Related Manuals for Fronius Robacta Reamer V Twin
Summary of Contents for Fronius Robacta Reamer V Twin
- Page 1 / Perfect Charging / Perfect Welding / Solar Energy Operating Instructions Robacta Reamer V Twin Spare parts list Welding torch cleaning 42,0426,0142,EN 020-12122018...
- Page 3 Thank you for the trust you have placed in our company and congratulations on buying this high-quality Fronius product. These instructions will help you familiarise yourself with the product. Reading the instructions carefully will enable you to learn about the many different features it has to offer.
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Page 5: Table Of Contents
Transport notices on the packaging...................... Controls, connections and mechanical components Safety................................. Safety..............................Robacta Reamer V Twin control elements, connections and mechanical components......Controls, connections and mechanical components................Standard I/O connecting plug (X1) pin assignment for robot control ............General .............................. - Page 6 Welding torch cleaning position ......................Adjusting the lifting device ......................... Adjusting the lifting device ........................Installing the compressed air supply ......................Establishing the compressed air supply for the cleaning device, function of the compressed air relief valve..............................Starting up the parting agent nebuliser ...................... Fill parting agent container (1 litre) and connect to the cleaning device ..........
- Page 7 Robacta Reamer V Twin........................Appendix Spare parts list: Robacta Reamer V Twin ....................Circuit diagrams: Robacta Reamer V Twin ....................Robacta Reamer V Twin pneumatic diagram .................... Declarations of Conformity.........................
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Page 9: Safety Rules
Proper use The device is to be used exclusively for its intended purpose. The device is intended solely for the mechanical cleaning of Fronius robot welding torches in automatic mode. Any use above and beyond this purpose is deemed improper. The manufacturer shall not be held liable for any damage arising from such usage. -
Page 10: Obligations Of The Operator
Relative humidity: up to 50 % at 40 °C (104 °F) up to 90 % at 20 °C (68 °F) Keep ambient air free from dust, acids, corrosive gases and substances, etc. Can be used at altitudes of up to 2000 m (6500 ft) Obligations of the The operator must only allow persons to work with the device who: operator... -
Page 11: Protecting Yourself And Others
During operation Ensure that all covers are closed and fitted properly Keep all covers closed Protecting your- Anyone working with the device exposes themselves to numerous risks. In addition to self and others these Operating Instructions, the safety rules of the manufacturer of the entire welding sys- tem must also be observed. -
Page 12: Emf Measures
EMF measures Electromagnetic fields may pose as yet unknown risks to health: effects on the health of others in the vicinity, e.g. wearers of pacemakers and hearing aids wearers of pacemakers must seek advice from their doctor before approaching the de- vice or any welding that is in progress for safety reasons, keep distances between the welding cables and the welder's head/ torso as large as possible... -
Page 13: Commissioning, Maintenance And Repair
Commissioning, It is impossible to guarantee that bought-in parts are designed and manufactured to meet maintenance and the demands made of them, or that they satisfy safety requirements. repair Use only original spare and wearing parts (also applies to standard parts). Do not carry out any modifications, alterations, etc. -
Page 15: General
General... -
Page 17: General
Device concept The clamping device on the front of the Robacta Reamer V Twin holds the gas nozzle in place during cleaning. A cleaning cutter is used to clean the nozzle. After the cleaning pro- cess, a parting agent is applied to the inside and front of the gas nozzle through the spray nozzle that is fixed in the middle of the cleaning motor. -
Page 18: Scope Of Supply
Warning notices The Robacta Reamer V Twin is fitted with warning notices and a rating plate. The warning on the device notices and rating plate must not be removed or painted over. - Page 19 Chargen No. Wels - Austria 24 V p max 6 bar (87psi.) Warning notices affixed to the Robacta Reamer V Twin WARNING! Risk of serious injury from: mechanically powered parts compressed air/parting agent mixture escaping from the parting-agent injection nozzle flying parts (shavings, etc.)
- Page 20 Wear eye protection Notice warning of automatic start-up of the device...
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Page 21: Transport
Transport Vehicles The device is to be transported by the following vehicles: on pallets using a counterbalanced lift truck on pallets using a lift truck manually WARNING! Equipment that falls or topples over can cause serious or even fatal injury. ►... -
Page 23: Controls, Connections And Mechanical Components
Controls, connections and mechani- cal components... -
Page 25: Safety
Safety Safety Observe the following safety instructions for all work described in the "Control elements, connections and mechanical components" section. WARNING! Operating the equipment incorrectly can cause serious injury and damage. The functions described must only be used by trained and qualified personnel. Do not use the functions described here until you have thoroughly read and understood the following documents: ►... -
Page 26: Robacta Reamer V Twin Control Elements, Connections And Mechanical Components
Robacta Reamer V Twin control elements, connec- tions and mechanical components Controls, connec- tions and me- chanical components (13) (12) (11) (10) Side view Front view Function Standard I/O connection (X1) for a 24 V DC supply CAUTION! Risk of damage to standard I/O connection (X1) supply due to overcurrent. - Page 27 (11) Cleaning cutter with internal through hole for the parting-agent injection nozzle (12) Gas nozzle clamping device holds the gas nozzle in place during cleaning (13) Wire cutter (15) (14) Side view (14) Compressed air and electrical connections for the wire cutter (15) Parting-agent injection nozzle Applies the parting agent to the inside and front of the gas nozzle...
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Page 28: Standard I/O Connecting Plug (X1) Pin Assignment For Robot Control
Standard I/O connecting plug (X1) pin assignment for robot control General CAUTION! Risk of damage to standard I/O connection (X1) supply due to overcurrent. Secure supply against overcurrent with a 500 mA slow-blow fuse. NOTE! To avoid malfunction, keep the cable length between the cleaning device and robot control as short as possible. -
Page 29: Installation And Commissioning
Installation and commissioning... -
Page 31: Safety
Safety Safety Observe the following safety rules for all work described in the "Installation and start-up" section. WARNING! Incorrect operation or shoddy workmanship can cause serious injury or damage. All activities described in these operating instructions may only be carried out by trained and qualified personnel. -
Page 32: Ensuring That The Cleaning Device Is Depressurised
Wear protective goggles with side protection Ensure that the cleaning device has been disconnected from the compressed air sup- Briefly turn the "Lifting device up/down" screw on the Robacta Reamer V Twin 90° to the right, then turn it straight back to its original position. -
Page 33: Before Commissioning
Before commissioning Proper use The cleaning device is to be used exclusively for cleaning Fronius robot welding torches, especially the gas nozzle and its interior, in automatic mode and within the scope of the technical data. Any use above and beyond this purpose is deemed improper. The manu- facturer shall not be held liable for any damage arising from such usage. -
Page 34: Screwing The Cleaning Device To The Underlying Surface
Screwing the cleaning device to the underlying sur- face Screwing the NOTE! cleaning device and installation Different fixings may be required to set up the installation stand depending on the stand to the un- type of underlying surface (foundation). derlying surface Fixings are therefore not included in the scope of supply of the installation stand. - Page 35 Position the spatter tray on the clea- ning device as shown For an underlying surface (foundation) thickness of less than 5 mm (0.197 in.): Securely screw the cleaning device and spatter tray to the underlying sur- face (foundation) as shown using the fixings supplied For an underlying surface (foundation) thickness greater than 5 mm (0.197 in.) or an instal- lation different to that shown above:...
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Page 36: Fitting The Cleaning Cutter
Fitting the cleaning cutter Fitting the clean- CAUTION! ing cutter A cleaning cutter that has become very hot through use can cause severe burns. Before handling cleaning cutters, allow cleaning cutter to cool to room temperature (+25°C, +77 °F). NOTE! Only use the device manufacturer's contact tips, gas nozzles and cleaning cutters. -
Page 37: Torch Cleaning Position
Torch cleaning position Welding torch cleaning position NOTE! The gas nozzle must sit on the inside of the holder (1). NOTE! Ensure that the coolant lines on the gas nozzle cannot be damaged by the exten- ding/retracting gas nozzle clamping de- vice. -
Page 38: Adjusting The Lifting Device
Adjusting the lifting device Adjusting the lift- To make it easier to adjust the lifting device, it is advisable to fit one of the following adjust- ing device ment aids to the torch neck: Robacta Twin 500 adjustment aid, item no. 42,0001,5559 Robacta Twin 900 adjustment aid, item no. - Page 39 Loosen the Allen screw (2) on the lif- ting device Push the lifting device (3) by hand into its highest position and hold in place Manually push cleaning motor (4) and cleaning cutter to the cleaning position NOTE! The cleaning cutter must not touch any welding torch components.
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Page 40: Installing The Compressed Air Supply
Installing the compressed air supply Establishing the To establish the compressed air supply: compressed air Depressurise the compressed air supply line of the cleaning device and ensure that it supply for the remains depressurised for the duration of the following work on the device cleaning device, Screw the supplied compressed air relief valve into the compressed air connection on function of the... -
Page 41: Starting Up The Parting Agent Nebuliser
Starting up the parting agent nebuliser Fill parting agent NOTE! container (1 litre) and connect to Only use "Robacta Reamer" parting agent (item number 42,0411,8042) supplied by the cleaning de- the manufacturer. vice The composition of the manufacturer's parting agent is designed specifically for the clean- ing device. -
Page 42: Adjusting The Parting Agent Nebuliser Spray Amount
2 2 2 2 2 2 * Option (long parting agent hose) Adjusting the NOTE! parting agent nebuliser spray To ensure that the spray amount is adjusted properly, the welding torch must be in amount the cleaning position. Establish a compressed air supply to the cleaning device Connect the cleaning device to the robot control Start the spraying process using the robot control and check that sufficient spray is be- ing applied... - Page 43 If the spray amount is not sufficient, increase it as required by adjusting the spray time using the robot control - a spray time of ~ 0.7 seconds is recommended or by using the parting agent adjuster - see figure below Finely adjusting the spray amount on parting agent ad- juster...
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Page 44: Using The Fill-Level Control Sensor
Using the fill-level control sensor Optional fill-level NOTE! control sensor The fill-level control sensor is only available as an option. The fill-level control sensor emits a signal once the fill level in the parting agent container falls below a specified level. Controls and indi- Function cators on the sen-... -
Page 45: Fitting The Fill-Level Control Sensor
Fitting the fill-lev- el control sensor NOTE! First press the upper part of the sensor into the installation adapter as shown - the sockets (1) on the installation adap- ter must fit into the recesses (2) in the sensor. When the upper part of the sensor is pro- perly lined up in the installation adapter, press the sensor fully into the installation adapter - the latch (3) on the installation ad-... -
Page 46: Calibrating The Empty State
Calibrating the Drain the parting agent container until empty state the parting agent level is at least 20 mm (0.787 in.) below the sensor Establish a power supply to the sensor 20 mm (0.79 in.) Press the "OUT OFF" button for bet- ween 2 and 6 seconds The LED on the sensor flashes slowly... -
Page 47: Locking/Unlocking The Fill-Level Control Sensor
Press the "OUT OFF" button for at least 6 seconds The sensor LED flashes slowly at first, then more rapidly after 6 se- conds After releasing the "OUT OFF" > 6 s button the LED goes out - the sen- sor has detected a high fluid level Locking/unlock- ing the fill-level... -
Page 48: Manually Checking The Cleaning Device Functions
Manually checking the cleaning device functions General NOTE! Before starting the automatic cleaning process, the functions of the cleaning device must be checked manually. NOTE! To ensure that the functions are checked properly, the welding torch must be in the cleaning position. - Page 49 The following must be checked when the function is being performed: how far the cleaning cutter is inserted in the gas nozzle (lifting device moves up/ down) Lifting device up/down Deactivating the function The following must be checked when the function is being performed: parting agent exit (parting agent is sprayed in) Spraying in parting agent Deactivating the function...
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Page 50: Starting Up The Cleaning Device
Starting up the cleaning device Prerequisites for The following requirements must be met before the cleaning device is started up: start-up Cleaning device is bolted to underlying surface Cleaning cutter is fitted Lifting device has been adjusted Parting agent nebuliser has been started up Compressed air supply has been established Functions have been checked manually Cleaning device connected to robot control... -
Page 51: Cleaning Programme
Cleaning programme Safety CAUTION! Risk of damage. Do not start in automated mode until the cleaning device has been properly installed and started up. NOTE! Not coating the interior of the welding torch may result in permanent soiling of the torch when welding begins. -
Page 52: Cleaning Program Sequence
Cleaning program sequence... -
Page 57: Signal Waveform For Cleaning
Signal waveform for cleaning Signal inputs Gas nozzle clamped: 1,5 s Move swivel mechanism to the 0,5 s right: 0,5 s Move swivel mechanism to the left: 2,0 s 2,0 s Cleaning motor up: ca. 3 s ca. 3 s 0,7 s 0,7 s Spray parting agent:... -
Page 58: Signals Not Defined Using Time
Swivel mechanism right: Swivel mechanism left: Signals not de- Parting agent level OK: fined using time Signal waveform: Cut wire electrode input signal: wire cutter (in- puts and outputs) -
Page 59: Care, Maintenance And Disposal
Care, maintenance and disposal... -
Page 61: Safety
Safety Safety Observe the following safety rules for all work described in the "Care, maintenance and dis- posal" section. WARNING! Incorrect operation or shoddy workmanship can cause serious injury or damage. All activities described in these operating instructions may only be carried out by trained and qualified personnel. -
Page 62: Ensuring That The Cleaning Device Is Depressurised
Wear protective goggles with side protection Ensure that the cleaning device has been disconnected from the compressed air sup- Briefly turn the "Lifting device up/down" screw on the Robacta Reamer V Twin 90° to the right, then turn it straight back to its original position. -
Page 63: Care, Maintenance And Disposal
Care, maintenance and disposal General The cleaning device generally needs no maintenance. However, to keep the cleaning de- vice in good working condition for years to come, several points on care and maintenance must be observed. Before each start- Check fill level in parting agent container and top up if necessary Check fill level in parting agent spatter tray and empty if necessary Check cleaning cutter for wear and replace if necessary Empty the cleaning device spatter tray... -
Page 64: Adjust The Swivel Mechanism Stop Angle
Adjust the swivel mechanism stop angle General To make it easier to adjust the stop angle, it is advisable to fit one of the following adjust- ment aids to the torch neck: Robacta Twin 500 adjustment aid, item no. 42,0001,5559 Robacta Twin 900 adjustment aid, item no. -
Page 65: And Finally
Undo nut (2) or (3) depending on the stop angle to be adjusted Depending on the stop angle to be ad- justed, undo banking screw (4) or (5) until the cleaning motor can be moved to the highest position where it is not in contact with the welding torch parts Manually tilt the cleaning motor to the side to be adjusted and move to the highest po- sition... -
Page 67: Troubleshooting
Troubleshooting... -
Page 69: Safety
Safety Safety Observe the following safety rules for all work described in the "Troubleshooting" section. WARNING! Incorrect operation or shoddy workmanship can cause serious injury or damage. All activities described in these operating instructions may only be carried out by trained and qualified personnel. -
Page 70: Ensuring That The Cleaning Device Is Depressurised
Wear protective goggles with side protection Ensure that the cleaning device has been disconnected from the compressed air sup- Briefly turn the "Lifting device up/down" screw on the Robacta Reamer V Twin 90° to the right, then turn it straight back to its original position. -
Page 71: Troubleshooting
Troubleshooting Errors in program Parting agent does not spray sequence Parting agent container is full Cause: Not enough spray Remedy: Adjust spray amount (spray time or parting agent adjuster) Cause: Parting agent hose suction filter in the parting agent container is soiled Remedy: Clean the parting agent hose suction filter with compressed air (see "Starting up the parting agent nebuliser") - Page 72 Lifting device is not moving 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: Mechanical fault on solenoid valve Remedy: Contact After-Sales Service (arrange for solenoid valve to be replaced) Cause: Choke valve not adjustable, or faulty Remedy:...
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Page 73: Technical Data
Technical data... -
Page 75: Technical Data
Technical data Robacta Reamer Supply voltage + 24 V DC V Twin Nominal output 14.4 W Nominal pressure 6 bar 86.99 psi Air consumption 440 l/min 465 qt./min Standard I/O (X1) Input: + 24 V DC / max. 300 mA Output: + 24 V DC / max. -
Page 77: Appendix
Appendix... -
Page 78: Spare Parts List: Robacta Reamer V Twin
Spare parts list: Robacta Reamer V Twin... -
Page 79: Circuit Diagrams: Robacta Reamer V Twin
Circuit diagrams: Robacta Reamer V Twin Gasdüse spannen und Reinigungsmotor ein Clamp gas nozzle and Cleaning motor on Reinigungsmotor auf Cleaning motor up Trennmittel einsprühen Spray parting agent Gasdüse frei Gas nozzle free Gasdüse gespannt Gas nozzle clamped Trennmittel-Stand I.O... -
Page 80: Robacta Reamer V Twin Pneumatic Diagram
Robacta Reamer V Twin pneumatic diagram... -
Page 81: Declarations Of Conformity
Produkt: responsibility that the following que le produit suivant: product: Robacta Reamer V Twin Robacta Reamer V Twin Robacta Reamer V Twin Gasdüsenreinigungsgerät Gas nozzle cleaner Appareil de nettoyage de buses gaz auf das sich diese Erklärung... - Page 84 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...