ESAB RT Robo Welding Torch System User manual
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ESAB RT Robo Welding Torch System is a versatile and reliable solution for fully-automatic MIG/MAG welding using welding robots. It features various torch options, gas or water cooling, and compatibility with different robot types. The system's modular design allows for easy customization to suit specific welding needs, ensuring efficient and precise welding operations.
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RT Robo Welding Torch System Instruction manual 0463 373 001 GB 20131212 TABLE OF CONTENTS 1 SAFETY ................................................................................................................ 4 2 WARRANTY.......................................................................................................... 6 3 TECHNICAL DATA ............................................................................................... 7 3.1 Application............................................................................................................ 7 3.2 Compatibility ........................................................................................................ 7 3.3 Overview of the RT welding torch system.........................................................7 3.4 Specifications....................................................................................................... 8 3.4.1 Field of use......................................................................................................... 8 3.4.2 Torch rating ........................................................................................................ 8 3.4.3 Voltage rating ..................................................................................................... 9 3.4.4 Torch cooling circuit limits (water cooled version only) ...................................... 9 4 3.5 Selection of a suitable torch ............................................................................... 9 3.6 Selection of a suitable torch mount for the torch neck ....................................9 3.7 Conditions of intended use ............................................................................... 10 INSTALLATION................................................................................................... 11 4.1 Preparation ......................................................................................................... 11 4.2 Installing the RT KS-1 on the robot arm .......................................................... 11 4.3 Installation of torch mount ................................................................................ 11 4.3.1 Direct mounting to KS-1 ................................................................................... 11 4.3.2 Installation of the mounting flange on the RT KS-1.......................................... 12 4.4 Cable assembly installation .............................................................................. 13 4.4.1 Installing the cable assembly (RT flange) in the torch mount .......................... 13 4.5 Robot welding torch .......................................................................................... 14 4.5.1 Equipping the torch neck.................................................................................. 14 4.5.2 Mounting the torch neck................................................................................... 15 4.6 Wire guide installation in cable assembly .......................................................16 4.6.1 Installation of a split wire guide (cable assembly) ............................................ 16 4.6.2 Installation of a continuous wire guide (cable assembly) ................................. 17 4.7 Connection at the wire feeder cabinet .............................................................18 5 INITIAL OPERATION.......................................................................................... 20 6 SERVICING AND MAINTENANCE .................................................................... 21 7 SPARE PARTS LIST........................................................................................... 23 8 7.1 Robot Welding Torch ......................................................................................... 23 7.2 System components .......................................................................................... 23 7.3 Wire Guides ........................................................................................................ 23 TROUBLESHOOTING ........................................................................................ 25 Rights reserved to alter specifications without notice. 0463 373 001 © ESAB AB 2013 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 equpment 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 extinquishing equipment must be clearly marked and close at hand ○ Lubrication and maintenance must not be carried out on the equipment during operation 0463 373 001 -4- © ESAB AB 2013 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. 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! CAUTION! Read and understand the instruction manual before installing or operating. 0463 373 001 -5- © ESAB AB 2013 2 WARRANTY 2 WARRANTY Before delivery, our products are carefully checked. We guarantee, 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. 0463 373 001 -6- © ESAB AB 2013 3 TECHNICAL DATA 3 TECHNICAL DATA 3.1 Application The RT welding torch system is developed for fully-automatic MIG/MAG welding using welding robots. Its components consist of: • • • • an RT welding torch cable assembly torch mount safety-off mechanism or rigid intermediate flange It is possible to use gas or water cooling. For different needs in the welding process a large selection of suitable torches with different geometries can be used. 3.2 Compatibility Depending on the type of robot, an adapter flange is required for the assembly of the system at the robot wrist. The robot should have a load-bearing capacity of at least approximately 5 kg at its wrist. NOTE! Correct selection of the system components to suit the welding task is the prerequisite for the faultless functioning of the system. 3.3 Overview of the RT welding torch system Item Description Function 1 RT welding torch Different versions available A RT flange Interface to the RT welding torch 2 Cable assembly Different versions available, gas or water cooled 3 Torch mount In various designs to fit the torch necks (for example torch bent by 45°) - Mounting flange (not shown) Only needed for some versions of the torch mount (3) (see "Installation" section) 0463 373 001 -7- © ESAB AB 2013 3 TECHNICAL DATA 4 RT KS-1 Fully mechanical, spring supported safety-off mechanism Alternatively: Rigid intermediate flange for robots with electronic collision detection system, can be used instead of the RT KS-1 Rigid intermediate flange RT FL-1 (not shown) 5 Control plug Electrical connection to RT KS-1 for the signal for collision monitoring 6 EURO central connector or other connector Connection to the wire feeder 7 Control cable with connecting plug Electrical connection for the safety-off signal RT KS-1 (4-wire) and signal “nozzle sense” (1-wire) 8 Blow out hose For cleaning the torch with compressed air after welding 9 Water inlet (blue cap) Water inlet for cooling of the torch (water cooled version only) 10 Water return (red cap) Water return of heated water from the torch (water cooled version only) 3.4 Specifications 3.4.1 Field of use 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. 3.4.2 Torch rating For detailed information regarding the rating and technical specifications of your torch please see the spare parts list included with the torch. The ratings are valid for cable lengths from 1 to 5 m. The values for torch rating and duty cycle are valid for a 10 min. cycle. The indicated ratings refer to a standardized case of use. In special cases, e.g. incase 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. Type of guidance Guidance by machine only Weights Approximately • • • • • • • • • • • • Robot welding torch Cable assembly, 1,2 m long, G Cable assembly, 1,2 m long, W Torch Mount (Std.) RT KS-1 RT FL-1 Environmental temperature 0,66 kg 2,35 kg 2,35 kg 0,43 kg 1,96 kg 0,37 kg Storage -15° to 50°C (5° to 122°F) Operation 5° to 40°C (41° to 104°F) 0463 373 001 -8- © ESAB AB 2013 3 TECHNICAL DATA Rating Cable assemblies Rating/Duty cycle (Mixed gas, 10 min. cycle) • • 500 A/60 %, 350 A/100 % gas cooled water cooled Blow-out gas pressure 3.4.3 • • • 600 A/100 % max. 10 bar, separate gas hose Voltage rating The maximum permitted welding voltage for the system is 141 V (peak value). The maximum permitted voltage for the safety-off control circuit is 24 V, max 1 A, for the push-button 48 V and max. 0,1 A The maximum permitted voltage for the push-button (cable assembly) is 48 V and max. 0,1 A 3.4.4 Torch cooling circuit limits (water cooled version only) 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 of more than 60°C / 140°F may cause damage or destroy the cable assembly. The cooler must always be filled with sufficient cooling liquid, please consult the user manual of the cooling unit. In case of a high thermal load on the torch, please use a cooler with sufficient capacity. The ESAB products have been designed and manufactured according to the state-of-the-art. They are safe and reliable when used according to their specifications. The RT torches are in compliance with the European Norm IEC 60974-7 and marked with the CE-sign. 3.5 Selection of a suitable torch The torch model must be chosen according to the welding application. The required duty-cycle and capacity, the cooling method and the wire diameter have to 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 choosing a welding torch with adequate reserve in power rating. 3.6 Selection of a suitable torch mount for the torch neck Torch mounts must always be selected in accordance with the type of torch and its geometry. Various mount types may be used. Choosing the right one is important. 0463 373 001 -9- © ESAB AB 2013 3 TECHNICAL DATA 3.7 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 RT 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. The maximum required duty cycle, load capacity, type of cooling, type of guidance and wire diameter must be taken into consideration for this. In case of higher demands, for example due to pre-heated workpieces, high heat reflection in corners, etc. a type of torch must be selected with a corresponding reserve capacity. 3. The RT System was designed for use as a complete system. The incorporation of components from other manufacturers into the system is not permissible. 4. The RT 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. 5. The product must be kept dry and protected from humidity when transported, stored or used. 6. The system is designed for environmental temperatures range from 5° and 40°C (41 to 104°F). In case these limits are exceeded, specific action is needed. In case of frost risks use a suitable coolant. 0463 373 001 - 10 - © ESAB AB 2013 4 INSTALLATION 4 INSTALLATION 4.1 Preparation DANGER! For you own safety, prior to starting maintenance work in the moving radius of the robot, make sure that all necessary safety measures have been taken will stay effective while in the danger area. Please refer to the chapter “Safety instructions“ in the beginning of this manual. 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. To obtain the best repeatability and stability of the system, only use 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. 4.2 Installing the RT KS-1 on the robot arm Use the separate installation and operating instructions for the RT KS-1 safety-off mechanism for installation of the RT KS-1 on the robot arm. 4.3 Installation of torch mount Various mounts are available for mounting the RT torch. Depending on the design of the mount, it may be attached directly or via a mounting flange (a) on the mounting surface (b) of the safety-off mechanism RT KS-1 or, if applicable, on the intermediate flange RT FL-1. Only torch mounts having a hole pattern coinciding with that of the mounting surface may be attached. 4.3.1 Direct mounting to KS-1 1. If necessary, carefully press the cylindrical pins (1) into the corresponding holes in the bracket. Avoid the formation of burrs. The pins (Ø4×20) should protrude by approximately 5 mm. 2. Position the mount on the safety-off mechanism KS-1 and carefully insert the cylindrical pins (1) into the holes provided. In doing so, take the later position of the torch into account; 2 mounting positions may be potentially possible. 3. Then screw down the mount evenly using the enclosed cylinder screws (M6×20) with hexagon socket (2). For further information please refer to the RT KS-1 Installation and Operating Instructions, Chapter “Installation of torch mount”. NOTE! The maximum tightening torque for the cylinder screw is 7 Nm and the property class category is 8.8. 0463 373 001 - 11 - © ESAB AB 2013 4 INSTALLATION Side view 4.3.2 Installation of the mounting flange on the RT KS-1 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 (Ø4×14) should protrude by approximately 5 mm. 2. Position the mount on the safety-off mechanism RT KS-1 and carefully insert the cylindrical pins (1) into the holes provided. In doing so, take the later position of the torch into account; 2 mounting positions may be potentially possible. 3. Then screw down the mounting flange evenly using the enclosed cylinder screws (M6×16) with hexagon socket (2). For further information please refer to the RT KS-1 Installation and Operating Instructions, Chapter “Installation of torch mount”. NOTE! The maximum tightening torque for the cylinder screws (M6×16) is 7.1 Nm and the property class category is 8.8. 4. Unscrew the axial cylinder screw (M8×16) with hexagon socket (4) out of the mounting flange together with the Ø9mm washer (3). 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). 0463 373 001 - 12 - © ESAB AB 2013 4 INSTALLATION 6. Insert the clamping mandrel (8) into the lateral hole (see illustration) and position it such 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 cylinder screw (M6×30) with hexagon socket (10) and the Ø22×6.4 mm washer (10a). 8. Finally, screw the axial cylinder screw (4) with the washer (3) into the mounting flange and tighten firmly. 4.4 Cable assembly installation 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. 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. 4.4.1 Installing the cable assembly (RT flange) in the torch mount The front part of the cable assembly is directly clamped into the torch mount. 1. Unscrew the cylinder screws (12) and lift off the top section (5a) of the torch mount. 2. Insert the feather key (13) into the recess of the RT flange (cable assembly) from below. 0463 373 001 - 13 - © ESAB AB 2013 4 INSTALLATION 3. Align the RT flange including the feather key (13) to the groove (14) of the torch mount and push into the groove right up to the stop (15). 4. Hold the cable assembly in this position and simultaneously place the top section (5a) back onto the torch mount. First screw both cylinder screws (12) loosely in to about the same length, then tighten alternately. The top section (5a) of the mount should have an even gap to the bottom section (see illustration below). 4.5 Robot welding torch 4.5.1 Equipping the torch neck The torch must always be equipped to suit the wire diameter and material. 1. For this, select the correct wire guide, contact tip, nozzle holder, gas nozzle, gas diffuser and spatter protection. You will find an exact overview and possible alternative equipment elements for various torch models in the spare parts list of your torch. Only use original ESAB parts; only then is the fitting accuracy ensured. 2. Firmly tighten the nozzle 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 (16) from the torch flange upon delivery if necessary (see illustration under "Installation/removal of the wire guide in the torch neck in case of continuous wire guidance" section) 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. Installation or replacement of the wire guide in the torch neck in the case of a separate wire guide 0463 373 001 - 14 - © ESAB AB 2013 4 INSTALLATION The wire guide must be selected to fit the material and diameter of the welding wire. (See spare parts list) 1. Unfasten sleeve nut and remove torch neck. 2. If applicable, loosen the screw connection of the connecting nipple and pull the neck liner (wire guide) out of the torch neck from the rear. 3. Remove the gas nozzle and contact tip from the torch. 4. Blow down torch neck with compressed air. 5. Insert the new neck liner into the torch neck from the rear and fasten with the connecting nipple. Cut the wire guide at the tip holder. 6. For the determination of the thread projection of the contact tip, loosen the connecting nipple and pull the liner back again; then screw in the contact tip. 7. Insert the neck liner into the torch again until it reaches the contact tip. Now measure the remaining length that needs to be cut from the liner. 8. Now remove the neck liner again and cut the additional length measured off it’s front end. If needed, grind down the burred edges. 9. Insert the shortened neck liner into the torch neck again from the rear and screw in the connecting nipple. Position or screw on the gas nozzle again. 10. Check o-rings on the flange of the torch neck for damage or wear, replace as required. 11. Mount the torch neck as described in "Mounting the torch neck" section. Do not use tools to tighten the sleeve nut! Installation/removal of the wire guide in the torch neck in case of continuous wire guidance A continuous wire guide, which reaches from the central connection of the cable assembly to the contact tip of the torch, can be installed as an alternative to the separate wire guide. For this, the description in "Wire guide installation in cable assembly" section applies. The guide nipple including o-ring (16) must be inserted in the torch neck for this. 4.5.2 Mounting the torch neck Check the o-rings on the flange of the torch neck before each mounting for damage or loss and replace the o-rings if necessary. Missing or faulty o-rings lead to leaks of shielding gas and coolant. Depending on the wire guide the torch neck must be equipped as described in "Equipping the torch neck" section and the cable assembly as in "Installation of a split wire guide (cable assembly)" section. 0463 373 001 - 15 - © ESAB AB 2013 4 INSTALLATION 1. Position the torch necks as shown below and tighten the sleeve nut by hand in clockwise direction. Do not use tools! 2. The correct seating of the torch at the RT flange of the cable assembly can be checked by means of the window (11). If the torch has been correctly mounted, no gap should be able to be seen through the window (11). 4.6 Wire guide installation in cable assembly The wire guide is inserted through the cable assembly from the rear. The correct liner must be selected to suit the filler material used and wire diameter. The correct function of the total system can only be guaranteed if original ESAB wire guides are used. It is possible to use a continuous wire guide from the cable assembly to the contact tip or a split wire guide (torch neck extra, cable assembly extra). 4.6.1 Installation of a split wire guide (cable assembly) Installing a steel liner The wire guide is inserted through the cable assembly from the rear and reaches to the RT flange. The following worksteps must be followed for the correct calculation of the length (example for Euro central connector): 1. Install the guide nipple with stop (E) in the center hole of the RT flange. 2. Remove the sleeve nut (D) from the Euro connector. 3. Insert the liner through the central connection and push forwards as far as it will go in the guide nipple (E) applying light pressure. CAUTION! Ensure that the wire guide has advanced right up to on the stop at the front. To do this, rotate the wire guide and push forward again gently. 4. Now measure the excess length that needs to be cut from the liner. 0463 373 001 - 16 - © ESAB AB 2013 4 INSTALLATION 5. Now remove the liner again and cut the additional length measured off it’s front end. If needed, grind down the burred edges. Make sure the inner opening of the liner is not obstructed by the cut wire end. 6. Reinstall the wire guide and attach the sleeve nut (D). Installing a plastic liner 1. Install the guide nipple with stop (E) in the center hole of the RT flange. 2. Remove the sleeve nut (D) from the Euro connector. 3. Make a clean cut at the front end of the liner and chamfer the edges (for example with a pencil sharpener). 4. Insert the liner (E) through the central connector into the cable assembly until it reaches the stop. If it gets stuck, rotate the liner to free it and facilitate installation. Note: Make sure the liner is completely inserted by rotating it and slightly pushing it forward, until you can feel it has reached its stop. 5. Mount the nipple (B) and the o-ring (C), move it to the right position and fix it with the sleeve nut (D) of the euro central connector. 6. Measure the required overlap needed inside the wire feeder cabinet and cut the liner accordingly. 4.6.2 Installation of a continuous wire guide (cable assembly) Installing a steel liner The wire guide is inserted through the cable assembly from the rear and reaches to the contact tip. The following worksteps must be followed for the correct calculation of the length (example for Euro central connector): 1. 2. 3. 4. 5. Install the torch (see "Mounting the torch neck" section). Remove the gas nozzle and contact tip from the torch. Remove the sleeve nut (D) from the Euro connector. Push in the liner through the central connector and fix with the sleeve nut. Cut off the liner flush with the nozzle holder. To determine the thread projection of the contact tip, pull the liner backwards and screw in the contact tip. 6. Push the liner forwards as far as it will go to the contact tip applying light pressure on the liner and measure the length to be shortened at the rear. 7. Now remove the liner again and cut the excess length measured off it’s front end. If needed, grind down the burred edges. Make sure the inner opening of the liner is not obstructed by the cut wire end. 0463 373 001 - 17 - © ESAB AB 2013 4 INSTALLATION 8. The insulation of the liner must be removed after cutting off in the front area, such that the insulation protrudes out of the RT flange by approximately 5 cm. For this, briefly remove the torch neck. 9. Push the liner back in again and fix with the sleeve nut (D). Re-install the gas nozzle. Installing a plastic liner 1. Mount the torch neck (see "Mounting the torch neck" section) and equip it with a gas nozzle and contact tip. 2. Remove the sleeve nut (D) from the Euro connector. 3. Cleanly cut off the liner, slightly break the outer edges, point slightly. (for example with a pencil sharpener). 4. Insert the liner through the central connector into the cable assembly with fitted torch. If it gets stuck, rotate the liner to free it and facilitate installation. Note: Make sure the liner is completely inserted by rotating it and slightly pushing it forward, until you can feel it has reached its stop. 5. Mount the nipple (B) and the o-ring (C), move it to the right position and fix it with the sleeve nut (D) of the euro central connector. 6. Measure the required overlap needed inside the wire feeder cabinet and cut the liner accordingly. 4.7 Connection at the wire feeder cabinet In order to be able to create the connection, the cable assembly must be mounted as described in "Cable assembly installation" section and equipped following "Wire guide installation in cable assembly" section. Only then can the central and media connection take place. Proceed as described below: 0463 373 001 - 18 - © ESAB AB 2013 4 INSTALLATION 1. Connect the central connector of the cable assembly to the wire feeder cabinet socket. Tighten the central connector sleeve nut fingertight. Do not use tools! 2. Connect the water hoses to the cooling circuit in water cooled systems. The end of the hose marked blue to the water outlet, and the end marked red to the water return. 3. Connect the blow-out line to the corresponding connection of the wire feeder cabinet. 4. Connect the control line plug to the wire feeder cabinet. NOTE! All hoses and the control line must be installed such that they cannot bend or be damaged! 0463 373 001 - 19 - © ESAB AB 2013 5 INITIAL OPERATION 5 INITIAL OPERATION CAUTION! Before starting the system, check the whole installation according to the manufacturer's instructions and applicable safety regulations. Check the following to make sure that the system has been installed correctly: 1. Are all parts securely attached (torch, torch mount, cable assembly, RT KS-1 safety-off mechanism or RT FL-1 rigid intermediate flange and wire feeder)? 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? The cable must not be bent sharply, any risk of the cable catching on another object must be eliminated. 5. Is the safety-off circuit of the RT KS-1 connected correctly and functional? (move torch by hand to test). 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 they can not be damaged or bent? Take the necessary safety precautions before starting up the welding process! The wire run-in can now be started either via the wire run-in pushbutton (2a) see "Overview of the RT welding torch system" section or via the wire run-in at the wire feeder cabinet. 0463 373 001 - 20 - © ESAB AB 2013 6 SERVICING AND MAINTENANCE 6 SERVICING AND MAINTENANCE DANGER! • Before performing maintenance on the system, the main power of the installation must be turned off. Note the safety regulations at the beginning of this manual! • Damaged torches or cable assemblies must no be used any more! Known defects must be repaired by qualified personnel prior to the next use of the equipment. • In order to avoid damage to the system or injuries to persons, the following must be observed: Repairs on the RT KS-1 safety-off mechanism may only be carried out by ESAB! DANGER! Risk of burn injuries Gas nozzle and torch head get very hot during welding. Let the torch cool down prior to doing maintenance work! To assure a faultless function and long life of the equipment, torch and cable assembly must be checked and serviced regularly. Cleaning and maintenance work must be done at the latest, if the welding performance is degrading. 1. Check the torch and cable assembly for damages before every use. Damages must be repaired by qualified personnel prior to further use of the product. This is especially important in regard of damages on the electrical insulation of the torch or cable. 2. Worn out and damaged parts on the torch have to be exchanged immediately against original spare parts and consumables. 3. The contact tip should be exchanged if the inner hole is countersunk or if there are ignition problems. 4. Change the contact tip and the liner if there are wire feeding problems. Take care to install the new liner correctly and precisely fit it to the length of the cable. 5. When changing the liner, or more often if necessary, blow out the liner guide tube of the torch with compressed air to remove dust and wire grit. 6. The use of a high quality anti-spatter spray, for example RT Anti spatter liquid, is highly recommended and will tremendously increase the life time of the consumables. 7. Contact tip and gas nozzle should be cleaned as soon as there is noticeable spatter adhesion. It must be avoided that a spatter bridge will build up between contact tip and gas nozzle, the torch could be damaged. 8. The gas nozzle should be cleaned regularly on the inside to prevent adhering spatter from causing gas swirling. 9. Make sure that the cooling liquid is clean, if required exchange it. Impurities in the cooling liquid can obstruct the water channels of the torch. The following service intervals apply to the ESAB RT welding torch system: Daily: • • • Visual inspection for damages – for example bends or cracks. Verify the correct position of the cable assembly, it should be neither under tension, nor compression. Inspect the media connections for leakage. 0463 373 001 - 21 - © ESAB AB 2013 6 SERVICING AND MAINTENANCE Monthly or more often in heavy use: • • • Blow out the wire guide channel with compressed air (remove contact tip and wire guide). Ascertain that all screws are tightened. If necessary: Inspect all connections and hoses for damages. 0463 373 001 - 22 - © ESAB AB 2013 7 SPARE PARTS LIST 7 SPARE PARTS LIST 7.1 Robot Welding Torch For spare and wearing parts, refer to the enclosed respective spare parts list of your RT torch. Only use original ESAB parts; only then is the fitting accuracy ensured. 7.2 System components Item Part No. Designation 4 700300434 RT KS-1 safety-off mechanism complete 17 on request Rubber boot for KS-1 safety-off mechanism E on request Fitting with stop 18 on request Connector cover, red 19 on request Connector cover, blue 20 on request Quick connector (for water) 21 on request Quick connector 6 mm (for gas) 22 on request O-ring 4.0 x 1.0 mm (for gas) 23 on request O-ring 4.0 x 1.0 mm (for gas) 24 on request Nut M10x1 7.3 Wire Guides Please choose the wire guide suitable for the wire diameter and material. Only use original ESAB parts; only then is proper functioning ensured. 0463 373 001 - 23 - © ESAB AB 2013 7 SPARE PARTS LIST Item Part No. Designation A (for steel wire) 700300498 Liner blue 1.50m, wire 0.8-1.0 mm 700300499 Liner blue 1.70m, wire 0.8-1.0 mm 700300500 Liner blue 2.00m, wire 0.8-1.0 mm 700300322 Liner blue 3.50m wire 0.8-1.0 mm 700300501 Liner red, 1.50m, wire 1.0-1.2 mm 700300502 Liner red, 1.70m, wire 1.0-1.2 mm 700300503 Liner red, 2.00m, wire 1.0-1.2 mm 700300507 Liner red, 2.50m, wire 1.0-1.2 mm 700300508 Liner red, 3.50m, wire 1.0-1.2 mm 700300504 Liner yellow, 1.50m, wire 1.2-1.6 mm 700300505 Liner yellow, 1.70m, wire 1.2-1.6 mm 700300506 Liner yellow, 2.00m, wire 1.2-1.6 mm B (for alu and stainless steel wire) 700300320 PTFE Liner, 3.50m wire 1.0-1.2 mm 700300321 PA Liner, 3.50m, wire 1.0-1,2 mm D (for alu and stainless steel wire) 700300468 Neck liner bronze, 217 mm, wire 1.2-1.6 mm 700300469 Neck liner steel, 217 mm, wire 0.8-1.2 mm D (for steel wire) 700300470 Neck liner steel, 217 mm, wire 1.2-1.6 mm 700300472 Neck liner bronze, 217 mm, wire 0.8-1.0 mm 700300473 Fitting with stop size 4.0-4.7 mm E 0463 373 001 - 24 - © ESAB AB 2013 8 TROUBLESHOOTING 8 TROUBLESHOOTING Fault Possible cause Action Cannot feed in Have you straightened the welding the wire wire before feeding into the cable assembly? Were the RT torch and the cable assembly equipped correctly for the wire diameter and wire material? Check wire guide (cable assembly and torch neck) and the contact tip. Only when using a split wire guide: Has the wire guide been correctly inserted into the cable assembly? Pull the wire guide a short way out of the Euro-connector. When inserting you should feel the last centimetre slip into the guide nipple in the torch interface. Otherwise the wire guide may be too short and not fully inserted. Is the contact tip blocked with wire debris or the wire guide worn, is the wire feed impeded by dirt and debris in the torch? Replace the contact tip and/or wire guide, blow out torch neck, wire guide conduit and wire guide with compressed air. Torch is Contact tip or tip holder are not getting too hot tightened correctly. Wire feeding problems 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. Use a suitable tool for tightening hand-tight. 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 for the wire diameter or material. Check with spare part list. 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 Check the cable assembly for too small radii or flexed. damages. Can the liner be inserted easily? Install as instructed (see "Cable assembly installation" section). Wire is contaminated. 0463 373 001 Use a cleaning felt. - 25 - © ESAB AB 2013 8 TROUBLESHOOTING Wire feed stops during welding Wire spool is empty? Check the quantity of the welding wire on the spool in the wire feeder. Is there a wire blockage in the cable Check wire feed (possibly too fast), assembly? check the contact tip for contamination/clogging, clean or replace the contact tip if required. Wire burn back into the contact tip or Replace the contact tip. worn contact tip. Welding process is stopping Pores in the seam Safety-off mechanism has triggered. Search for collision points and prevent them. Check control line for a loose contact . Safety-off mechanism has triggered without collision. Check control line for cable breakage/loose contact. Gas swirl caused by spatter adherence. Clean the torch head, use gas diffuser/spatter protection. Too small or extremely high gas flow Check flow rate with measurement in the torch. tool. Arc is not stable 0463 373 001 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 antispatter liquid. Contact tip is worn. Exchange contact tip. Wrong welding parameters. Check the set-up of the welding torch. Insufficient electrical connections in the circuit. Check all electrical connections (including ground cable) between the power source torch or workpiece for firm seating. - 26 - © ESAB AB 2013 8 TROUBLESHOOTING 0463 373 001 - 27 - © ESAB AB 2013 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. Brussels Tel: +32 2 745 11 00 Fax: +32 2 745 11 28 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 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 www.esab.com Africa EGYPT ESAB Egypt Dokki-Cairo Tel: +20 2 390 96 69 Fax: +20 2 393 32 13 MEXICO ESAB Mexico S.A. Monterrey Tel: +52 8 350 5959 Fax: +52 8 350 7554 SOUTH AFRICA ESAB Africa Welding & Cutting Ltd Durbanvill 7570 - Cape Town Tel: +27 (0)21 975 8924 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 SINGAPORE ESAB Asia/Pacific Pte Ltd Singapore Tel: +65 6861 43 22 Fax: +65 6861 31 95 THE NETHERLANDS ESAB Nederland B.V. Amersfoort Tel: +31 33 422 35 55 Fax: +31 33 422 35 44 UNITED ARAB EMIRATES ESAB Middle East FZE Dubai Tel: +971 4 887 21 11 Fax: +971 4 887 22 63 CANADA ESAB Group Canada Inc. Missisauga, Ontario Tel: +1 905 670 02 20 Fax: +1 905 670 48 79 MALAYSIA ESAB (Malaysia) Snd Bhd USJ Tel: +603 8023 7835 Fax: +603 8023 0225 ITALY ESAB Saldatura S.p.A. Bareggio (Mi) Tel: +39 02 97 96 8.1 Fax: +39 02 97 96 87 01 SOUTH KOREA ESAB SeAH Corporation Kyungnam Tel: +82 55 269 8170 Fax: +82 55 289 8864 Distributors For addresses and phone numbers to our distributors in other countries, please visit our home page www.esab.com
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