Fronius Robacta Reamer Operating Instructions Manual
Welding torch cleaning
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Summary of Contents for Fronius Robacta Reamer
- Page 1 / Perfect Charging / Perfect Welding / Solar Energy Operating instructions Robacta Reamer Welding torch cleaning 42,0426,0143,EN 014-05032021 Fronius prints on elemental chlorine free paper (ECF) sourced from certified sustainable forests (FSC).
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Page 3: Table Of Contents
Transport notices on the packaging Controls, connections and mechanical components Safety Safety Robacta Reamer control elements, connections and mechanical components Control elements, connections and mechanical components Standard I/O connecting plug (X1) pin assignment for robot control General Standard I/O (X1) connecting plug pin assignment... - Page 4 Daily Weekly Every 6 months As necessary Disposal Troubleshooting Safety Safety Ensuring that the cleaning device is depressurised Troubleshooting Errors in program sequence Technical data Technical data Robacta Reamer Appendix Robacta Reamer Robacta Reamer V pneumatic diagram Declarations of Conformity...
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Page 5: Safety Rules
Safety rules Explanation of DANGER! safety notices Indicates immediate danger. ▶ If not avoided, death or serious injury will result. WARNING! Indicates a potentially hazardous situation. ▶ If not avoided, death or serious injury may result. CAUTION! Indicates a situation where damage or injury could occur. ▶... -
Page 6: Proper Use
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 7: Protecting Yourself And Others
The device must be incorporated into a higher-level safety system within a secured area. If this area has to be accessed when setup and maintenance work is carried out, make sure that the entire system is switched off for the duration of the work in this area and that it is prevented from starting up accidentally, e.g. -
Page 8: Emc Measures
EMC measures In certain cases, even though a device complies with the standard limit values for emis- sions, it may affect the application area for which it was designed (e.g. when there is sensitive equipment at the same location, or if the site where the device is installed is close to either radio or television receivers). -
Page 9: Safety Measures In Normal Operation
Safety measures Only operate the device if all safety devices are fully functional. If the safety devices are in normal opera- not fully functional, there is a risk of tion injury or death to the operator or a third party, damage to the device and other material assets belonging to the operator, inefficient operation of the device. -
Page 10: Disposal
Disposal Do not dispose of this device with normal domestic waste! To comply with the European Directive on Waste Electrical and Electronic Equipment and its implementation as national law, electrical equipment that has reached the end of its life must be collected separately and returned to an approved recycling facility. -
Page 11: General Information
General information... -
Page 13: General
The parting agent container is attached to the outside of the steel housing. The Robacta Reamer can optionally be fitted with a wire cutter. During the cleaning pro- cess, the wire electrode is shortened to a defined length for the next welding process. -
Page 14: Scope Of Supply And Options
Scope of supply and options Robacta Reamer NOTE! scope of supply The "Robacta Reamer" parting agent (item number 42,0411,8042) and the cleaning cutter are not part of the scope of supply. Robacta Reamer cleaning device Spatter tray retainer Spatter tray... -
Page 15: Warning Notices On The Device
Warning notices on the device Warning notices NOTE! on the cleaning The cleaning device is fitted with warning notices and a rating plate. device The warning notices and rating plate must not be removed or painted over. Type Art.No. Chargen No. Wels - Austria 0.25 A 24 V... - Page 16 For indoor use only Wear eye protection Notice warning of automatic start-up of the device...
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Page 17: Transport
Transport Transport The device is to be transported by the following devices: devices On pallets using a forklift truck On pallets using a lift truck Manual WARNING! Danger from machines and objects falling. This can result in serious injury and damage to property. ▶... -
Page 19: Controls, Connections And Mechanical Components
Controls, connections and mechan- ical components... -
Page 21: 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 fol- lowing documents: ▶... -
Page 22: Robacta Reamer Control Elements, Connections And Mechanical Components
Robacta Reamer control elements, connections and mechanical components Control elements, connections and mechanical com- ponents Side view Front view Parting agent adjuster for setting the spray amount on the parting agent spray nozzles "Cleaning" screw for manually checking the following functions:... - Page 23 Lifting device Lifts the cleaning motor and the cleaning cutter to the cleaning position ready to commence cleaning "Spray" button Starts the spraying process. Bleeds the feed pipes after filling with parting agent (10) Parting agent spray nozzles Sprays the parting agent into the interior and onto the front of the gas nozzles using compressed air (10)
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Page 24: 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 25: Installation And Commissioning
Installation and commissioning... -
Page 27: 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 28: Ensuring That The Cleaning Device Is Depressurised
WARNING! Whenever the cleaning device and connected system components are supplied with voltage and/or compressed air, a risk of serious injury exists from: ▶ rotating cleaning cutter ▶ lifting device moving up/down ▶ extending/retracting gas nozzle clamping device ▶ activated wire cutter ▶... -
Page 29: 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 30: Measures For The Safe Operation Of The Device With Untrained Personnel
Measures for the If untrained operators have access to the device, its compressed air supply must be dis- safe operation of connected for the duration of work in accordance with 'Performance Level d' of the ISO the device with 13849-1 standard. untrained person- To ensure that the compressed air supply is interrupted as required, MS6-SV pressure build-up and pressure relief valves from FESTO are recommended. -
Page 31: Screwing The Cleaning Device To The Underlying Surface
Screwing the cleaning device to the underlying sur- face Screwing the WARNING! cleaning device and installation Danger from machines falling or toppling over. stand to the This can result in serious injury and damage to property. ▶ underlying sur- Always secure the installation stand to the underlying surface. ▶... -
Page 32: Screwing The Cleaning Device To The Underlying Surface
Attach the spatter tray retainer as shown Screwing the WARNING! cleaning device to the underlying Danger from machines falling or toppling over. surface This can result in serious injury and damage to property. ▶ Always secure the cleaning device to the underlying surface. ▶... - Page 33 Attach the spatter tray retainer as shown...
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Page 34: Torch Cleaning Position
Torch cleaning position Welding torch cleaning position... -
Page 35: Adjust Gas Nozzle Clamping Device
Adjust gas nozzle clamping device Adjust gas nozzle NOTE! clamping device The gas nozzle clamping device must be adjusted so that no bearing pressure is transferred to the robot. The gas nozzle must only be clamped onto the cylindrical surface. Loosen Allen screws on the guide bolts (1) and (2) Move the welding torch to the cleaning... -
Page 36: Fitting The Cleaning Cutter
The cleaning cutter is not part of the scope of suppl.. Consult the manufacturer's spare parts list for the appropriate cleaning cutter: https://spareparts.fronius.com/ Remove the protective covering from the cleaning device Fit the protective covering to the cleaning device in its original position... -
Page 37: Adjusting The Lifting Device
Adjusting the lifting device Adjust lifting Remove protective covering (1) device Remove gas nozzle from torch neck Ensure that the lifting device is in its lowest position Undo screw (2) on the lifting device Move the welding torch to the cleaning position Push the lifting device (3) by hand into its highest position and hold in place... -
Page 38: Starting Up The Parting Agent Nebuliser
NOTE! parting agent nebuliser Only use "Robacta Reamer" parting agent (item number 42,0411,8042) supplied by the manufacturer. The composition of the manufacturer's parting agent is designed specifically for the cleaning device. If other manufacturers' products are used, trouble-free operation cannot be guaranteed. -
Page 39: Correct Setting Of The Parting Agent Spray Nozzles
Correct setting of NOTE! the parting agent spray nozzles Both jets of parting agent must meet in front of the gas nozzle so that they both enter the nozzle. -
Page 40: Installing The Mechanically Controlled Wire Cutter (Optional)
Installing the mechanically controlled wire cutter (optional) Installing the Position the mounting bracket (1) on mechanically the wire cutter (2) as illustrated and controlled wire screw into place using the fixings cutter provided as shown in the detailed dia- gram Undo 3 screws and washers (3) Remove cleaning device housing cover (4) - Page 41 Undo screws and washers (6) Keep the screws and washers for future use Screw the wire cutter to the cleaning device using the previously removed screws and washers (6) Cut through the compressed air hose (7) in the interior of the cleaning device housing at the position shown...
- Page 42 Detach compressed air connection (8) from compressed air connection (9) Attach the wire cutter compressed air connection (9) to the compressed air connection (8) on the cleaning device housing as shown Insert the compressed air hose (10) firmly into the compressed air distrib- utor (11) Insert the two loose ends (12) and (13) of the previously cut compressed...
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Page 43: Installing The Electrically Controlled Wire Cutter (Optional)
Installing the electrically controlled wire cutter (optional) Installing the Position the mounting bracket (1) on electrically con- the wire cutter (2) as illustrated and trolled wire cutter screw into place using the fixings provided as shown in the detailed dia- gram Undo 3 screws and washers (3) Remove cleaning device housing... - Page 44 Screw the wire cutter to the cleaning device using the previously removed screws and washers (5) Fit the cleaning device housing cover (4) to the cleaning device in its original position NOTE! The wire cutter must be supplied with compressed air from an additional supply line.
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Page 45: Wire Cutter Function
Wire cutter function Maximum wire Wire electrodes with a diameter of up to 1.6 mm (0.063 in.) can be cut with an electrically diameter or mechanically controlled wire cutter. How the mechan- If a torch neck pushes the valve lever (1) ically-controlled to the side by more than 15°... -
Page 46: 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 supply for the it 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 function of the... -
Page 47: 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 If present, the cleaning device installation stand is bolted to underlying surface Cleaning device is bolted to underlying surface Gas nozzle clamping device is adjusted Cleaning cutter is fitted Lifting device has been adjusted... -
Page 48: Program Sequence And Signal Waveform
Program sequence and signal waveform Cleaning pro- CAUTION! gram sequence 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 49 Start Wire cutter option Start from position C - c. 25 mm (0.98 in.) next to wire cutter - Speed: high speed Start from position D - Enter wire cutter - Speed: 10 cm/s (236.22 ipm) Wait 0.5 sec. Start from position A - c.
- Page 50 Start from position B (cleaning position) - Enter gas nozzle clamping device - Speed: 10 cm/s (236.22 ipm) - Blow compressed air through welding torch - Input 'Start cleaning' Wait 3 sec. Reset - Input 'Start cleaning' Reset - Blow compressed air through welding torch Wait 1.5 sec.
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Page 51: Signal Waveform
Signal waveform Meaning Input "Begin cleaning" Output "Gas nozzle free" Gas nozzle free Cleaning time: 3.0 - 5.0 seconds... -
Page 53: Care, Maintenance And Disposal
Care, maintenance and disposal... -
Page 55: Safety
Safety Safety Observe the following safety rules for all work described in the "Care, maintenance and disposal" 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 56: Ensuring That The Cleaning Device Is Depressurised
WARNING! Whenever the cleaning device and connected system components are supplied with voltage and/or compressed air, a risk of serious injury exists from: ▶ rotating cleaning cutter ▶ lifting device moving up/down ▶ extending/retracting gas nozzle clamping device ▶ activated wire cutter ▶... -
Page 57: Care, Maintenance And Disposal
Care, maintenance and disposal General The cleaning device generally needs no maintenance. However, to keep the cleaning device in good working condition for years to come, several points on care and mainten- ance must be observed. Before each start- Check fill level in parting agent container and top up if necessary Check the cleaning cutter for wear and replace if necessary Empty the cleaning device spatter tray If fitted, empty the wire cutter tray... -
Page 59: Troubleshooting
Troubleshooting... -
Page 61: 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 62: Ensuring That The Cleaning Device Is Depressurised
WARNING! Whenever the cleaning device and connected system components are supplied with voltage and/or compressed air, a risk of serious injury exists from: ▶ rotating cleaning cutter ▶ lifting device moving up/down ▶ extending/retracting gas nozzle clamping device ▶ activated wire cutter ▶... -
Page 63: Troubleshooting
Troubleshooting Errors in program Parting agent does not spray sequence Parting agent container is full Cause: Not enough spray Remedy: Adjust spray amount Cause: Parting agent spray nozzles are blocked Remedy: Clean parting agent spray nozzles If cleaning does not rectify problem, contact After-Sales Service - replace parting agent spray nozzles Cause: No signal from robot... -
Page 65: Technical Data
Technical data... -
Page 67: Technical Data
Technical data Robacta Reamer Supply voltage + 24 V DC Nominal output 3.2 W Nominal pressure 6 bar 86.99 psi Air consumption 420 l/min 443.81 qt./min Thread identification compressed air connection G ¼“ Standard I/O (X1) Input: + 24 V DC / max. 150 mA Output: + 24 V DC / max. -
Page 69: Appendix
Appendix... -
Page 70: Robacta Reamer
Circuit diagram: Robacta Reamer... -
Page 71: Robacta Reamer V Pneumatic Diagram
Robacta Reamer V pneumatic diagram... -
Page 72: Declarations Of Conformity
(technische Dokumentation) (technical documents) (technique documentation) Ing. Josef Feichtinger Ing. Josef Feichtinger Ing. Josef Feichtinger Günter Fronius Straße 1 Günter Fronius Straße 1 Günter Fronius Straße 1 A - 4600 Wels-Thalheim A - 4600 Wels-Thalheim A - 4600 Wels-Thalheim 2016 ppa. - Page 76 FRONIUS INTERNATIONAL GMBH Froniusstraße 1 A-4643 Pettenbach AUSTRIA contact@fronius.com www.fronius.com Under www.fronius.com/contact you will find the addresses of all Fronius Sales & Service Partners and locations...
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