Daihen OTC RT3500S Instruction Manual
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Daihen OTC RT3500S Instruction Manual

Daihen OTC RT3500S Instruction Manual

Welding torch for robot coaxial power cable for robot shock sensor built-in type for co2/mag
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Welding Torch for Robot
Coaxial Power Cable for Robot
Instruction Manual
= Safety and Operation =
Thoroughly read this
instruction manual to
operate the units correctly.
• Installation, maintenance, and repair of this
welding torch shall be made by qualified
persons or persons who fully understand
welding machines to secure the safety.
• To secure the safety, operation of this welding
torch shall be made by persons who have
knowledge
and
understand the contents of this manual and
handle the machine.
• Regarding safety education, utilize courses
and classes held by head/branch offices of
the Welding Society /Association and the
related societies/associations, and qualifying
examinations for welding experts/consultant
engineers.
• After thoroughly reading this manual, be sure
to retain it with the warranty in the place
where the persons concerned can read any
time. Read it again as occasion demands.
• If incomprehensible, contact our offices. For
servicing, contact our local distributor or sales
representatives in your country.
Our addresses and telephone numbers are
listed in the back cover of this Instruction
Manual.
<Shock sensor built-in type>
technical
skill
to
RT3500S /H /L
RT5000S /H /L
RTW5000S /H /L
RZ3500S /H /L
①NOTES ON SAFETY .......................... S1
②IMPORTANT SAFEGUARDS ............. S2
③NOTES ON USE..................................... S7
1. Specifications ............................................1
2. Checking the Contents.............................6
Manipulator....................................................................8
fully
Manipulator ............................................................... 14
(RTW5000S/RTW5000H/RTW5000L).................. 19
4.1 Type of Coaxial Power Cables ............................... 25
4.4 Cutting the Liner........................................................ 29
4.5 Liner Crump Function .............................................. 30
5.1 Checking the Tool Parameter ................................. 31
6. Troubleshooting ..................................... 34
of Torch ........................................................................ 35
of Coaxial Power Cable ............................................ 38
8. Parts List ................................................. 39
For CO
Instruction Manual No.
1L10603-E-2
Contents
/MAG
2

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  • Page 1: Table Of Contents

    Welding Torch for Robot For CO /MAG Coaxial Power Cable for Robot <Shock sensor built-in type> RT3500S /H /L RT5000S /H /L RTW5000S /H /L RZ3500S /H /L Instruction Manual Instruction Manual No. = Safety and Operation = 1L10603-E-2 Contents Thoroughly read this instruction manual to ①NOTES ON SAFETY ......

  • Page 3: ①Notes On Safety

    NOTES ON SAFETY 1. Notes on Safety ●Before operating this product, thoroughly read this instruction manual first to operate the product correctly. ●Cautions described in this instruction manual are to prevent you and other people from being injured or damaged by having the product operated correctly and safely. ●Although this product is designed and manufactured in due consideration of safety, carefully follow the notes and cautions described in this manual.
  • Page 4 IMPORTANT SAFEGUARD 2. Important Safeguard 2.1 Read, understand, and comply with all safety rules described at the beginning of each instruction manual in addition to the following ones before starting Arc welding operation. Observe the following notices to prevent a serious accident WARNING that results in serious injury or death.
  • Page 5 IMPORTANT SAFEGUARD (continued) 1) Only qualified personnel should perform grounding work of the welding power supply and workpiece, or a workpiece and powered peripheral jigs while abiding by domestic regulations. 2) Do not touch live electrical parts. 3) Always wear dry insulating gloves and other body protection. Do not wear torn or wet gloves/ work clothes.
  • Page 6 IMPORTANT SAFEGUARD (continued) 2.4 All the personnel in and around the working area including an operator should wear appropriate protection to protect themselves from fumes and gases produced by welding. ●DO NOT inhale fumes and gases generated by welding. WARNING ●Ventilate the area sufficiently and wear a welder’s shield mask if necessary.
  • Page 7 IMPORTANT SAFEGUARD (continued) 2.5 Prevent fire, explosion, burns and injury caused by heated workpiece, spatters, slag, and arc sparks right after welding as described below. ●Do not weld near flammable materials. ●Watch for fire: keep a fire extinguisher nearby. WARNING ●NEVER do welding on inflammables such as a piece of wood or cloth.
  • Page 8 IMPORTANT SAFEGUARD (continued) For reference PRINCIPAL SAFETY STANDARDS Safety in Welding and Cutting, ANSI Standard Z49.1, from American Welding Society. Safety and Health Standards, OSHA 29 CFR 1910, from Superintendent of Documents, U.S. Government Printing Office. Recommended Practices for Plasma Arc Cutting, American Welding Society Standard AWS C5.2, from American Welding Society.

  • Page 9: ③Notes On Use

    NOTES ON USE 3. Notes on Use 3.1 Duty cycle ● Use the torch with the specified rated duty cycle or under CAUTION Otherwise, the welding torch may be deteriorated or burned out. Welding torch Rated duty cycle ● The rated duty cycle of 50% indicates that the RT3500S ）...
  • Page 10 Replacement of Parts CAUTION ●To prevent burns, comply with the following cautions. ● Do not directly touch the high-temperature parts of a nozzle, an electrode and so on. ● When welding, wear suitable protection such as leather gloves for welding. ●...

  • Page 11: Specifications

    S h o c k s e n s o r SSV、SSB Note) 1. While using RTW5000S, RTW5000H and RTW5000L, are sure that DAIHEN coolant liquid is being supplied with the water tank (PU-301). 2. The maximum operating current and rated duty cycle are different between CO and MAG welding system.
  • Page 12 Weight 1.9[kg] 4.18[lb] Weight 2.3[kg] 5.06[lb] Air-cooled 350A CO /MAG curved torch Air-cooled 350A CO /MAG curved torch RT3500H with shock sensor “SSV” RT3500H with shock sensor “SSB” Weight 2.4[kg] 5.28[lb] Weight 1.9[kg] 4.18[lb] Air-cooled 350A CO /MAG curved torch Air-cooled 350A CO /MAG curved torch RT3500L with shock sensor “SSV”...
  • Page 13 Weight 2.3[kg] 5.06[lb] Weight 2.0[kg] 4.40[lb] Air-cooled 500A CO /MAG curved torch Air-cooled 500A CO /MAG curved torch RT5000H with shock sensor “SSV” RT5000H with shock sensor “SSB” Weight 2.4[kg] 5.28[lb] Weight 1.9[kg] 4.18[lb] Air-cooled 500A CO /MAG curved torch Air-cooled 500A CO /MAG curved torch RT5000L with shock sensor “SSV”...
  • Page 14 Weight 2.4[kg] 5.28[lb] Weight 2.1[kg] 4.62[lb] Liquid-cooled 500A CO /MAG curved torch Liquid-cooled 500A CO /MAG curved torch RTW5000H with shock sensor “SSV” RTW5000H with shock sensor “SSB” 192.8 Weight 2.6[kg] 5.72[lb] Weight 2.0[kg] 4.40[lb] Liquid-cooled 500A CO /MAG curved torch Liquid-cooled 500A CO /MAG curved torch RTW5000L with shock sensor “SSV”...
  • Page 15 Weight 2.3[kg] 5.06[lb] Weight 2.0[kg] 4.40[lb] Air-cooled 350A CO /MAG true constant contact Air-cooled 350A CO /MAG true constant contact curved torch RZ3500H with shock sensor “SSV” curved torch RZ3500H with shock sensor “SSB 197.7 Weight 2.5[kg] 5.50[lb] Weight 2.0[kg] 4.40[lb] Air-cooled 350A CO /MAG true constant contact Air-cooled 350A CO...

  • Page 16: Checking The Contents

    2. Checking the Contents Shock sensor unit Shock sensor unit Hood Mounting bolt （ M5×15） ･･･････････････････ 4 pieces Power cable cover Spring washer （ M5） ･･････････････････････ 4 pieces Mounting bolt （ M5×20） ･･･････････････････ 4 pieces Washer （M5） ･････････････････････････････ 4 pieces Spacer･･････････････････････････････････...
  • Page 17 RT3500S RT3500H RT3500L Welding torch main body Welding torch main body Welding torch main body RT5000S RT5000H RT5000L Welding torch main body Welding torch main body Welding torch main body RTW5000S RTW5000H RTW5000L V6用 B4用 V6用 B4用 V6用 B4用 Welding torch main body Welding torch main body Welding torch main body Wrench ････････････････････...

  • Page 18: Installing And Adjusting Procedure Of Welding Torch

    3. Installing and Adjusting Procedure of Welding Torch 3.1 Mounting of Welding Torch on AII-V6 Type Manipulator 3.1.1 Mounting of shock sensor and mounting bracket Torch mounting bracket ASSY (L10620B) Output flange Insulating bracket （ ） L10620B02 Mount （ ） L6300B01 Hexagon socket head cap screw （...
  • Page 19 Torch mounting bracket ASSY (L10620C):[RT3500L/RT5000L] (L10620D):[RTW5000L/RZ3500L] Output flange Insulating bracket Mount （ ） L10620B02 （ ） L6300B01 Hexagon socket head cap screw （ ） 4-M6X12 For 31° torch L bracket （L10620C01）:[RT3500L/RT5000L] (L10620D01):[RTW5000L/RZ3500L] Hexagon socket head cap screw （ ） 2-M8X25 Hexagon socket head cap screw （...
  • Page 20 3.1.2 Mounting the torch gauge L317Z L10319H L317X L10669D 500A 500A 350A トーチ用 RZ トーチ用 空冷トーチ用 水冷トーチ用 for 350A torch for RZ torch for 500A torch for 500A torch エクステンション エクステンション エクステンション エクステンション Extension Extension Extension Extension 15mm 20mm 20mm 15mm Hexagon socket head cap screw...
  • Page 21 Table 3.1 Type of Torch mounting bracket ASSY / Torch gauge ASSY / Tip gauge Torch mounting Torch model Torch gauge ASSY Tip gauge bracket ASSY RT3500S L6300E L10620B RT3500H L6300C L317X RT3500L L10620C L10620E RT5000S L6300E L10620B RT5000H L6300C L317Z RT5000L L10620C...
  • Page 22 3.1.3 Adjusting procedure of the torch L-bracket （ L10620B03 ） Insulating bracket （ L10620B02 ） Loosen the screw that fixes the Nozzle holder ASSY, and adjust the torch right and left so that the point of tip gauge can align with the reference point. Mount （...
  • Page 23 (3) If the tip gauge point is out of alignment in the horizontal direction to the reference point of the touch gauge, make alignment adjustment following the procedure shown below. 1. Dismount the hood (L10602B02). 2. Disconnect the power cable (L10601D) from the nozzle holder assembly (L10602C), unfasten the hexagon socket head cap screws (M5×20) that fix the nozzle holder to rotate it to the direction of misalignment (or to the left or right), and then make adjustment.

  • Page 24: Mounting Of Welding Torch On Aii-B4 Type Manipulator

    3.2 Mounting of Welding Torch on AII-B4 Type Manipulator 3.2.1 Mounting of curved torch Insulating case （L10601B07） No displacement or misalignment of insulating case Shock sensor cable Coaxial power cable Welding torch Insulating plate （L10601B08） Hole for insulating knock pin Power cable cover Tab of Hood Tumor of cover...
  • Page 25 3.2.2 Reference point teaching procedure (Creation of home position confirmation program) (1) On the RT series, dismount the nozzle and the contact tip from the torch. On the RZ series, dismount the nozzle and the tip holder from the torch. (2) Secure the tip gauge to the torch.
  • Page 26 3.2.3 Mounting of gauge ASSY (option) (1) Dismount the nozzle and the contact tip from the torch to the RT series. Dismount the nozzle and the tip holder from the torch to the RZ series. (2) Secure the tip gauge (L317X, L317Z, L10319H or L10669D01) to the torch. (3) Dismount the hood from the shock sensor.
  • Page 27 3.2.4 Teaching the reference point using the gauge ASSY (Option) (Creating the origin position checking program) (1) Align the point of gauge ASSY with the reference gauge prepared when the gauge ASSY was installed, and teach it as the reference point (1) (point-teaching). This reference point (1) is used for checking the mechanical deviation of robot.
  • Page 28 3.2.6 Adjustment procedure with the tool length automatic setting (1) Copy the existing origin position check program (Program “A” for example), and newly create the program B. Running this program B, align the tip of reference gauge and the point of tip gauge fixed on the torch tip by performing the rectangular manual operation holding the torch posture from the position of program A to perform teaching (point-teaching).

  • Page 29: Connecting The Water-Cooled Torch (Rtw5000S/Rtw5000H/Rtw5000L)

    3.3 Connecting the Liquid-cooled Torch (RTW5000S, RTW5000H, RTW5000L) 3.3.1 Mounting on AII-V6 type (1) Remove the taper plugs from the nozzle holder and mount the elbows（WL-06-01）onto it. The elbows are attached components of the liquid-cooled torch. (2) Connect the cooling water hoses to each of the elbows and fix the protection caps for each. (3) Run the cooling water hoses along the coaxial power cable to connect them to the water tank (PU-301).
  • Page 30 3.3.2 Mounting on AII-B4 type The connection of the liquid-cooled torch to the AII-B4 type manipulator requires the hose mounting kit (L7898P). (1) Remove the hood from the shock sensor. (2) Mount the elbows（M-5HL-6-X112）to the nozzle holder. The elbows are attached components of the liquid-cooled torch.

  • Page 31: Connecting The Hose To Aii-B4

    3.4 Connecting the Hose to AII-B4 1. Connect the hose to the torch along with the coaxial power cable. 2. Bind up the hose and coaxial power cable with a spiral tube. Connect spiral tubes to the W/F side as shown with *1 to *3. [Caution] Slacken off the portions marked with“*”in Fig.3.17.

  • Page 32: Handling Instructions For Rt Series Torch

    (2) Remove the spatter adhered to the nozzle and contact tip before it gets deposited. (3) Be sure to use the DAIHEN genuine tip. Use of a worn-out tip with an enlarged diameter causes conduction defect and wire deflection, which results in unstable Arc and aiming deviation.

  • Page 33: Handling Instructions For Rz Series Torch

    (1) Remove spatters that adhered to the nozzle and tip holder before they accumulate there. (2) For the tip and tip holder, be sure to use the DAIHEN genuine parts. Using a tip or tip holder with enlarged hole-diameter will cause faulty power supply or swaying weld wire, thus resulting unstable arcs or a deviation from the aiming point.
  • Page 34 (8) To teach a program with the torch evacuated from the weld wire after the completion of welding, pull the torch obliquely upward so that the shock sensor will be activated even if the wire and base metal are deposited together. Fig.3.22 Evacuating direction (9) The shock sensor may cause a slight deviation from the teaching point at the torch tip (i.e., torch aiming point).

  • Page 35: Coaxial Power Cable For Robot

    4. Coaxial Power Cable for Robot 4.1 Type of Coaxial Power Cables The coaxial power cable is to lead the wire and shield gas from the wire feeding unit, shock sensor cable, and voltage detection cable (when DL W.P.S used) to the torch. Refer to the table below to choose the coaxial power cable according to the manipulator that you use.

  • Page 36: When Using The Dl Welding Power Supply

    4.2 When Using the DL Welding Power Supply To use the DL welding power supply with the manipulator other than AII-B4/AII-B4L, the voltage detection cable is required in addition to the coaxial power cable as described in Table 4.1. (If you use AII-B4/AII-B4L, see Table 4.1 and choose a suitable coaxial power cable (for DL W.P.S exclusive use) accordingly.) 4.2.1 Type of voltage detection cables To use the DL welding power supply with the manipulator other than AX-V4AP/V4LAP, refer to...
  • Page 37 4.2.3 Connecting the voltage detection cable to the shock sensor Connect a voltage detection wire to the shock sensor as shown in the figure below. To connect a voltage detection wire to SSB, bundle the excess portion of the voltage detection wire together with the shock sensor cable, and then put it in the power cable cover.

  • Page 38: Connecting The Coaxial Power Cable

    4.3 Connection of Coaxial Power Cable 4.3.1 For AII-V6 type Hexagon socket Faston terminal head cap screw (M5) Shock sensor cable Gas hose (Power cable) Fig.4.7 Connection of the coaxial power cable (For AII-V6 type) Protect the FASTON terminal of the shock sensor cable with the silicon tube that comes with the coaxial power cable, and then secure it to the coaxial power cable with the cable tie.

  • Page 39: Cutting The Liner

    4.3.3 Adjustment of the coaxial power cable (AII-B4) (1) Mount a torch, wire feeding unit (fixing bracket), and coaxial power cable. (2) Operate the 5 axis to the maximum (soft limit) toward the manipulator’s inner side as shown in Fig.4.9. (3) Operate the 6 axis to the maximum (soft limit).

  • Page 40: Liner Crump Function

    4.5 Liner Clamp Function A liner clamp is equipped with the nozzle holder of each shock sensor. During welding, weld wire may sway to cause unstable wire feeding due to clearance between the sensor and the liner in the coaxial power cable. This problem will result in faulty weld arc start or fluctuations in the protrusion length of weld wire.

  • Page 41: Setting The Robot Controller

    For the installation posture of torch, see Fig. 5.1 in this page. Table 5.1 Tool constants of arc welding torch (for V6 type) manufactured by Daihen N series...
  • Page 42 Table 5.2 Tool constants of arc welding torch (for B4 type) manufactured by Daihen N series Reference Length Angle Center of G Weight Moment of inertia Dia. - B type drawing Mass [mm] [mm] [mm] [deg] [deg] [deg] [mm] [mm]...

  • Page 43: Checking The Shock Sensor Operation

    5.2 Checking the Shock Sensor Operation 5.2.1 External force for actuating the shock sensor Table 5.3 External force The left table shows the Direction External force (kg) rough standard load to actuate the shock sensor when the external force is applied on the torch tip.

  • Page 44: Troubleshooting

    6. Troubleshooting Phenomena Possible cause No arc generation Contact failure or breaking of welding cable ・ Shortage of wire pressure in the feed roll No smooth wire feeding ・ Tip wear Unstable welding performance ・ Outlet guide wear ・ Wire waste powder has deposited in a wire feeding path. ・...

  • Page 45: Replacement Parts For Various Wire Diameters

    7. Replacement Parts for Various Wire Diameters Liner 7.1 Replacement Parts for Various Wire Diameters of Torch Following parts shall be changed depending on the wire diameter in use. 【Torch related】 Outlet guide (1) Tip 【Coaxial power cable】 (2) Coil liner Feeding roll (Refer to Wire feeding unit manual) (3) Outlet guide...
  • Page 46 ● Standard △ Option Table 7.2 Combination of contact tip (M8) Wire dia. φ1.2 φ1.4 φ1.6 Torch model Design No. L10361B04 L10361B05 L10361B06 Outline drawing △ △ ● RTW5000S △ △ ● RTW5000H △ △ ● RTW5000L ● Standard △ Option Table 7.3 Combination of collet tip Wire dia φ0.9...
  • Page 47 ● Standard Table 7.5 Combination of nozzles △ Option Nozzle dia. φ17 φ20 Torch model Design No. L10603C02 L10603C03 Outline drawing ● △ RT3500S ● △ RT3500H ● △ RT3500L Nozzle dia. φ25 φ22 Torch model Design No. U2774E01 U2774E04 Outline drawing ●...

  • Page 48: Replacement Parts For Various Wire Diameters Of Coaxial Power Cable

    7.2 Replacement Parts for Various Wire Diameters of Coaxial Power Cable ● Standard Table 7.6 Combination of the outlet guide △ Option Wire dia. φ0.8 φ0.9～1.2 φ1.2～1.6 Coaxial power cable Design No. U2770K01 U69B34 U69B35 Outline drawing △ ● △ L-10621／1.1M △...

  • Page 49: Parts List

    8. Parts List For this torch, a shock sensor unit, hood ASSY, nozzle holder, and power-feeding cable are the common parts. A nozzle fitting part is interchangeable for all the models. Note) 1. When interchanging the nozzle ASSY, also change the torch gauge, tool parameter and others. 2.
  • Page 50 Table 8.1 Parts list for RT3500S, RT3500H, RT3500L Remarks № Part No. Item For straight torch L 1 0 6 0 3 B To r c h b o d y A S S Y L 1 0 6 0 5 B To r c h b o d y A S S Y For 45°...
  • Page 51 Table 8.3 Parts list for RT5000S, RT5000H, RT5000L № Part No. Item Remarks For straight torch L 1 0 6 0 6 B To r c h b o d y A S S Y L 1 0 6 0 8 B To r c h b o d y A S S Y For 45°...
  • Page 52 Table 8.5 Parts list for RZ3500S, RZ3500H, RZ3500L № Part No. Item 数量 R e m a r k s For straight torch L 1 0 6 1 2 B To r c h b o d y A S S Y L 1 0 6 1 4 B To r c h b o d y A S S Y For 45°...
  • Page 53 Table 8.7 Parts list for SSV № Part No. Item 数量 Remarks L 1 0 6 0 1 D Power-feeding cable ASSY L 1 0 6 0 2 C N o z z l e h o l d e r A S S Y L10602B02 3 5 7 4 - 0 1 7 “...
  • Page 54 Table 8.8 Parts list for the coaxial power cable № Part No. Item Remarks № Part No. Item Remarks See Table. below. P o w e r c a b l e A S S Y 1st 【List of Power cable ASSY】 For L-10621 2 See Table.
  • Page 55 Table 8.9 Parts list for the coaxial power cable (For AII-B4／B4L exclusive) Remarks № Part No. Item Remarks № Part No. Item See Table. below. Power cable ASSY 【List of Power cable ASSY】 L 1 0 1 1 0 C Connection ASSY L 1 0 6 3 8 B P o w e r c a b l e A S S Y For B4 2-1 L 1 0 11 0 C 0 1...
  • Page 56 Table 8.10 Parts list for the coaxial power cable (For AII-B4／B4L exclusive [DL W.P.S]) R e m a r k s Remarks № Part No. Item № Part No. Item See Fig. below. Power cable ASSY 【List of Power cable ASSY】 L 1 0 1 1 0 C Connection ASSY L10110C01 C o n n e c t i o n...
  • Page 57 Instruction Manual for CO /MAG Welding Torch RT350 0S／ H／ L RT5000S／ H／ L RTW50 00S ／ H／ L RZ3500S／H／L N o . 1 L 1 0 6 0 3 - 1 September. ,2008 edition copy N o . 1 L 1 0 6 0 3 - 2 October.

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