Related Manuals for Fronius Robacta Reamer X-Line J
Summary of Contents for Fronius Robacta Reamer X-Line J
- Page 1 / Perfect Charging / Perfect Welding / Solar Energy Operating Instructions Robacta Reamer X-Line J Spare parts list Robacta Reamer X-Line J Alu Welding torch cleaning 42,0426,0240,EA 002-11122018...
- Page 3 Fronius product. These instructions will help you familiarize yourself with the product. Reading the instructions carefully will enable you to learn about the many different features your Fronius product has to offer. This will allow you to make full use of its advan- tages.
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Page 5: Table Of Contents
Contents Safety Instructions ............................. General ..............................Intended Use............................Environmental Conditions ........................Obligations of the Operating Company....................Obligations of Personnel........................Particular Hazard Areas........................Personal Protection and Protection of Others..................EMC Device Classifications ........................EMC Measures ............................. EMF measures............................Safety Measures at the Setup Location and during Transport.............. Safety Measures in Normal Operation.................... - Page 6 Spare parts list: Robacta Reamer X-Line J, Robacta Reamer X-Line J Alu ..........Circuit diagrams: Circuit Diagram for Robacta Reamer X-Line J, Robacta Reamer X-Line J Alu ..... Pneumatic Plan for Robacta Reamer X-Line J, Robacta Reamer X-Line J Alu.........
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Page 7: Safety Instructions
Intended Use The device is to be used exclusively for its intended purpose. The device is intended exclusively for the mechanical cleaning of Fronius robot welding torches in automatic mode. Utilization for any other purpose, or in any other manner, shall be deemed to be "not in ac- cordance with the intended purpose."... -
Page 8: Obligations Of The Operating Company
Relative humidity: Up to 50% at 40°C (104°F) Up to 90% at 20°C (68°F) Ambient air: free of dust, acids, corrosive gases or substances, etc. Altitude above sea level: up to 2000 m (6500 ft.) Obligations of the The operating company must only allow persons to work with the device if they Operating Com- Are familiar with the basic occupational safety and accident prevention regulations pany... -
Page 9: Personal Protection And Protection Of Others
During operation: ensure that all covers are closed, and all side parts have been mounted properly keep all covers closed Personal Protec- You are exposed to numerous hazards while handling the device. In addition to these Op- tion and Protec- erating Instructions, the safety rules of the manufacturer of the entire welding system must tion of Others be followed. -
Page 10: Emf Measures
EMF measures Electromagnetic fields may cause health problems that are not yet known: Effects on the health of persons close by, e.g., those with pacemakers and hearing aids Persons with pacemakers must seek advice from their doctor before staying in the im- mediate vicinity of the device and the welding process Keep distances between welding cables and the head/torso of the welder as large as possible for safety reasons... -
Page 11: Maintenance And Repair
Maintenance and It is impossible to guarantee that bought-in parts are designed and manufactured to meet repair the demands made of them, or that they satisfy safety requirements. Use only original spare and wearing parts (also applies to standard parts). Do not carry out any modifications, alterations, etc. -
Page 13: General
General... -
Page 15: General
General Principle The cleaning device is intended to auto- matically clean MIG/MAG welding torches. The cleaning device can be used to reliably clean the inside of gas nozzles and the face of the gas nozzles in a range of welding torch geometries. -
Page 16: Warning Notices On The Cleaning Device
The cleaning device has warning notices and a rating plate fitted. These warning notices on the Cleaning and the rating plate must not be removed or painted over. Device Type Art.No. www.fronius.com Chargen No. 24 V p max 6 bar (87psi.) Warning notices on the cleaning device... - Page 17 Wear eye protection Warning before the device switches on automatically...
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Page 18: Transport
Transport Transport Equip- Transport the device using the following transport equipment: ment on a pallet using a forklift on a pallet using a lift truck manually WARNING! Falling or toppling devices can be deadly. ► When transporting the device by forklift or lift truck, secure the device from falling ►... -
Page 19: Scope Of Supply
Scope of Supply Scope of Supply NOTE! The “Robacta Reamer” parting agent (item number 42,0411,8042) and the cleaning cutter are not included in the scope of supply. Work stand Cleaning device Maintenance unit Wrench for cleaning motor Compressed air relief valve Collecting container not shown: Operating Instructions... -
Page 21: Operating Controls, Connections And Mechanical Components
Operating controls, connections and mechanical components... -
Page 23: Safety
Safety Safety Please follow the safety rules below when using all the functions described in the "Operat- ing Controls, Connections, and Mechanical Components" chapter. WARNING! Operating the device incorrectly can cause serious injury and damage. The functions described may only be used by trained personnel. Do not use the functions described here until you have fully read and understood the following documents: ►... -
Page 24: Operating Controls, Connections And Mechanical Components
Operating controls, connections and mechanical components Operating Con- trols, Connec- tions, and Mechanical Com- ponents - Front of Device Front of device Function Gas nozzle clamping device holds the gas nozzle in place during the cleaning process Parting agent injection device includes the parting-agent injection nozzle;... -
Page 25: Operating Controls, Connections, And Mechanical Components - Rear Of Device
Operating Con- trols, Connec- tions, and Mechanical Com- ponents - Rear of Device Rear of device Function Parting agent adjusting controller to set the parting agent injection quantity Connection area for robot control Compressed air connection to supply dry compressed air at 6 bar (86.99 psi) - for more information on com- pressed air quality, see the “Specifications for the Compressed Air Supply”... -
Page 26: Operating Controls, Connections, And Mechanical Components - Side Of Device
Operating Con- trols, Connec- tions, and Mechanical Com- ponents - Side of Device Side of device Function “Spray in parting agent” screw to manually check the injection device (compressed air or compressed air/parting agent mixture is sprayed out of the parting-agent injection nozzle) “Lifting device up/down”... -
Page 27: Connections For Robot Control
Connections for robot control Function Bus system connection Bus system connection Bus system connection Bus system connection Connections for robot control... -
Page 29: Installation And Startup
Installation and Startup... -
Page 31: Safety
Safety Safety Please follow the safety rules below during all the tasks described in the "Installation and Commissioning" chapter. WARNING! Incorrect operation and incorrectly performed work can cause serious injury and damage to property. All work listed in these Operating Instructions may only be performed by trained specialist personnel. -
Page 32: Ensure That The Cleaning Device Is Depressurized
If work is required on the cleaning device while the cleaning device is being supplied with voltage and/or compressed air: ► keep your body, especially hands, face and hair, as well as objects and all items of clothing away from the cleaning cutter, cleaning motor, lifting device, gas nozzle clamping device, wire cutter, and parting-agent injection nozzle ►... -
Page 33: Before Installation
Before installation Intended Use The cleaning device is used exclusively to mechanically clean Fronius robot welding torch- es in automatic mode within the limits of technical data, especially to clean the gas nozzle and gas nozzle internal space. Any other use does not constitute proper use. The manu- facturer shall not be liable for any damage resulting from such improper use. -
Page 34: Diagram Of The Programmable Logic Control (Plc)
Diagram of the programmable logic control (PLC) Diagram of the Bus module link: XXXXXXXX++ST010+IR001.ZM001-KF70 programmable Placement: XXXXXXXX++ST010+IR001.ZM001+.&EFA/1.4 logic control (PLC) Type: ProfiNet MVK-Metall DO8 /DI8 PushPull MVK-MPNIO D08 / DI8 PushPull Address: Symbolname: Function text: I777 ++ST010+IR001.ZM001-VQ01-BG01:4 Gas nozzle free I778 ++ST010+IR001.ZM001-VQ01-BG02:4 Gas nozzle clamped... -
Page 35: Screwing The Cleaning Device To The Solid Surface
Screwing the Cleaning Device to the Solid Surface Screwing the NOTE! cleaning device and work stand to Depending on the surface (foundation), different mounting materials may be re- the surface quired to assemble the work stand. The mounting materials for the work stand are not part of the scope of supply for the work stand. -
Page 37: Welding Torch Cleaning Position
Welding Torch Cleaning Position Welding Torch Cleaning Position... -
Page 38: Adjusting The Gas Nozzle Clamping Device
Adjusting the Gas Nozzle Clamping Device Adjusting the gas CAUTION! nozzle clamping device An incorrectly set gas nozzle clamping device may damage the cleaning device and the welding torch. ► When using gas nozzles with an outside diameter of 25 mm (0.98 inches), the gas noz- zle clamping device must not be adjusted - the gas nozzle clamping device has already been set for the use of gas nozzles with an outside diameter of 25 mm (0.98 inches) as part of the factory calibration. -
Page 39: Fitting The Cleaning Cutter
Fitting the Cleaning Cutter Fitting the clean- CAUTION! ing cutter Burning hazard due to hot cleaning cutter as a result of operation. Before handling the cleaning cutter, allow it to cool to room temperature (+25°C, +77°F). NOTE! Only use contact tips, gas nozzles and cleaning cutters provided by the manufactur- Correct operation is not ensured if products made by other manufacturers are used. -
Page 40: Adjusting The Position Of The Cleaning Motor
Adjusting the Position of the Cleaning Motor Adjusting the po- Remove protective cover (1) sition of the Remove the gas nozzle from the torch cleaning motor body Loosen the screw (2) on the lifting de- vice Make sure that the lifting device (3) is in the bottom lift position Position the welding torch in the clea- ning position (approx. -
Page 41: Setting Up The Compressed Air Supply
Setting up the Compressed Air Supply Setting up the Set up the compressed air supply: cleaning device Disconnect the compressed air supply to the cleaning device and ensure that this compressed air compressed air supply remains disconnected while the tasks described below are be- supply, com- ing carried out on the device pressed air relief... -
Page 42: Starting Up The Parting Agent Atomizer
Starting Up the Parting Agent Atomizer Filling the parting NOTE! agent container (1 liter) and con- Only use the “Robacta Reamer” parting agent (item number 42,0411,8042) provided necting it to the by the manufacturer. cleaning device Its composition is specifically tailored for use with the cleaning device. Correct operation is not ensured when other products are used. -
Page 43: Connecting The Parting Agent Container (10 Liter) To The Cleaning Device
Connecting the NOTE! parting agent container (10 li- Only use the “Robacta Reamer” parting agent (item number 42,0411,8042) provided ter) to the clean- by the manufacturer. ing device Its composition is specifically tailored for use with the cleaning device. Correct operation is not ensured when other products are used. -
Page 44: Setting The Injection Quantity Of The Parting Agent Atomizer
Setting the injec- NOTE! tion quantity of the parting agent To correctly set the injection quantity, the welding torch must be in the cleaning po- atomizer sition. Connect the cleaning device’s compressed air supply Connect the device to the robot control Activate the injection process using the robot control and check whether the injection quantity is adequate If the injection quantity is not adequate, adjust the injection quantity as required... -
Page 45: Starting Up The Fill-Level Control Sensor
Starting up the fill-level control sensor General The fill-level control sensor releases a signal as soon as the fill level in the parting agent container falls below a defined level. Operating con- Function trols and displays on the sensor ‘OUT OFF’ key to program the sensor ‘OUT ON’... -
Page 46: Performing A Full Adjustment
Performing a full Fill the parting agent container with adjustment parting agent Hold the ‘OUT OFF’ key for at least 6 seconds The LED on the sensor first flas- hes slowly and then faster after 6 seconds after releasing the ‘OUT OFF’ key, >... -
Page 47: Manually Checking The Cleaning Device Functions
Manually Checking the Cleaning Device Functions General NOTE! The cleaning device’s functions must be manually checked before starting the au- tomatic cleaning process. NOTE! To correctly check the functions, the welding torch must be in the cleaning position. Manually check- NOTE! ing the cleaning device functions... - Page 48 Clamp gas nozzle/cleaning motor on Check the following while the function is executed: The function of the gas nozzle clamping device The function of the cleaning motor Clamp gas nozzle/cleaning motor on Clamp gas nozzle/cleaning motor on Cleaning motor up/down function Check the following while the function is executed: The insertion depth of the cleaning cutter into the gas nozzle Cleaning motor up/down...
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Page 49: Start Up The Cleaning Device
Start up the Cleaning Device Requirements for The following requirements must be met in order to start up the cleaning device: Start-up Opera- Cleaning device work stand screwed tightly to the surface tion Cleaning device screwed tightly to the work stand Gas nozzle clamping device set - not when using a gas nozzle with an outside diam- eter of 25 mm (0.98 inches). -
Page 50: Cleaning Program Sequence
Cleaning Program Sequence Safety CAUTION! Danger of damage to property. Only start automatic mode once the cleaning device has been installed and commissioned properly. NOTE! If wetting agent has not been applied to the inside of the welding torch, this may lead to the permanent contamination of the welding torch. -
Page 51: Cleaning Program Sequence
Cleaning Pro- gram Sequence... -
Page 55: Cleaning Device Signal Sequences
Cleaning Device Signal Sequences Cleaning device signal sequences 24 VDC 0 VDC Clamp gas nozzle, cleaning motor on Cleaning motor up/down Spray in parting agent Gas nozzle free Gas nozzle clamped Cleaning motor rotated (pulse signal) Parting agent container full Cleaning motor bottom Cleaning motor top... -
Page 56: Wire Cutter Signal Sequence
Wire Cutter Signal Sequence Wire cutter signal sequence 24 VDC 0 VDC Cut the wire electrode Wire cutter open Wire cutter closed... -
Page 57: Service, Maintenance And Disposal
Service, maintenance and disposal... -
Page 59: Safety
Safety Safety Please follow the safety rules below during all the tasks described in the "Service, Mainte- nance, and Disposal" chapter. WARNING! Incorrect operation and incorrectly performed work can cause serious injury and damage to property. All work listed in these Operating Instructions may only be performed by trained specialist personnel. -
Page 60: Ensure That The Cleaning Device Is Depressurized
If work is required on the cleaning device while the cleaning device is being supplied with voltage and/or compressed air: ► keep your body, especially hands, face and hair, as well as objects and all items of clothing away from the cleaning cutter, cleaning motor, lifting device, gas nozzle clamping device, wire cutter, and parting-agent injection nozzle ►... -
Page 61: Service, Maintenance And Disposal
Service, maintenance and disposal General The cleaning device does not usually require maintenance. To ensure the cleaning device remains operational over time, there are a number of care and maintenance tasks that need to be carried out, however: Before every Check the fill level in the parting agent container and top up the parting agent container start-up if necessary... -
Page 63: Troubleshooting
Troubleshooting... -
Page 65: Safety
Safety Safety Please follow the safety rules below during all the tasks described in the "Troubleshooting" chapter. WARNING! Incorrect operation and incorrectly performed work can cause serious injury and damage to property. All work listed in these Operating Instructions may only be performed by trained specialist personnel. -
Page 66: Ensure That The Cleaning Device Is Depressurized
If work is required on the cleaning device while the cleaning device is being supplied with voltage and/or compressed air: ► keep your body, especially hands, face and hair, as well as objects and all items of clothing away from the cleaning cutter, cleaning motor, lifting device, gas nozzle clamping device, wire cutter, and parting-agent injection nozzle ►... -
Page 67: Troubleshooting
Troubleshooting Errors in the Pro- Parting agent is not sprayed in gram Sequence Parting agent container is full Cause: Injection quantity too low Remedy: Adjust the injection quantity (injection time or parting agent adjusting control- ler) Cause: Intake filter of the parting agent hose in the parting agent container is contam- inated Remedy: Clean the intake filter of the parting agent hose with compressed air (see... - Page 68 Lifting device does not move up or down Cause: Compressed air relief valve closed Remedy: Open compressed air relief valve Cause: No signal from robot Remedy: Check robot program Cause: Solenoid valve has mechanical fault Remedy: Contact service team (solenoid valve needs replacing) Cause: Throttle valve cannot be adjusted or is faulty Remedy:...
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Page 69: Technical Data
Technical Data... -
Page 71: Technical Data
Technical Data Robacta Reamer Supply voltage + 24 V DC X-Line J, Robacta Nominal output 10.8 W Reamer X-Line J Nominal pressure 6 bar 86.99 psi Air consumption 420 l/min 443.81 qt./min Standard I/O (X1) Input: + 24 V DC / max. 100 mA Output: + 24 V DC / max. -
Page 73: Appendix
Appendix... -
Page 74: Spare Parts List: Robacta Reamer X-Line J, Robacta Reamer X-Line J Alu
Spare parts list: Robacta Reamer X-Line J, Robacta Reamer X-Line J Alu Robacta Reamer X-Line J 44,0450,1969 Robacta Reamer X-Line J Alu 44,0450,1996... - Page 75 Wire Cutter Robacta Reamer X-Line J 44,0450,1029...
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Page 76: Circuit Diagrams: Circuit Diagram For Robacta Reamer X-Line J, Robacta Reamer X-Line J Alu
Circuit diagrams: Circuit Diagram for Robacta Reamer X-Line J, Robacta Reamer X-Line J Alu -XS0 WHITE Q778 BLUE BLACK Q777 -XS1 Q780 BLUE BLACK Q779 -XS2 Q782 BLUE BLACK Q781 -XS4 BROWN +24V US WHITE I778 BLUE BLACK I777 +A1-X1... -
Page 77: Pneumatic Plan For Robacta Reamer X-Line J, Robacta Reamer X-Line J Alu
Pneumatic Plan for Robacta Reamer X-Line J, Ro- bacta Reamer X-Line J Alu... -
Page 78: Declaration Of Conformity
Verantwortung, Hereby certifies on its sole se déclare seule responsable du fait dass folgendes Produkt: responsibility that the following que le produit suivant: product: Robacta Reamer X-Line J Robacta Reamer X-Line J Robacta Reamer X-Line J (Alu) (Alu) (Alu) Gasdüsenreinigungsgerät... - Page 80 FRONIUS INTERNATIONAL GMBH Froniusplatz 1, A-4600 Wels, Austria Tel: +43 (0)7242 241-0, Fax: +43 (0)7242 241-3940 E-Mail: sales@fronius.com www.fronius.com www.fronius.com/addresses Under http://www.fronius.com/addresses you will find all addresses of our Sales & service partners and Locations...