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Summary of Contents for Fronius Robacta Reamer Braze+
- Page 1 / Perfect Charging / Perfect Welding / Solar Energy Operating instructions Robacta Reamer Braze+ Welding torch cleaning 42,0426,0281,EA 005-04032021 Fronius prints on elemental chlorine free paper (ECF) sourced from certified sustainable forests (FSC).
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Page 3: Table Of Contents
Table of contents Safety Instructions Explanation of 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 Maintenance and repair Safety Inspection... - Page 4 Start up the Cleaning Device Requirements for Starting Up Start-up Operation Cleaning Program Sequence Safety Cleaning Program Sequence Signal Sequences Signal Sequences Service, maintenance and disposal Safety Safety Service, maintenance and disposal General Before Every Start-up Weekly Every 6 months Whenever Required Changing the Cleaning Blades Changing the Cleaning Brushes...
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Page 5: Safety Instructions
Safety Instructions Explanation of DANGER! Safety Instruc- tions Indicates an immediate danger. ▶ Death or serious injury may result if appropriate precautions are not taken. WARNING! Indicates a possibly dangerous situation. ▶ Death or serious injury may result if appropriate precautions are not taken. CAUTION! Indicates a situation where damage or injury could occur. -
Page 6: Intended Use
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 accordance with the intended purpose."... -
Page 7: Personal Protection And Protection Of Others
Always integrate the device into a superordinate safety system in a secured area. If this area has to be accessed for preparatory or maintenance work, ensure that the entire system is shut down for the duration of access to this area and remains shut down to prevent unintended operation, for example, as a result of a control error. -
Page 8: Emf Measures
close to either radio or television receivers). If this is the case, then the operating company is obliged to take appropriate action to rectify the situation. Check and evaluate possible problems and the interference immunity of equipment in the vicinity according to national and international regulations: Safety devices Grid power lines, signal lines, and data transfer lines EMC and telecommunications equipment... -
Page 9: Safety Measures In Normal Operation
Safety Measures Only operate the device when all safety devices are fully functional. If the in Normal Opera- safety devices are 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 operating company Inefficient operation of the device. -
Page 10: Safety Symbols
Copyright Copyright of these Operating Instructions remains with the manufacturer. Text and illustrations were accurate at the time of printing. Fronius reserves the right to make changes. The contents of the Operating Instructions shall not provide the basis for any claims whatsoever on the part of the purchaser. If you have any suggestions for improvement, or can point out any mistakes that you have found in the Operating Instructions, we will be most grateful for your comments. -
Page 11: General
General... -
Page 13: Warning Notices Affixed To The Device
Warning notices affixed to the device Warning Notices The cleaning device has warning notices and a rating plate fitted. These warning on the Cleaning notices and the rating plate must not be removed or painted over. Device Warning notices on the cleaning device WARNING! Risk of serious injuries due to: moving mechanical parts flying debris (chips, etc.) - Page 14 Warning before the device switches on automatically...
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Page 15: Transport
Transport Transport equip- Transport the device using the following transport equipment: ment On a pallet using a counterbalanced lift truck On a pallet using a lift truck Manually WARNING! Danger from devices and objects falling. This can result in severe personal injury and damage to property. ▶... - Page 16 NOTE! When lifting the device out of the pack- aging, do not hold the motor cover to lift it.
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Page 17: Scope Of Supply
Scope of Supply Scope of Supply Cleaning device Compressed air relief valve not shown: Harting Han6P (X1) connecting plug without cable Operating instructions Available Options Teach-gauge Open collecting container... -
Page 19: Operating Controls, Connections And Mechanical Components
Operating controls, connections and mechanical components... -
Page 21: Safety
Safety Safety Please follow the safety rules below when using all the functions described in the "Oper- ating controls, connections, and mechanical components" chapter. WARNING! Danger from incorrect operation and work that is not carried out properly. This can result in severe personal injury and damage to property. ▶... -
Page 22: Operating Controls, Connections And Mechanical Components
Operating controls, connections and mechanical components Operating Con- trols, Connec- tions, and Mech- anical Compon- ents Status display illuminates when the device is ready for cleaning does not illuminate when there is a fault or the device is in operation Motor cover Lock bolt for motor cover locks the motor cover in place (2) -
Page 23: Harting Han6P (X1) Connecting Plug Configuration For The Robot Control
Harting Han6P (X1) Connecting Plug Configuration for the Robot Control General CAUTION! Danger of damage to the Harting Han6P (X1) connection power supply due to over- current. Provide the power supply with 500 mA fuse protection against overcurrent. NOTE! To avoid interference, keep the line length between the cleaning device and the robot control as short as possible. -
Page 25: Installation And Startup
Installation and Startup... -
Page 27: 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 28: Before Installation
Before installation Intended Use The cleaning device is used exclusively to mechanically clean Fronius robot welding torches 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 manufacturer shall not be liable for any damage resulting from such improper use. -
Page 29: Measures To Ensure Safe Operation Of The Device When Operating Personnel Are Untrained
Measures to If untrained operating personnel have access to the device, the compressed air supply to ensure safe oper- the device must be disconnected for the duration of this access in accordance with "Per- ation of the formance Level d" of ISO 13849-1. device when operating person- We recommend FESTO's MS6-SV soft-start and quick exhaust valve for interrupting the... -
Page 30: Screwing The Cleaning Device To The Solid Surface
Screwing the Cleaning Device to the Solid Surface Screwing the NOTE! Cleaning Device to the Solid Sur- Depending on the solid surface (base) you have, you may need to use a different face mounting material to screw the device in place. The installer is responsible for selecting the proper mounting materials. -
Page 31: 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 supply, com- being carried out on the device pressed air relief... -
Page 32: Cleaning The Cleaning Head
Cleaning the Cleaning Head Installing the Cleaning Head NOTE! Producing the compressed air supply will move the cleaning motor into its top position. This will make it easier to install the clean- ing head. CAUTION! Risk of crushing. Only open the motor cover when the cleaning motor is in its top position (when 6 bar the cleaning motor is no longer moving). - Page 33 5,0 mm (0,197 inch) 4x 5Nm NOTE! Hearing the locking bolt (1) clicking into place tells you that the motor cover is now closed.
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Page 34: Defining The Welding Torch Cleaning Position
Defining the Welding Torch Cleaning Position Welding Torch Adjust the welding torch cleaning position as shown below. Cleaning Position Set the “Calibrate cleaning head” input sig- nal for one second – this will move the cleaning head to the correct starting position Deactivate the “Calibrate cleaning head”... - Page 35 NOTE! Always screw the Teach-gauge tightly up to the torch body. NOTE! The diagram opposite shows the end position with Teach-gauge. Use this position as the starting point for the program sequence when cleaning the welding torch. NOTE! Ensure that the torch body including the Teach-gauge is positioned correctly on the cleaning head—observe the fol- lowing information for this purpose.
- Page 36 NOTE! Ensure that the Teach-gauge ▶ is positioned entirely on the cleaning head ▶ is positioned precisely in the center of the cleaning head NOTE! The machine zero position, which is determined using the Teach-gauge, should also be used as the machine zero position with installed gas nozzle when pro- graming the robot.
- Page 37 Machine zero position with installed gas nozzle Machine zero position with installed Teach-gauge (same as machine zero position with installed gas (same as machine zero position with installed Teach- nozzle) gauge) NOTE! The cleaning position of the welding torch is 80.5 mm (3.17 inches) below the machine zero position.
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Page 38: 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: Starting Up cleaning device screwed tightly to the solid surface compressed air supply set up cleaning head installed cleaning device connected to the robot control cleaning position of the welding torch defined all covers installed and all safety devices in good order and installed in the location intended... -
Page 39: 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 commis- sioned properly. -
Page 40: Cleaning Program Sequence
Cleaning Pro- gram Sequence Start Move to position A - Machine zero position - Speed: High speed mode Output query (output signal ready for cleaning) Query = low - Low or high (Cleaning blade faulty or the cleaning head has not reached the end position ) Query = high (device is ready for cleaning) - Page 41 Withdraw wire electrode up to behind the contact tip – see diagram opposite Move to position B - 30 mm (1.18 inch) below the machine’s zero position - Speed: High speed mode Move to position C - 50.5 mm (1.99 inch) below the machine’s zero position - Speed: 60 cm/min (23.62 ipm)
- Page 42 Move to position A - approx. 50 mm (1.97 inch) centrally positioned above cleaning head - Speed: 400 cm/min (157.48 ipm) Important! The cleaning is complete. The operating mode of the robot can be continued again Wait three seconds - Input “Calibrate cleaning head” Wait two seconds Reset - Input “Calibrate cleaning head”...
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Page 43: Signal Sequences
Signal Sequences Signal Input signals: Sequences (1) Calibrate cleaning head (2) Start cleaning motor Output signal: (3) Ready for cleaning... -
Page 45: Service, Maintenance And Disposal
Service, maintenance and disposal... -
Page 47: Safety
Safety Safety Please follow the safety rules below during all the tasks described in the "Service, Main- tenance, 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 48: 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 In general, you should visually inspect the cleaning device and ensure that any dam- Start-up age is repaired immediately (before commissioning) - Page 49 5,0 mm (0,197 inch) 180° 4,0 mm (0,157 inch) 2,5 mm (0,098 inch)
- Page 50 2,5 mm (0,098 inch)
- Page 51 180° 5,0 mm (0,197 inch)
- Page 52 4x 5Nm NOTE! Hearing the locking bolt (1) clicking into place tells you that the motor cover is now closed.
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Page 53: Changing The Cleaning Brushes
Changing the Set the “Calibrate cleaning head” input signal for one second Cleaning Brushes – this will move the cleaning head to the correct starting position Deactivate the “Calibrate cleaning head” input signal 5,0 mm (0,197 inch) - Page 54 180° 4,0 mm (0,157 inch) 2,5 mm 2,0 mm (0,078 inch) (0,098 inch) 2,0 mm 2,5 mm (0,078 inch) (0,098 inch)
- Page 55 180° 5,0 mm (0,197 inch) 4x 5Nm...
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Page 56: Disposal
NOTE! Hearing the locking bolt (1) clicking into place tells you that the motor cover is now closed. Disposal Materials should be disposed of according to valid national and regional rules. -
Page 57: Troubleshooting
Troubleshooting... -
Page 59: Safety
Safety Safety Please follow the safety rules below during all the tasks described in the "Troubleshoot- ing" 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: Troubleshooting
Troubleshooting Errors in the Pro- Welding torch has been poorly cleaned or is damaged gram Sequence Cause: Cleaning blades worn or damaged Remedy: Change the cleaning blades Cause: Cleaning brushes worn or damaged Remedy: Change the cleaning brushes Cause: Incorrect cleaning position Remedy: Define cleaning position as per Operating Instructions—see section Weld-... -
Page 61: Technical Data
Technical data... -
Page 63: Technical Data
Technical data Robacta Reamer Supply voltage + 24 V DC Braze+ Nominal output 15 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. 360 mA Output: + 24 V DC/max. -
Page 65: Appendix
Appendix... -
Page 66: Declaration Of Conformity
Declaration of conformity EU-KONFORMITÄTSERKLÄRUNG 2018 EU-DECLARATION OF CONFORMITY 2018 DÉCLARATION UE DE CONFORMITÉ, 2018 Wels-Thalheim, 2018-05-07 FRONIUS INTERNATIONAL GMBH Froniusstraße 1, A-4643 Pettenbach erklärt in alleiniger Verantwortung, Hereby certifies on its sole se déclare seule responsable du fait dass folgendes Produkt:... - Page 68 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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