Daihen OTC RT3500S User manual

Welding Torch for Robot
Coaxial Power Cable for Robot
<Shock sensor built-in type>
RT3500S /H /L
RT5000S /H /L
RTW5000S /H /L
RZ3500S /H /L
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 technical skill to fully
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.
Contents
①NOTES ON SAFETY .......................... S1
②IMPORTANT SAFEGUARDS ............. S2
③NOTES ON USE..................................... S7
1. Specifications ............................................1
2. Checking the Contents.............................6
3.
Installing and Adjusting Procedure of Welding Torch ......8
3.1 Mounting of Welding Torch on AII-V6 type
Manipulator.................................................................... 8
3.2 Mounting of Welding Torch on AII-B4 Type
Manipulator ............................................................... 14
3.3 Connecting the Water-cooled Torch
(RTW5000S/RTW5000H/RTW5000L).................. 19
3.4 Connecting the Hose to AII-B4 ...................... 21
3.5 Handling Instructions for RT series Torch ............ 22
3.6 Handling Instructions for RZ series Torch ............ 23
4. Coaxial Power Cable for Robot ........... 25
4.1 Type of Coaxial Power Cables ............................... 25
4.2 When Using the DL Welding Power Supply......... 26
4.3 Connecting the Coaxial Power Cable ................... 28
4.4 Cutting the Liner........................................................ 29
4.5 Liner Crump Function .............................................. 30
5. Setting the Robot Controller................. 31
5.1 Checking the Tool Parameter ................................. 31
5.2 Checking the Shock Sensor Operation ................ 33
6. Troubleshooting ..................................... 34
7.
Replacement Parts for Various Wire Diameters ..... 35
7.1 Replacement Parts for Various Wire Diameters
of Torch ........................................................................ 35
7.2 Replacement Parts for Various Wire Diameters
of Coaxial Power Cable ............................................ 38
8. Parts List ................................................. 39
Instruction Manual
= Safety and Operation = Instruction Manual No.
1L10603-E-2
For CO2/MAG

-S1-
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. Otherwise, there may occur an
accident causing serious injury or death.
●Various ranks of accidents resulting in injury, damage, or death may occur if mishandling the
product. The caution alert symbols and signals are classified into three ranks as below, used
throughout these instruction manual as well as warning labels put on each unit and device.
Symbol Signal Description
DANGER
Mishandling may cause seriously dangerous
situation that could result in serious injury or death to
personnel. Limited situation of great urgency.
WARNING Mishandling may cause a dangerous situation that
could cause serious injury or death to personnel.
CAUTION
Mishandling may cause a dangerous situation that
could cause medium or slight injury to personnel, or
material damage.
Hazards and special instructions described by CAUTION are very important as well.
Neglect of them may occasionally cause serious injury or death to personnel. Therefore, be sure to
follow the instructions described by all three safety alert symbols and signal words.
The meanings of "serious injury", "medium or slight injury", and "material damage" are as follows.
Serious injury ：Injury with a sequela due to a loss of eyesight, injury, burn (high
temperature and low temperature), electric shock, a bone fracture,
poisoning and so on as well as injury that requires hospital
treatment or long treatment as an outpatient.
Medium or slight injury ：Injury, burn, electric shock and so on that require no hospital
treatment nor long treatment as an outpatient.
Material damage ：Damage to property, and direct and incidental / consequential
damage due to the damage to devices.
Ref.: IMPORTANT : The sign “IMPORTANT” indicates special instructions
necessary for the most efficient operation.
NOTES ON SAFETY

-S2-
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.
WARNING Observe the following notices to prevent a serious accident
that results in serious injury or death.
1) This torch is designed and manufactured in due consideration of safety, but you must follow
the handling precautions described in this instruction manual. If you fail to do so, there may
occur an accident resulting in serious injury or death.
2) Related laws, regulations, and your company's standards should be observed in constructing
input power source, selecting an installation area, handling/storing/piping high pressure gas,
storing welded products, and disposing wastes.
3) Keep out of the robot operating zone and the welding area.
4) A person with pacemaker should not approach the operating welding machine and the welding
area unless his or her doctor permits. A welding machine generates a magnetic field around it
during powered, which will have a bad effect on the pacemaker.
5) Installation, maintenance, and repair of this torch should be performed by qualified personnel
or those who fully understand a welding torch for further safety.
6) Operation of this torch should be done by personnel who have knowledge and technical skill
to fully understand the contents of this manual and to handle the torch safely.
7) This torch must not be used for purposes other than welding.
2.2 Observe the following to prevent electric shock.
WARNING Do not touch live electrical parts.
Touching live electrical parts can cause fatal shock or severe
burns.
IMPORTANT SAFEGUARD
NV6 NB4

-S3-
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.
4) Before doing the installation, inspection, maintenance, etc. of this product be sure to turn off
all the input power sources and check, several minutes later, that there is no charging voltage
since the condenser and the like may have been recharged.
5) Do not use cables with insufficient capacity, with damage, or with naked conductors.
6) Be sure to tighten the connections of cables and insulate them in order to prevent personnel
from touching those parts easily.
7) DO NOT use a welding machine with its case or cover removed.
8) Secure a firm foothold before initiating work. DO NOT perform work with an unstable
foothold or with a foothold at a height of two meters or above.
9) Make periodic inspection and maintenance. Damaged parts should be repaired before use.
10) Turn off POWER switch when not in use.
2.3 All the personnel in and around the working area including an operator should wear
appropriate protection to protect themselves from arc rays, spatters, slag, and noise
produced by welding.
●Install a lightproof wall where arc is generated.
WARNING
●Wear appropriate eye, ear, and body protection.
●Arc rays may cause inflammation of eyes and burns on skin
●Spatter s and slag may cause eye troubles and burns.
●Noise may cause hearing problems.
1) Wear lightproof glasses or a welder’s shield helmet with a proper shade of filter when welding
or watching a welder work.
2) INSTALL ARC PROTECTIVE CURTAINS in between an operator and arc rays.
3) WEAR PROPER SAFETY GLASSES in work area at all times.
4) WEAR PROPER EAR PROTECTION.
5) WEAR PROPER BODY PROTECTION including woolen clothing, flameproof apron and
gloves, leather leggings, high boots and leather arm and shoulder gauntlets.
6) WEAR PROPER SAFETY GLASSES to protect eyes and skin from spatters and slag.
IMPORTANT SAFEGUARD (continued)