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 CO
2
/MAG

Daihen OTC RT3500S Specifications

General

Brand	Daihen
Model	OTC RT3500S
Category	Welding Accessories
Language	English

Summary

Safety Guidelines and Warnings

Safety Symbol and Warning Definitions

Explains safety symbols (DANGER, WARNING, CAUTION) and defines injury/damage terms.

General Operational Safety Precautions

General notices to prevent serious accidents and injury or death.

Electrical Safety Precautions

Instructions to prevent electric shock hazards during operation.

Personal Protective Equipment Requirements

Requirements for wearing appropriate protection for eyes, ears, and body.

Fume and Gas Hazard Protection

Precautions to protect against welding fumes and gases.

Fire and Explosion Prevention Measures

Measures to prevent fire, explosion, and burns from welding operations.

Technical Specifications and Package Contents

Welding Torch Specifications Overview

Details torch types, process, current, duty cycle, wire, cooling, and shock sensor.

Torch Outline Drawings and Dimensions

Provides dimensional drawings for air-cooled 350A torches.

Package Contents Verification Procedure

Details the parts included in the package for SSV and SSB shock sensors.

Torch Installation and Alignment Procedures

Mounting on V6 Type Manipulator

Step-by-step guide for mounting the torch and shock sensor on an All-V6 manipulator.

Mounting on B4 Type Manipulator

Instructions for mounting the torch and shock sensor on an All-B4 manipulator.

Torch Alignment and Adjustment Guide

Procedures for adjusting the torch position for accurate alignment.

Reference Point Teaching Procedures

Guides on teaching reference points for robot and torch deviation checks.

Coaxial Power Cable Management

Coaxial Power Cable Selection Guide

Lists available coaxial power cable types by length and applicable manipulator.

DL Welding Power Supply Integration

Details DL-dedicated voltage detection cables and their assembly.

Power Cable and Hose Connection Procedures

Procedures for connecting the coaxial power cable to All-V6 and All-B4 manipulators.

Liner Preparation and Cutting Instructions

Instructions for cutting the liner to the correct length for different torches.

Robot Controller Configuration and Shock Sensor

Robot Tool Parameter Configuration

Specifies tool constants (parameters) for welding torches on V6 type manipulators.

Shock Sensor Functional Check Procedure

Steps to check the shock sensor's response to external forces.

Welding Troubleshooting Guide

Common Welding Problems and Solutions

Addresses common problems like no arc, poor wire feeding, and aim deviation with possible causes.

RZ Series Torch Specific Issues

Lists specific issues for RZ series torches, such as spatter accumulation and liner length.

Wire Diameter Specific Replacement Parts

Torch Component Replacements by Wire Diameter

Lists replacement parts for torch components like tips, liners, and nozzles by wire diameter.

Coaxial Power Cable Component Replacements

Details replacement parts for coaxial power cable components like outlet guides and liners.

Component Parts Identification

Torch and Shock Sensor Assembly Parts List

Exploded diagrams and part numbers for RT, RTW, and RZ series torches.

Coaxial Power Cable Assembly Parts List

Lists parts for coaxial power cables and associated shock sensor/voltage detection cables.