬁers, Control P.C. Boards, Power Switch Semi-Conductors 3 years / 3 years All Other Original Circuits and Components Including, but not Limited to, Relays, Switches, Contactors, Solenoids, Fans, Electric Motors 1 year / 1 year

Original Main Power Magnetics 5 years / 3 years Original Main Power Rectiﬁers, Control P.C. Boards, Power Switch Semi-Conductors 3 years / 3 years Welding Console, Weld Controller, Weld Timer 3 years / 3 years All Other Original Circuits and Components Including, but not Limited to, Relays, Switches, Contactors, Solenoids, Fans, Electric Motors, Coolant Recirculators 1 year / 1 year

Original Main Power Magnetics 1 year / 1 year Original Main Power Rectiﬁers, Control P.C. Boards 1 year / 1 year All Other Original Circuits and Components Including, but not Limited to, Relays, Switches, Contactors, Solenoids, Fans, Power Switch Semi-Conductors 1 year / 1 year

Original Main Power Magnetics 5 years / 3 years Original Main Power Rectiﬁers, Control P.C. Boards 3 years / 3 years All Other Original Circuits and Components Including, but not Limited to, Relays, Switches, Contactors, Solenoids, Fans, Power Switch Semi-Conductors 1 year / 1 year

Water Recirculators 1 year / 1 year Plasma Welding Torches 180 days / 180 days Gas Regulators (Supplied with Power Sources) 180 days / NA MIG and TIG Torches (Supplied with Power Sources) 90 days / NA Replacement Repair Parts 90 days / NA MIG, TIG and Plasma Welding Torch Consumable Items NA / NA

Victor® Professional 5 years / NA Oxygen Conservers 2 years / NA Aluminum Cylinders Lifetime / NA Cutting Machine Motors 1 year / NA HP&I Brass Regulators/Manifolds 2 years / NA HP&I Stainless Regulators/Manifolds 1 year / NA HP&I Corrosive Gas Regulators/Manifolds 90 days / NA TurboTorch® 3 years / NA CutSkill® 2 years / NA Steel Cylinders 1 year / NA Victor Medical 6 years / NA Victor VSP 2 years / NA Firepower® MIG Welders 5-2-1 years / NA Transformers 5 years / NA Parts Used in Rental Applications 1 year from date sold by seller to authorized

Arcair® N6000 90 days / NA Eliminator® Spool and Pull Guns 90 days / NA Robotic Deﬂection Mounts 90 days / NA QRM-100 Anti-Spatter Applicator 90 days / NA TC and TCV Water Coolers 1 year / NA TSC-96 Smoke Collector 1 year / NA ESG-1, EPG-CR1, EPG-CR2 Control Boxes for Eliminator Spool & Pull Guns 1 year / NA QRC-2000 Nozzle Cleaning Stations 1 year / 1 year All other products 30 days from date purchaser purchases from seller. 30 days / NA

Automated Plasma 2 years / 1 year CutMaster™ 3 years / 3 years PakMaster® XL PLUS 3 years / 1 year Drag-Gun® 1 year / 1 year Drag-Gun Plus 2 years / 1 year Torches 1 year / 1 year Consoles, Control Equipment, Heat Exchangers and Accessory Equipment 1 year / 1 year

GTAW (TIG) & Multi-process Inverter Welding Equipment Parts / Labor

Scout®, Raider®, Explorer™

See the Engine Manufacturers’ Warranty

GMAW/FCAW (MIG) Welding Equipment Parts / Labor

Plasma Welding Equipment Parts / Labor

Ultima® 150

SMAW (Stick) Welding Equipment Parts / Labor

Dragster™ 85

160S, 300S, 400S

General Arc Equipment Parts / Labor

Gas Welding and Cutting Equipment Parts / Labor

MIG Torches and Arc Accessories Parts / Labor

Plasma Cutting Systems Parts / Labor

for Details

distributor

GLOBAL CUSTOMER SERVICE CONTACT INFORMATION

Thermadyne USA

2800 Airport Road Denton, TX 76207 USA Telephone: (1) 800-535-1888 Fax: (1) 800-535-0557

Thermadyne Canada

2070 Wyecroft Road Oakville, Ontario Canada, L6L5V6 Telephone: (1) 905-827-9777 Fax: (1) 905-827-9797

Thermadyne Europe

Europe Building Chorley North Industrial Park Chorley, Lancashire England, PR6 7Bx Telephone: (44) 1257-261755 Fax: (44) 1257-224800

Thermadyne Asia Sdn Bhd

Lot 151, Jalan Industri 3/5A Rawang Integrated Industrial Park - Jln Batu Arang 48000 Rawang Selangor Darul Ehsan West Malaysia Telephone: 603+ 6092 2988 Fax : 603+ 6092 1085

Cigweld Australia

71 Gower Street Preston, Victoria Australia, 3072 Telephone: 1300-654-674 Fax: 613+ 9474-7391

Thermadyne Italy

OCIM, S.r.L. Via Benaco, 3 20098 S. Giuliano Milan, Italy Tel: (39) 02-98 80320 Fax: (39) 02-98 281773

Thermadyne China

RM 102A 685 Ding Xi Rd Chang Ning District Shanghai, PR, 200052 Telephone: 86 21+6280-1273 Fax: 86 21+3226-0955

Thermadyne International

2070 Wyecroft Road Oakville, Ontario Canada, L6L5V6 Telephone: (1) 905-827-9777 Fax: (1) 905-827-9797

World Headquarters

Thermadyne Holdings Corporation Suite 300, 16052 Swingley Ridge Road St. Louis, MO 63017 Telephone: (636) 728-3000 Fascimile: (636) 728-3010 www.thermadyne.com

Tweco RDM-2000 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual