Daihen OTC RT3500S User manual

Welding Torch for Robot

Coaxial Power Cable for Robot

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

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

Replacement Parts for Various Wire Diameters .....

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)

-S4-

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.

●Fumes and gases generated by welding have a harmful effect on

human body.

●Welding in a small area may cause suffocation due to the lack of

air.

1) KEEP YOUR HEAD out of fumes and DO NOT inhale any.

2) USE FORCED EXHAUST VENTILATION at the arc.

3) VENTILATE the area to prevent build-up of fumes and gases.

4) If ventilation is insufficient, USE APPROVED BREATHING DEVICES.

5) READ AND FOLLOW WARNING LABELS on all containers of welding materials.

6) Before use, READ AND UNDERSTAND the manufacture's instructions, Material Safety Data

Sheets (MSDSs), and follow your employer's safety practices.

7) To prevent gas poisoning and suffocation, use a local ventilator or a respirator specified by

your country’s domestic laws.

8) Be sure to ventilate the area or wear a respirator by welding in a small place. A well-trained

watchman should observe the work.

9) Do not weld near the place where degreasing, cleaning or spraying is carried out. The heat

and rays of the arc can react with vapors to form highly toxic and irritating gases. If welding is

carried out there, harmful gases may be produced.

10) Toxic fumes and gases are produced when coated steel is welded. Be sure to ventilate the

area sufficiently or use a respirator.

IMPORTANT SAFEGUARD (continued)

-S5-

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.

●NEVER do welding on inflammables such as a piece of wood or

cloth.

WARNING

●Do not weld on closed containers.

●Heated workpiece, spatters, slag and arc sparks right after welding

may cause fire.

●Incomplete cable connections, incomplete contacts in the current

circuit of the workpiece such as steel frames may cause a fire due to

the heat generated when powered.

●Arc generated on containers of inflammables such as gasoline may

cause an explosion.

●Welding of airtight tanks and pipes may cause a bursting.

●Touching a heated workpiece, spatters, slag or arc sparks will

cause a serious burn.

1) KEEP FLAMMBLE MATERIALES out of the robotic cell.

2) Welders should wear appropriate protection such as flameproof leather gloves, work clothes

with long sleeves, a leg cover, a flameproof leather apron in order to prevent burns caused by

touching heated workpiece, spatters, slag and arc sparks right after welding.

3) WATCH for fire.

4) Have a fire extinguisher nearby Operators should know how to use it.

5) DO NOT touch heated workpiece and peripheral jigs with inflammables such as a piece of wood

or cloth. Doing so might cause not only a fire but also burns.

6) DO NOT put heated workpiece close to inflammables right after welding..

7) Remove inflammables from the place where welding is carried out so that spatters and slag will

not strike them.

8) Do not use inflammable gases near the welding sight.

9) Tighten and insulate the cable connections completely.

10) Connect the cables on the workpiece side as close to the welding area as possible to prevent

the welding current from traveling along unknown paths and causing electric shock and fire

hazards.

11) A gas pipe with gas sealed in, an airtight tank and a pipe must not be welded, because they

might explode.

12) NEVER do welding on inflammables such as a piece of wood or cloth.

13) When welding a large-size structure such as a ceiling, floor, wall, etc., remove any inflammables

hidden behind a workpiece.

IMPORTANT SAFEGUARD (continued)

-S6-

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.

Recommended Safe Practices for the Preparation for Welding and Cutting

of Containers That Have Held Hazardous Substances, American Welding

Society Standard AWS F4.1, from American Welding Society.

National Electrical Code, NFPA Standard 70, from National Fire Protection

Association.

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, from

Compressed Gas Association.

Code for Safety in Welding and Cutting, CSA Standard W117.2, from

Canadian Standards Association, Standards Sales.

Safe Practices For Occupation And Educational Eye And Face Protection,

ANSI Standard Z87.1, from American National Standards Institute.

Cutting And Welding Processes, NFPA Standard 51B, from National Fire

Protection Association.

IMPORTANT SAFEGUARD (continued)

-S7-

3. Notes on Use

3.1 Duty cycle

CAUTION ●Use the torch with the specified rated duty cycle or under

Otherwise, the welding torch may be deteriorated or burned out.

● The rated duty cycle of 50% indicates that the

torch shall be used at the rated welding current

for 5 minutes and then suspended for 5 minutes

out of 10 minutes.

● The rated duty cycle of 70% indicates that the

torch shall be used at the rated welding current

for 7 minutes and then suspended for 3 minutes

out of 10 minutes.

● Use of the welding torch with the excess rated

duty cycle may lead to the temperature rise

exceeding the allowable value, resulting in

damage or burn.

● When using RTW5000S, RTW5000H and

RTW5000L, are sure that coolant is being

supplied with the water tank. Otherwise, the

temperature of welding torch may rise to over

the allowable value, leading to damage or burn.

3.2 Inching

●Do not look into the tip hole in inching to cheek.

WARNING ●In inching, the welding torch tip must not be put near to your

face, eye, and body.

●Do not look into the tip hole in inching to check if the wire is fed.

The wire may spring out and stick into your face, eyes, and

body. It is very dangerous.

●In inching, the welding torch tip must not be put near to your face,

eyes, and body. The wire may spring out and stick into your face,

eyes, and body to injure.

Set the welding torch straight, feed the wire with pressing the INCH button, and then release the

button when the wire is protruded by 10mm from the tip of torch.

NOTES ON USE

Welding torch Rated duty cycle

RT3500S

RT3500H

RT3500L

350A 80%（CO2）

350A 60%（MAG）

RT5000S

RT5000H

RT5000L

500A 50%（CO2）

350A 70%（MAG）

RTW5000S

RTW5000H

RTW5000L

500A 70%（CO2）

400A 60%（MAG）

RZ3500S

RZ3500H

RZ3500L

350A 80%（CO2）

350A 60%（MAG）

-S8-

3.3 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.

●Do not replace torch tip elements before they cool off.

CAUTION ●If any parts are damaged, replace them with new ones for further

safety and better quality.

●Be sure to place an order for replacement parts at our sales office or our agency.

CAUTION ●Do not disassemble the shock sensor. If disassembled, gas

leak and malfunction may be caused.

3.4 Coolant

CAUTION ●Be sure to run the coolant for the torch of liquid-cooled specification.

Insufficient amount of running water may lead to damage of torch.

3.5 Cable hose

CAUTION

●Never let cable hoses neither touch any heated part of the

welded, put something heavy on top nor bend them excessively

because the welding torch might become damaged.

3.6 Shock sensor

CAUTION

●In the main body of shock sensor inside, a powerful coil spring is

had built-in.

Because there is a threat that a coil spring protrudes, please do

not dismantle a shock sensor.

CAUTION

●The shock sensor absorbs damage at the speed of the manual

operation (or equal with the manual operation).

The shock sensor is damaged at the speed faster than manual

operation.

SPRING

コイルバネ

CAUTION!

DO NOT DISASSEMBLE

分解禁止

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