Fronius Robacta Reamer Single Operating Instructions Manual
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Fronius Robacta Reamer Single Operating Instructions Manual

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Operating
Instructions
Robacta Reamer Single/Twin
EN-US
Operating instructions
42,0426,0447,EA
005-16012024

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Summary of Contents for Fronius Robacta Reamer Single

  • Page 1 Operating Instructions Robacta Reamer Single/Twin EN-US Operating instructions 42,0426,0447,EA 005-16012024...

  • 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 Weekly Every 6 months Whenever required: Disposal Troubleshooting Safety Safety Ensuring that the cleaning device is depressurized Troubleshooting Errors in the Program Sequence Technical data Technical data Robacta Reamer Single/Twin Appendix Declaration of conformity UKCA Conformity Assesment UKCA Conformity Assesment...

  • Page 5: Safety Instructions

    Safety Instructions Explanation of WARNING! safety instruc- tions Indicates a potentially dangerous situation. ▶ Death or serious injury may result if appropriate precautions are not taken. CAUTION! Indicates a potentially harmful situation. ▶ Minor injury or damage to property may result if appropriate precautions are not taken.

  • 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 higher-level 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, e.g., as a result of a control error.

  • Page 8: Emc Measures

    EMC device classification as per the rating plate or technical data. 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

    It is essential to conduct a visual inspection of the device to check for damage after it has been transported but before it is commissioned. Have any damage re- paired by trained service technicians before commissioning the device. Safety Measures Only operate the device when all safety devices are fully functional.

  • 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: General

    General Device concept The cleaning device is intended to automatically 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. This significantly increases the service life of wearing parts.
  • Page 14 Robacta Reamer Single/Twin 4,044,068 Warning notices on the cleaning device PLEASE NOTE! Risk of serious injury from mechanically moving parts. Keep the device de-energized and depressurized during main- tenance and servicing. Do not use the functions described here until you have fully...
  • Page 15 Warning before the device switches on automatically. Warning of hand injuries.

  • Page 16: 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 17: Scope Of Supply And Options

    Scope of Supply and Options Scope of supply Robacta Reamer Single/Twin cleaning device 2x parting agent containers Collection container with mounting bracket Harting Han12P (X1) without cable Compressed air relief valve Operating Instructions Wrench for cleaning motor Mounting material to assemble the cleaning device:...

  • 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 Knife / wire cutter (available option) 2x knives for cutting the welding wire (max. 2 welding wires à 1.6 mm dia- meter). Clamping device gas nozzle (available option) fixes the gas nozzle during the cleaning process.
  • Page 23 (12) Actuator/sensor connection (13) Compressed air connection socket For supplying dry compressed air at 6 bar (86.99 psi). For more information on compressed air quality, see chapter Specifica- tions for the compressed air supply on page 41. Thread identification for compressed air connection: G ¼” (14) Harting Han12P (X1) connection socket + 24 V DC power supply...

  • Page 24: Harting Han12P (X1) Connecting Plug Configuration For The Robot Control

    Harting Han12P (X1) connecting plug configura- tion for the robot control General CAUTION! Danger from overcurrent. Damage to the Harting Han12P (X1) connection power supply may result. ▶ Provide the power supply with 500 mA fuse protection against overcurrent. CAUTION! Danger due to long control line.

  • Page 25: Installation And Startup

    Installation and Startup...

  • Page 27: Safety

    Safety Safety WARNING! Danger from incorrect operation and work that is not carried out properly. This can result in severe personal injury and damage to property. ▶ All the work and functions described in this document must only be carried out by trained and qualified personnel.

  • Page 28: Ensuring That The Cleaning Device Is Depressurized

    Ensuring that To ensure that the cleaning device is depressurized, try to briefly activate the the cleaning cleaning device without the compressed air supply. To do this, proceed as follows: device is depres- Take protective measures: surized The cleaning cutter, lifting device, gas nozzle clamping device, wire cut- ter, and parting-agent injection nozzle could be activated.

  • Page 29: 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 30: Screwing The Cleaning Device To The Solid Surface

    Screwing the Cleaning Device to the Solid Sur- face Screwing the WARNING! cleaning device to the base Danger from devices falling or toppling over. This can result in severe personal injury and damage to property. ▶ Always screw the cleaning device to the base. ▶...

  • Page 31: Screwing The Cleaning Device And Work Stand To The Surface

    Hook the collecting vessel from left to right into the mounting bracket of the collecting vessel. Screwing the WARNING! cleaning device and work stand Danger from devices falling or toppling over. to the surface This can result in severe personal injury and damage to property. ▶...
  • Page 32 Place the collecting vessel mounting bracket and the cleaning device on the mounting stand in the order shown. Screw down the cleaning device, the mounting bracket of the collection con- tainer and the mounting stand with the supplied fastening material. Hook the collecting vessel from left to right into the mounting bracket of the collecting vessel.

  • Page 33: Installing/Removing The Protective Cover

    Installing/removing the protective cover Fitting the pro- Place the protective cover on the tective cover cleaning device in position. Tighten the fastening screws of the protective cover. Removing the Loosen the fixing screws of the protective cover protective cover. Pull the protective cover off the cleaning device towards the front.

  • Page 34: Mounting The Gas Nozzle Clamping Device

    Mounting the gas nozzle clamping device Mounting the gas Only fasten the gas nozzle clamp- nozzle clamping ing device to the gas nozzle clamp- device ing device holder using the screws supplied (strength class 12.9) and a torque of 11 Nm.

  • Page 35: Welding Torch Cleaning Position

    Welding Torch Cleaning Position Twin welding CAUTION! torch cleaning position Danger due to incorrectly adjusted cleaning position of the welding torch. The welding torch may be damaged. ▶ Only position the contact tips centrally and vertically over the cleaning mo- tor.

  • Page 36: Cleaning Position Of The Single Welding Torch

    Cleaning position of contact tip 2 Align the gas nozzle locking screw centrally in the second hole (2) of the clamping device. Set the exact position of the cleaning motor according to the chapter Adjust- ing the Position of the Cleaning Motor on page Cleaning posi- CAUTION!
  • Page 37 Position the contact tip of the single welding torch centrally and vertically above the cleaning cutter. IMPORTANT! The position of the cleaning motor may only be adjusted for the twin welding torch. If single and twin welding torches are to be cleaned with the Robacta Reamer Single/Twin, the distance to the cleaning cutter and the immersion depth in the contact tip for the respective single welding torch used must be set with the torch position in the clamping device.

  • Page 38: Fitting The Cleaning Cutter

    Danger due to incompatible wearing parts. Property damage and malfunctions may result. ▶ Only use original Fronius spare parts (contact tips, gas nozzles and cleaning cutters). IMPORTANT! No liability is accepted for damage caused by the use of contact tips, gas nozzles, or cleaning cutters from other manufacturers.

  • Page 39: Adjusting The Position Of The Cleaning Motor

    Adjusting the Position of the Cleaning Motor Setting the posi- tion of the clean- ing motor for twin welding torches Remove the protective cover of the clamping device (see chapter Removing the protective cover on page 33). Remove the gas nozzle from the torch body. Loosen the fixing screw (2) on the lifting device.

  • Page 40: Setting The Position Of The Cleaning Motor For Single Welding Torches

    Setting the posi- tion of the clean- ing motor for single welding torches Remove the protective cover of the clamping device (see chapter Removing the protective cover on page 33). Remove the gas nozzle from the torch body. Make sure that the lifting device (1) is in the bottom-most lift position. Move the welding torch into the cleaning position (see chapter Cleaning posi- tion of the single welding torch...

  • Page 41: Compressed Air Supply

    Compressed air supply Specifications To ensure the proper functioning of the cleaning device, fulfill the following spe- for the com- cifications for the compressed air supply: pressed air sup- Set up a compressed air supply using the pressure relief valve and com- pressed air filter Guarantee the compressed air quality in accordance with ISO 8573-1:2001, class 7 4 3, instrument air...

  • Page 42: Operation Of The Compressed Air Relief Valve

    Attach the compressed air sup- ply line to the compressed air relief valve. Thread identification Com- pressed air connection: G ¼” Operation of the You can interrupt and restore the compressed air supply to the cleaning device compressed air by moving the compressed air relief valve back and forth. relief valve Cleaning device is supplied with compressed air.

  • Page 43: Starting Up The Parting Agent Atomizer

    Starting Up the Parting Agent Atomizer Filling the part- ing agent con- tainer (1 liter) and connecting it to the cleaning device IMPORTANT! Only use the water-based “Robacta Reamer” parting agent (item number 42.0411.8042) provided by the manufacturer. Its composition is specifically tailored for use with the cleaning device.

  • Page 44: Connecting The Parting Agent Container (10 Liter) To The Cleaning Device

    Connecting the Remove the parting agent container (1 parting agent liter) from the cleaning device and ter- container (10 minate the parting agent hose. liter) to the cleaning device IMPORTANT! The parting agent hose must not be extended. For proper operation, use only ori- ginal parting agent hoses.

  • Page 45: Positioning Of The Parting Agent Container (10 Liters)

    tailored for use with the cleaning device. Correct operation is not ensured when other products are used. * “Long parting agent hose” option (item number 42.0300.3007) Connect the release agent hose to the cleaning device and fasten the cap of the parting agent container.

  • Page 47: Opt/I Tss Tcp Touch Sense

    Do not crush the ground cable or damage the insulation. Position the OPT/i TSS TCP Touch Sense option on top of the Robacta Reamer Single/Twin. Insert the 2 screws supplied (M4 x 10 mm) into the hole and fasten with a torque of 1.5 Nm.

  • Page 48: Manually Checking The Cleaning Device Functions

    Manually Checking the Cleaning Device Functions Safety WARNING! For the following tasks, the cleaning device must be supplied with compressed air. This results in danger from the rotating cleaning cutter, cleaning motor mov- ing up/down, gas nozzle clamping device moving out/in, flying parts (chips, etc.), compressed air/parting agent mixture escaping from the parting-agent in- jection nozzle.
  • Page 49 “Clamp gas nozzle” function Activate the function with the set screw and a 90° clockwise turn. Check that the gas nozzle is correctly held in the clamping device. “Cleaning motor on / lifting device up” function Activate the function with the set screw and a 90° clockwise turn. Check the function of the clamping device for the gas nozzle.
  • Page 50 “Spray parting agent” function Activate the function with the set screw and a 90° clockwise turn. After the function has been completed, check whether the gas nozzle is moistened with parting agent. IMPORTANT! The quantity of parting agent is controlled by the injection time (see chapter Program sequence from page 52).

  • Page 51: 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 commission- Screwing the Cleaning Cleaning device screwed to the base (see chapter Device to the Solid Surface on page 30). Clamping device gas nozzle mounted (see chapter Mounting the gas nozzle clamping device...

  • Page 52: Program Sequence

    Program sequence Safety CAUTION! Danger due to improper installation and commissioning. This can result in damage to property. ▶ The cleaning device’s functions must be manually checked before starting automatic operation. ▶ Only start automatic mode once the cleaning device has been installed and commissioned properly.

  • Page 53: Cleaning Program Sequence For Twin Welding Torches

    Cleaning pro- Start gram sequence for twin welding torches Move to position A Position: 50 mm over wire cutter Speed: High speed mode Gas nozzle free? External signal: Clamp gas nozzle / Cut Wire cutter open? wire High Wait 0.5 seconds Move to position B Position: Move into wire cutter Speed: 10 cm/s (236.22 ipm)
  • Page 54 Wait 0.7 seconds Move to position A Position: 25 mm over wire cutter Speed: 10 cm/s (236.22 ipm) Reset External signal: Clamp gas nozzle / Cut wire Gas nozzle free? External signal: Clamp gas nozzle / Cut Wire cutter open? wire High Wait 0.5 seconds...
  • Page 55 Retract wire Wait 2–3 seconds Lower cleaning motor? External signal: Motor on / Lifting device High Move to position D Wait 0.5 seconds (cleaning position KR1) Position: Move into clamping device Speed: 10 cm/s (236.22 ipm) Reset External signal: Motor on / Lifting device High Wait 0.3 seconds Lower cleaning motor?
  • Page 56 Gas nozzle clamped? External signal: Clamp gas nozzle High Gas nozzle clamped? External signal: Compressed air gas purging with welding torch Stop Error External signal: Cleaning motor on / Lifting device up Wait 2–3 seconds Stop Upper cleaning motor? Error High Reset External signal: Cleaning motor on /...
  • Page 57 Stop Lower cleaning motor? Error High Reset External signal: Clamp gas nozzle / Wire cutter closed Gas nozzle free? External signal: Clamp gas nozzle / Wire cutter open? Wire cutter closed High Wait 0.3 seconds Move to position E (Cleaning position KR2) Speed: 10 cm/s (236.22 ipm) Reset External signal: Clamp gas nozzle /...
  • Page 58 Gas nozzle clamped? External signal: Clamp gas nozzle High Gas nozzle clamped? External signal: Compressed air gas purging with welding torch Stop Error External signal: Cleaning motor on / Lifting device up Wait 2–3 seconds Stop Upper cleaning motor? Error High Reset External signal: Cleaning motor on /...
  • Page 59 Stop Lower cleaning motor? Error High Reset External signal: Clamp gas nozzle / Wire cutter closed Gas nozzle free? Stop Wire cutter open? Error High Move to position F Position: 25 mm above cleaning position Speed: 10 cm/s (236.22 ipm) Extend wire...
  • Page 60 Move to position B Position: Move into wire cutter Speed: 10 cm/s (236.22 ipm) External signal: Clamp gas nozzle / Cut wire Wait 0.5 seconds Move to position A Position: 25 mm over wire cutter Speed: High speed mode Reset External signal: Clamp gas nozzle / Cut wire Cleaning...

  • Page 61: Program Sequence Of Cleaning For Single Welding Torches

    Program se- If the diameter of the gas nozzle is too small, the gas nozzle may not be clamped quence of clean- properly in the clamping device. No signal is output that the clamping device is ing for single closed. welding torches Start Move to position A...
  • Page 62 Wait 0.7 seconds Move to position A Position: 50 mm over wire cutter Speed: 10 cm/s (236.22 ipm) Reset External signal: Clamp gas nozzle / Cut wire Gas nozzle free? External signal: Clamp gas nozzle / Cut Wire cutter open? wire High Wait 0.5 seconds...
  • Page 63 Retract wire Wait 2–3 seconds Lower cleaning motor? External signal: Motor on / Lifting device High Wait 0.5 seconds Move to position D Position: Move into clamping device Speed: 10 cm/s (236.22 ipm) Reset External signal: Motor on / Lifting device High Wait 0.3 seconds Lower cleaning motor?
  • Page 64 Gas nozzle clamped? External signal: Clamp gas nozzle High Gas nozzle clamped? External signal: Compressed air gas purging with welding torch Stop Error External signal: Cleaning motor on / Lifting device up Wait 2–3 seconds Stop Upper cleaning motor? Error High Reset External signal: Cleaning motor on /...
  • Page 65 Stop Lower cleaning motor? Error High Reset External signal: Clamp gas nozzle / Wire cutter closed Gas nozzle free? Stop Wire cutter open? Error High Move to position F Position: 25 mm above the cleaning position Speed: 10 cm/s (236.22 ipm) Extend wire...
  • Page 66 Move to position B Position: Move into wire cutter Speed: 10 cm/s (236.22 ipm) External signal: Clamp gas nozzle / Cut wire Wait 0.5 seconds Move to position A Position: 50 mm over wire cutter Speed: High speed mode Reset External signal: Clamp gas nozzle / Cut wire Cleaning...

  • Page 67: Cleaning Signal Sequence

    Cleaning signal sequence Signal input Cleaning motor on / lifting device up signal: = Pin 1 at the Harting Han12P connecting plug (X1) Contact tip 1 Contact tip 2 Spray in parting agent signal: = Pin 2 on the Harting Han12P connecting plug (X1) Contact tip 1 Contact tip 2 Clamp gas nozzle / cut wire signal:...

  • Page 68: Signal Output

    Actuator/sensor signal (Pin 8): = Pin 8 on the Harting Han12P connecting plug (X1) Signal output Upper cleaning motor signal: = Pin 5 at the Harting Han12P connecting plug (X1) Lower cleaning motor signal: = Pin 6 at the Harting Han12P connecting plug (X1) Gas nozzle free signal: = Pin 11 on the Harting Han12P connecting plug (X1) Gas nozzle clamped / wire cutter closed signal:...

  • Page 69: Service, Maintenance And Disposal

    Service, maintenance and disposal...

  • Page 71: Safety

    Safety Safety WARNING! Danger from incorrect operation and work that is not carried out properly. This can result in severe personal injury and damage to property. ▶ All the work and functions described in this document must only be carried out by trained and qualified personnel.

  • Page 72: Ensuring That The Cleaning Device Is Depressurized

    Ensuring that To ensure that the cleaning device is depressurized, try to briefly activate the the cleaning cleaning device without the compressed air supply. To do this, proceed as follows: device is depres- Take protective measures: surized The cleaning cutter, lifting device, gas nozzle clamping device, wire cut- ter, and parting-agent injection nozzle could be activated.

  • Page 73: Service, Maintenance And Disposal

    Service, maintenance and disposal Before every Check the fill level in the parting agent container and top up if necessary. start-up Check for wear of the cleaning cutter and replace the cleaning cutter if ne- cessary. Drain the cleaning device’s collecting container. In general, you should visually inspect the cleaning device and ensure that any damage is repaired immediately (before commissioning).
  • Page 74 serve this may lead to potential health/environmental impacts. Packaging materials Separate collection. Check your municipality’s regulations. Reduce the volume of the box.

  • Page 75: Troubleshooting

    Troubleshooting...

  • Page 77: Safety

    Safety Safety WARNING! Danger from incorrect operation and work that is not carried out properly. This can result in severe personal injury and damage to property. ▶ All the work and functions described in this document must only be carried out by trained and qualified personnel.

  • Page 78: Ensuring That The Cleaning Device Is Depressurized

    Ensuring that To ensure that the cleaning device is depressurized, try to briefly activate the the cleaning cleaning device without the compressed air supply. To do this, proceed as follows: device is depres- Take protective measures: surized The cleaning cutter, lifting device, gas nozzle clamping device, wire cut- ter, and parting-agent injection nozzle could be activated.

  • Page 79: Troubleshooting

    Troubleshooting Errors in the Parting agent is not injected Program Se- Parting agent container is full quence Cause: Injection quantity too low. Remedy: Extend the injection time. Cause: The intake filter of the parting agent hose in the parting agent con- tainer is contaminated.
  • Page 80 Lifting device does not move up or down Cause: Compressed air supply missing. Remedy: Set up the compressed air supply. Cause: No signal from robot. Remedy: Check robot program. Cause: Solenoid valve has mechanical fault. Remedy: Contact service team (have solenoid valve replaced). Cause: Throttle valve cannot be adjusted or is faulty.

  • Page 81: Technical Data

    Technical data...

  • Page 83: Technical Data

    Technical data Robacta Reamer Supply voltage + 24 V DC Single/Twin Nominal output 2.4 W Nominal pressure 6 bar 86.99 psi Air consumption 420 l/min 443.81 qt./min Thread identification for compressed air G ¼” connection Standard I/O (X1) Input: + 24 V DC/max. 100 mA Output: + 24 V DC/max.

  • Page 85: Appendix

    Appendix...

  • Page 87: Declaration Of Conformity

    ÿ 23 4 5 3 6 7 ÿ 83 9 ÿÿ  9  4 ÿ  3 4  ÿÿ 23 4 5 3 6 7 ÿ  4 Declaration of conformity  5  6 7 4 3 4  4    7 4  3 ÿ...
  • Page 88 ÿ 23 4 5 3 6 7 ÿ 83 9 ÿÿ  9  4 ÿ  3 4  ÿÿ 23 4 5 3 6 7 ÿ  4  4   ÿ  7 3 4  7   9 ÿ  !  3 ÿ...

  • Page 89: Ukca Conformity Assesment

    UKCA Conformity Assesment...

  • Page 91: Ukca Conformity Assesment

    UKCA Conformity Assesment...

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