AWS/NEMA D16.2/D16.

2M:2001
An American National Standard

Guide for
Components
of Robotic
and Automatic
Arc Welding
Installations
Key Words —Robot components, performance AWS/NEMA D16.2/D16.2M:2001
requirements, wire feeders, wire An American National Standard
dereelers, welding torches, welding
interfaces, connector arrangement, Approved by
connector pin functions
American National Standards Institute
November 30, 2001

Guide for Components

of Robotic and Automatic
Arc Welding Installations

Supersedes ANSI/AWS D16.2-94

Prepared by
AWS D16 Committee on Robotic and Automatic Welding

Under the Direction of

AWS Technical Activities Committee

Approved by
AWS Board of Directors
NEMA Codes and Standards Committee

Abstract
AWS/NEMA D16.2/D16.2M:2001, Guide for Components of Robotic and Automatic Arc Welding Installations, provides
performance recommendations for evaluating components of a typical robotic or automatic welding installation.
Emphasis is placed on the role of the welding interface. A pin arrangement and specific pin function for each location
in a standardized 37-pin connector are proposed.

National Electrical Manufacturers Association

2101 L Street, N.W., Washington, DC 20037

550 N.W. LeJeune Road, Miami, Florida 33126

 Table of Contents
Page No.
Personnel .................................................................................................................................................................... iii
Foreword.......................................................................................................................................................................v
List of Tables................................................................................................................................................................ix
List of Figures..............................................................................................................................................................ix
1. Scope .....................................................................................................................................................................1
2. Reference Documents ...........................................................................................................................................1
3. Definitions .............................................................................................................................................................1
4. Arc Welding Power Sources..................................................................................................................................3
4.1 Continuous Duty..........................................................................................................................................3
4.2 Remote Control............................................................................................................................................3
5. Arc Welding Torches and Accessories ..................................................................................................................3
5.1 Torch Design Requirements ........................................................................................................................4
5.2 Torch Holder Requirements.........................................................................................................................4
5.3 Collision Protection Device .........................................................................................................................4
5.4 Torch Accessories ........................................................................................................................................4
6. Dereeling System ..................................................................................................................................................5
6.1 Equipment....................................................................................................................................................5
6.2 Characteristics..............................................................................................................................................5
7. Welding Interfaces.................................................................................................................................................5
7.1 General Requirements .................................................................................................................................5
7.2 Input/Output Signal Requirements ..............................................................................................................6
8. Shielding Gas Delivery Systems ...........................................................................................................................6
8.1 Regulators and Flowmeters .........................................................................................................................7
8.2 Fitted Hose Assemblies ...............................................................................................................................7
9. Welding Electrode Feeding Equipment.................................................................................................................7
9.1 Service Conditions.......................................................................................................................................7
9.2 Rating and Performance ..............................................................................................................................7
9.3 Construction.................................................................................................................................................7
9.4 Installation and Operation............................................................................................................................8
10. Welding Circuit .....................................................................................................................................................8
10.1 Components .................................................................................................................................................8
10.2 Design ..........................................................................................................................................................8
10.3 Integrity........................................................................................................................................................8
10.4 Conductor Size.............................................................................................................................................8
10.5 Support Equipment Isolation .......................................................................................................................8
10.6 Methods of Weld Circuit Completions (Workleads) ...................................................................................8
11. Communication Control Wiring............................................................................................................................9
12. System Grounding.................................................................................................................................................9
12.1 Grounding Mechanics..................................................................................................................................9

vii
 Page No.
12.2 Ground Identification...................................................................................................................................9
13. Cable and Hose Management................................................................................................................................9
13.1 Routing ........................................................................................................................................................9
13.2 Voltage .......................................................................................................................................................10
13.3 Cable Fatigue .............................................................................................................................................10
13.4 Extended Length........................................................................................................................................10
14. Maintenance ........................................................................................................................................................10
14.1 Preventive Maintenance.............................................................................................................................10
14.2 Spare Parts .................................................................................................................................................10
Annex—Nonmandatory Information
Annex A—Guidelines for Preparation of Technical Inquiries for AWS Technical Committees..................................11
AWS List of Documents on Robotic and Automatic Welding......................................................................................13

viii
 List of Tables
Table Page No.
1 Connector Pin Assignments ...........................................................................................................................6
2 Minimum Hose Assembly Breaking Strength ...............................................................................................7

List of Figures
Figure Page No.
1 Typical Robotic Arc Welding Arrangement...................................................................................................2
2 Pin Layout for a Standard 37-Pin Connector .................................................................................................5
3 Typical Robot Weld Circuit............................................................................................................................9
4 Protective Earth (Ground) ............................................................................................................................10

ix

Guide for Components of Robotic and
Automatic Arc Welding Installations
1. Scope
This document applies to the recommended design,
integration, installation, and use of industrial welding ro-
botic and automatic systems. This document is intended
for the gas metal arc welding (GMAW) and flux cored
arc welding (FCAW) processes. Pertinent parts may ad-
dress additional welding processes.
Robotic and automatic arc welding systems consist of
a manipulator, power source, arc welding torch and ac-
cessories, electrode feed system, dereeling system,
shielding gas delivery system, welding circuit, shielding
and communication control, and grounding system.
There may be other accessories that are outside the scope
of this document, such as safety devices, monitoring,
joint tracking and vision systems. A typical system is il-
lustrated in Figure 1.
This standard makes use of both the International Sys-
tem of Units (SI) and U.S. Customary Units. The mea-
surements may not be exact equivalents; therefore, each
system must be used independently of the other without
combining in any way. The standard designation
D16.2:2001 uses U.S. Customary Units. The standard
with the designation D16.2M:2001 uses SI Units. The
latter are shown within brackets [ ] or in appropriate col-
umns in tables and figures.
2. Reference Documents
(1) AWS D16.3, Risk Assessment Guide for Robotic
Arc Welding1
(2) AWS D16.4, Specification for the Qualification of
Robotic Arc Welding Personnel
1. For ordering AWS and ANSI Z49.1 information, contact
Global Engineering Documents, 15 Inverness Way East, Engle-
wood, Colorado 80112-5776. Telephones: (800) 854-7179,
(303) 397-7956; FAX (303) 397-2740; www.global.ihs.com.
AWS/NEMA D16.2/D16.2M:2001
(3) AWS AWR, Arc Welding With Robots: Do’s and
Don’ts
(4) AWS A3.0, Standard Welding Terms and
Definitions
(5) AWS A5.18/A5.18M, Specification for Carbon
Steel Electrodes and Rods for Gas Shielded Arc Welding
(6) ANSI Z49.1, Safety in Welding, Cutting, and Allied
Processes
(7) NEMA EW-1, Electric Arc Welding Power
Sources2
(8) NEMA EW-3, Semiautomatic Wire Feed Systems
for Arc Welding
(9) IEC 60974-1, Arc Welding Equipment—Part 1:
Welding Power Sources3
(10) CGA E-1, Standard Connections for Regulator
Outlets, Torches and Fitted Hose for Welding and Cut-
ting Equipment 4
(11) RMA-CGA IP7, Specification for Rubber Welding
Hose5
(12) RIA 15.06, American National Standard for In-
dustrial Robot and Robot Systems—Safety Requirements6
3. Definitions
Welding terms used in this document should be in-
terpreted in accordance with AWS A3.0, Standard Weld-
ing Terms and Definitions, NEMA EW-1, Electric Arc
2. National Electrical Manufacturer’ Association, 1300 North
17th Street, Suite 1847, Rosslyn, VA 22209.
3. International Electrotechnical Commission (IEC) documents
are available from the American National Standards Institute,
25 West 43rd Street, Fourth Floor, New York, New York 10036.
4. Compressed Gas Association, 4221 Walney Road, 5th Floor,
Chantilly, VA 20151-2923.
5. Rubber Manufacturers Association, 1400 K Street, Suite
900, N.W., Washington, DC 20005.
6. Robotics Industries Association, 900 Victors Way, P.O. Box
3724, Ann Arbor, MI 48106.