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Summary of Contents for Fronius Robacta Reamer Braze+
- Page 1 Operating Instructions Robacta Reamer Braze+ EN-US Operating instructions 42,0426,0281,EA 008-03082022...
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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 Installing the cleaning head Defining the Welding Torch Cleaning Position Welding torch cleaning position 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...
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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: Emc Measures
EMC Measures In certain cases, even though a device complies with the standard limit values for emissions, 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 when all safety devices are fully functional. If the safety in normal opera- devices are not fully functional, there is a danger of: tion Serious or fatal injury to the operator or third parties 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... -
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 warn- on the Cleaning ing 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 packaging, do not hold the motor cov- er 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 Op- Teach-gauge tions 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 "Operating 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 indicator 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 Configura- tion for the Robot Control General CAUTION! Danger from overcurrent. Damage to the power supply for the Harting Han6P connection may result. ▶ Fuse the power supply of the cleaning device with 500 mA slow-blow fuse against overcurrent. -
Page 25: Installation And Startup
Installation and Startup... -
Page 27: Safety
Safety Safety Please follow the safety rules below when carrying out all the tasks described in the "Installation and commissioning" 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 28: Before Installation
Before installation Intended Use The cleaning device is used exclusively to mechanically clean Fronius robot weld- ing 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 con- stitute proper use. -
Page 29: Measures To Ensure Safe Operation Of The Device When Operating Personnel Are Untrained
Measures to en- If untrained operating personnel have access to the device, the compressed air sure safe opera- supply to the device must be disconnected for the duration of this access in ac- tion of the cordance with "Performance Level d" of ISO 13849-1. device when op- erating person- We recommend FESTO's MS6-SV soft-start and quick exhaust valve for inter-... -
Page 30: Screwing The Cleaning Device To The Solid Surface
Screwing the Cleaning Device to the Solid Sur- face Screwing the NOTE! cleaning device to the surface Depending on the solid surface (base) you have, you may need to use a different mounting material to screw the device in place. The installer is responsible for selecting the proper mounting materials. -
Page 31: Installation Of Optional Wire Cutter
Installation of optional wire cutter Assignment of the connecting plug Trim wire electrode + 24 V DC Assignment on the side of the wire cutter Installing the wire cutter Connect wire cutter to robot controller Detach compressed air hose from wire cutter... - Page 32 Compressed air hose from the wire cutter is no Connect external compressed air supply to wire longer required cutter...
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Page 33: 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 compressed air this compressed air supply remains disconnected while the tasks described supply, com- below are being carried out on the device pressed air relief... -
Page 34: Cleaning The Cleaning Head
Cleaning the Cleaning Head Installing the cleaning head NOTE! Establishing the compressed air sup- ply will move the cleaning motor into its top position. This will make it easier to install the cleaning head. CAUTION! Danger due to cleaning head moving up/down. - Page 35 5,0 mm (0,197 inch) NOTE! Hearing the locking bolt (1) clicking into place tells you that the motor cover is now closed.
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Page 36: 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 signal for one second this will move the cleaning head to the correct starting position Deactivate the "Calibrate cleaning head"... - Page 37 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 clean- ing the welding torch. NOTE! Ensure that the torch body including the Teach-gauge is positioned cor- rectly on the cleaning head - observe the following information for this pur-...
- Page 38 NOTE! Ensure that the teach-gauge: ▶ is positioned entirely on the clean- ing head ▶ is positioned precisely in the cen- ter 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 39 Machine zero position with installed Teach- Machine zero position with installed gas nozzle (same as machine zero position with installed gauge (same as machine zero position with in- stalled gas nozzle) Teach-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 40: Start Up The Cleaning Device
Start up the Cleaning Device Requirements The following requirements must be met in order to start up the cleaning device: for 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 41: Cleaning Program Sequence
Cleaning Program Sequence Safety CAUTION! Danger due to improper commissioning. This can result in damage to property. ▶ Only start automatic mode once the cleaning device has been installed and commissioned properly. -
Page 42: 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 43 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 44 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 45: Signal Sequences
Signal Sequences Signal Se- Input signals: quences (1) Calibrate cleaning head (2) Start cleaning motor Output signal: (3) Ready for cleaning... -
Page 47: Service, Maintenance And Disposal
Service, maintenance and disposal... -
Page 49: Safety
Safety Safety Follow the safety rules below when carrying out all the tasks described in the "Service, maintenance, and disposal" 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 50: 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 mainten- ance tasks that need to be carried out, however: Before Every In general, you should visually inspect the cleaning device and ensure that Start-up any damage is repaired immediately (before commissioning) - Page 51 5,0 mm (0,197 inch) 180° 4,0 mm (0,157 inch) 2,5 mm (0,098 inch)
- Page 53 180° 5,0 mm (0,197 inch)
- Page 54 NOTE! Hearing the locking bolt (1) clicking into place tells you that the motor cover is now closed.
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Page 55: Changing The Cleaning Brushes
Changing the Set the “Calibrate cleaning head” input signal for one second Cleaning – this will move the cleaning head to the correct starting position Brushes Deactivate the “Calibrate cleaning head” input signal 5,0 mm (0,197 inch) - Page 56 180° 4,0 mm (0,157 inch) 2,5 mm 2,0 mm (0,078 inch) (0,098 inch)
- Page 57 180° 5,0 mm (0,197 inch)
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Page 58: 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 local and national regulations. -
Page 59: Troubleshooting
Troubleshooting... -
Page 61: Safety
Safety Safety Follow the safety rules below when carrying out all the tasks described in the "Troubleshooting" 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 62: Troubleshooting
Troubleshooting Errors in the Welding torch has been poorly cleaned or is damaged Program Se- Cause: Cleaning blades worn or damaged quence Remedy: Change the cleaning blades Cause: Cleaning brushes worn or damaged Remedy: Change cleaning brushes Cause: Incorrect cleaning position Remedy: Define cleaning position as per the Operating Instructions - see sec- tion... -
Page 63: Technical Data
Technical data... -
Page 65: 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 connec- G ¼“ tion Standard I/O (X1) Input: + 24 V DC/max. 360 mA Output: + 24 V DC/max. -
Page 67: Appendix
Appendix... -
Page 69: 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:...
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