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ESAB RT EDGE Instruction Manual
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ESAB RT EDGE Instruction Manual

ESAB RT EDGE Instruction Manual

Robo welding torch systems
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ESAB RT EDGE
Robo welding torch systems
Instruction manual
0700 025 150   GB   20240214

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Summary of Contents for ESAB RT EDGE

  • Page 1 ESAB RT EDGE Robo welding torch systems Instruction manual 0700 025 150   GB   20240214...
  • Page 3 OPERATION ..... Important information for programming (hollow wrist system only) ............Important information for programming remote .......................... MAINTENANCE ....................Routine maintenance ........................ TROUBLESHOOTING ....................... ORDERING SPARE PARTS ............................. Wear parts 0700 025 150 - 3 - © ESAB AB 2024...
  • Page 4 Sheets (SDSs). Safety precautions 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.
  • Page 5 Reinstall panels or covers and close doors when service is finished and before starting the unit. FIRE HAZARD • Sparks (spatter) can cause fire. Make sure therefore that there are no inflammable materials nearby • Do not use on closed containers. 0700 025 150 - 5 - © ESAB AB 2024...
  • Page 6 MALFUNCTION - Call for expert assistance in the event of malfunction. PROTECT YOURSELF AND OTHERS! ESAB has an assortment of welding accessories and personal protection equipment for purchase. For ordering information contact your local ESAB dealer or visit us on our website. 0700 025 150 - 6 -...
  • Page 7 1. Torch 4. KS-2 safety-off mechanism 2. Cable assembly 5. FL-2 intermediate flange 3. Torch mount 6. Adapter flange NOTE! For more information, refer to corresponding chapter in "TECHNICAL DATA". 0700 025 150 - 7 - © ESAB AB 2024...
  • Page 8 Hollow wrist system 1. Torch 4. Adapter flange 2. Torch mount KSC-E 5. Cable assembly Helix E 3. Torch mount FLC-E NOTE! For more information, refer to corresponding chapters in "TECHNICAL DATA". 0700 025 150 - 8 - © ESAB AB 2024...
  • Page 9 For detailed information regarding the rating and technical specifications of your torch please see the spare parts list included with the torch. The values for torch rating and duty cycle are valid for a 10 min. cycle. 0700 025 150 - 9 - © ESAB AB 2024...
  • Page 10 The KS-2 safety mechanism is a spring supported devise that protects the robot and the torch system in case of a collision. FL-2 intermediate flange The rigid intermediate flange FL-2 can be used instead of the KS-2 if the robot has an electronic collision detection system. 0700 025 150 - 10 - © ESAB AB 2024...
  • Page 11 50 V DC / 5 A, max. 1 minute max. 1 minute After detection of contact, the After detection of contact, the sensing voltage should be sensing voltage should be disconnected quickly. disconnected quickly. 0700 025 150 - 11 - © ESAB AB 2024...
  • Page 12 For precise alignment to the adaptor flange Connector for control cable Electrical connection for collision signal and nozzle sense function Micro switch Sensor for collision detection Connectors Electrical connection for remote 0700 025 150 - 12 - © ESAB AB 2024...
  • Page 13 Max. 400 A 100% duty cycle Max. 270 A Max. 270 A Rating (10 min. cycle) for water cooled (mixed gas) 60% duty cycle Max. 500 A Max. 500 A 0700 025 150 - 13 - © ESAB AB 2024...
  • Page 14 Water return (red cap) Water return of heated water from the torch Control cable plug for safety-off mechanism Electrical connection with the KS-2 for the safety-off signal and nozzle sense function (if applicable) 0700 025 150 - 14 - © ESAB AB 2024...
  • Page 15 Blow out hose (black cap) For cleaning the torch with compressed air after welding Protective cover Protects the cable assembly from damage Control cable plug Connection to PCBA KSC-E / FLC-E 0700 025 150 - 15 - © ESAB AB 2024...
  • Page 16 This can lead to a short circuit, which may damage the electronics of the robot or the welding torch. Use only original ESAB components that have been specially developed for this purpose. Only then can the correct functioning of the whole welding torch system be guaranteed.
  • Page 17 6. Mounting flange journal 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. 0700 025 150 - 17 - © ESAB AB 2024...
  • Page 18 3) Position the main body (5) on the adapter flange (7) so that the index pin is correctly seated. Attach with the screws (6) enclosed. NOTE! Fastening torque max. 2.2 Nm (19.5 lbf in). 0700 025 150 - 18 - © ESAB AB 2024...
  • Page 19 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. 0700 025 150 - 19 - © ESAB AB 2024...
  • Page 20 In order to adjust the wire feeder position to the cable assembly length, it must be mounted on an adjustable support with a possible movement of ± 2-3 cm (± 1 inch) to the back and to the front. The 0700 025 150 - 20 - © ESAB AB 2024...
  • Page 21 5) The feeder should only be installed again after the correct mounting position with respect to the cable length has been determined (see "Installing the cable assembly" chapter). CAUTION! Axis 6 must be in 0° position. 0700 025 150 - 21 - © ESAB AB 2024...
  • Page 22 3) Pull the cable assembly approximately 15 cm (6”) from the main body (3). 4) Pull the rubber ring from the control line connectors back onto the coupling of the cable assembly. 0700 025 150 - 22 - © ESAB AB 2024...
  • Page 23 10)Gently push back the cable assembly into the robot arm and carefully seat the KSC-E or FLC-E cover (1) in place. Observe the index pin (13) to be in the correct position. Make sure the two micro switches (12) are not damaged if present. 0700 025 150 - 23 - © ESAB AB 2024...
  • Page 24 Unfasten the liner nipple using a hexagon wrench (size 6 mm) and remove nipple with liner from the torch neck. 3) Remove the gas nozzle and the contact tip. 0700 025 150 - 24 - © ESAB AB 2024...
  • Page 25 The wire guide is inserted through the cable assembly from the rear, reaching the guide nipple that is installed in the flange where the torch neck will be attached. The following steps must be followed in order to correctly determine the wire guide length (example for ESAB TAP connector). 1) For standard RT system Install the guide nipple (1) in the center hole of the neck support flange.
  • Page 26 Installing the torch Be sure to use the correct version of the torch mount and cable assembly (water or gas cooled). 0700 025 150 - 26 - © ESAB AB 2024...
  • Page 27 1) Select the correct wire guide, contact tip (4), tip holder (2), gas nozzle (5), and gas diffuser/spatter protection (3). You will find an exact overview and possible alternative equipment elements for various torch models in the spare parts list. Only use original ESAB parts; only then is the fitting accuracy ensured.
  • Page 28 1) In order to be able to create the connection, the cable assembly must be mounted as described in the "Installing the cable assembly" chapter, and equipped according to "Installing the wire guide" chapter. Only then can the central and media connection take place. 0700 025 150 - 28 - © ESAB AB 2024...
  • Page 29 It is helpful to loosen the positioning screws of the wire feeder before moving the robot arm to allow the feeder to follow the cable assembly. 0700 025 150 - 29 - © ESAB AB 2024...
  • Page 30 If the blow-out function is not used, the blow-out hose must be sealed with the rubber cap enclosed. 6) Install the necessary plug on the control cable and connect it to the safety off circuit interface of the wire feeder (see "Electrical connections" chapters). 0700 025 150 - 30 - © ESAB AB 2024...
  • Page 31 2) If a collision is detected, the control circuit for the safety-off signal (7), which is normally closed, will be interrupted. Rating of the control circuit: max. 48 V / 1 A. 0700 025 150 - 31 - © ESAB AB 2024...
  • Page 32 After detection of contact (gas nozzle on work piece), quickly reduce or cut off the maximum current in the nozzle sense circuit in order to avoid overloading of the system. (Allowed load max. 1 minute at the rated nominal current) 0700 025 150 - 32 - © ESAB AB 2024...
  • Page 33 Power source / robot control with nozzle sense function If the robot control provides a control circuit for nozzle sense functionality, this function can be implemented for both KSC-E and FLC-E. 0700 025 150 - 33 - © ESAB AB 2024...
  • Page 34 After detection of contact (gas nozzle on work piece), quickly reduce or cut off the maximum current in the nozzle sense circuit to avoid overloading of the system. (Allowed load max. 1 minute at the rated nominal current) 0700 025 150 - 34 - © ESAB AB 2024...
  • Page 35 60° of axis 5. In this position, the maximum available rotation speed of axis 6 can be used. When using the ESAB Helix cable assembly, the max. rotation of ±270° from the neutral position must not be exceeded.
  • Page 36 Remote settings capabilities Torch buttons: • F1 - forward feeding (default) wire inching • F2 - preset 1 out of 6 features from the list Hollow wrist water-cooled KSC-E W FLC-E W 0700 025 150 - 36 - © ESAB AB 2024...
  • Page 37 5   OPERATION Standard TCA water-cooled or gas-cooled TCA-E W or TCA-E G For detailed information on how to do the programming F1 and F2, refer to ESAB Connect. 0700 025 150 - 37 - © ESAB AB 2024...
  • Page 38 • Repair of the KSC-2 or FLC-2 torch mount, the KS-2 safety-off mechanism, the cable assembly must only be carried out by ESAB service support. • Never disassemble the KSC-2 or KS-2. This is a spring-loaded mechanism. Improper manipulation can lead to severe injury.
  • Page 39 Inspect all connections and hoses for damages. Damage to the electrical insulation must be repaired by trained personnel before the system can be operated safely. If in doubt, replace the entire cable assembly and return to ESAB for inspection and repair.
  • Page 40 Check the cable assembly for damages. Can out in too small radius. the liner be inserted easily? Install according to "Installing the cable assembly". Wire is contaminated Use a cleaning felt. 0700 025 150 - 40 - © ESAB AB 2024...
  • Page 41 Check the set-up of the welding equipment. Insufficient electrical Check all electrical connections (incl. ground connections in the circuit. cable) between the power source torch or work piece for firm seating. 0700 025 150 - 41 - © ESAB AB 2024...
  • Page 42 Spare parts and wear parts can be ordered through your nearest ESAB dealer, see esab.com. When ordering, please state product type, serial number, designation and spare part number in accordance with the spare parts list.
  • Page 43 CuCrZr, Ø1.2 (0.045) 0700 300 333 Contact tip M6×28 CuCrZr, Ø1.4 (0.055) 0700 300 334 Contact tip M6×28 CuCrZr, Ø1.6 (1/16) 0700 300 351 Contact tip M6×28 Alu, Ø0.8 (0.030) 0700 025 150 - 43 - © ESAB AB 2024...
  • Page 44 ECu, Ø1.6 (1/16) 0700 300 378 Contact tip M6×22 CuCrZr, Ø0.8 (0.030) 0700 300 379 Contact tip M6×22 CuCrZr, Ø1.0 (0.040) 0700 300 380 Contact tip M6×22 CuCrZr, Ø1.2 (0.045) 0700 025 150 - 44 - © ESAB AB 2024...
  • Page 45 APPENDIX 0700 025 150 - 45 - © ESAB AB 2024...
  • Page 46 For contact information visit http://esab.com ESAB AB, Lindholmsallén 9, Box 8004, 402 77 Gothenburg, Sweden, Phone +46 (0) 31 50 90 00 manuals.esab.com...