How it Works
Fronius
Loading...
R
Loading...
Loading...
Robacta Reamer

Fronius Robacta Reamer Operating Instruction [EN]

Download
Operating Instructions
Robacta Reamer
Operating Instructions
EN
42,0426,0143,EN 016-03082022
Contents
Safety rules 5
General information 11
General 13
Principle 13 Device concept 13 Application areas 13
Scope of supply and options 14
Robacta Reamer scope of supply 14 Robacta Reamer options 14
Warning notices on the device 15
Transport 17
Transport devices 17 Transport notices on the packaging 17
EN
Controls, connections and mechanical components 19
Safety 21
Safety 21
Robacta Reamer control elements, connections and mechanical components 22
Control elements, connections and mechanical components 22
Standard I/O connecting plug (X1) pin assignment for robot control 24
General 24 Standard I/O (X1) connecting plug pin assignment 24
Installation and commissioning 25
Safety 27
Safety 27 Ensuring that the cleaning device is depressurised 28
Before commissioning 29
Proper use 29 Operators, maintenance personnel 29 Setup regulations 29 Compressed air supply specifications 29 Measures for the safe operation of the device with untrained personnel 30
Screwing the cleaning device to the underlying surface 31
Screwing the cleaning device and installation stand to the underlying surface 31 Screwing the cleaning device to the underlying surface 32
Torch cleaning position 34
Welding torch cleaning position 34
3
Adjust gas nozzle clamping device 35
Adjust gas nozzle clamping device 35
Fitting the cleaning cutter 36
Fitting the cleaning cutter 36
Adjusting the lifting device 37
Adjust lifting device 37
Starting up the parting agent nebuliser 38
Starting up the parting agent nebuliser 38 Correct setting of the parting agent spray nozzles 39
Installing the mechanically controlled wire cutter (optional) 40
Installing the mechanically controlled wire cutter 40
Installing the electrically controlled wire cutter (optional) 43
Installing the electrically controlled wire cutter 43
Wire cutter function 45
Installing the compressed air supply 46
Establishing the compressed air supply for the cleaning device, function of the com­pressed air relief valve
Starting up the cleaning device 47
Prerequisites for start-up 47 Start-up 47
Program sequence and signal waveform 48
Cleaning programme sequence 48 Signal waveform 50
46
Care, maintenance and disposal 51
Safety 53
Care, maintenance and disposal 55
General 55 Before each start-up 55 Daily 55 Weekly 55 Every 6 months 55 As necessary 55 Disposal 55
Troubleshooting 57
Safety 59
Safety 59 Ensuring that the cleaning device is depressurised 60
Troubleshooting 61
Errors in program sequence 61
Technical data 63
Technical data 65
Appendix 67
Circuit diagram Robacta Reamer 69 Robacta Reamer pneumatic diagram 70 Declaration of conformity 71
4
Safety rules
EN
Explanation of safety notices
DANGER!
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.
If not avoided, minor injury and/or damage to property may result.
▶
NOTE!
Indicates a risk of flawed results and possible damage to the equipment.
General The device is manufactured using state-of-the-art technology and according to
recognised safety standards. If used incorrectly or misused, however, it can cause:
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.
-
All persons involved in commissioning, operating, maintaining and servicing the device must:
be suitably qualified,
-
have sufficient knowledge of automated welding, and
-
read and carefully follow these operating instructions as well as the operat-
-
ing instructions for all system components.
The operating instructions must always be at hand wherever the device is being used. In addition to the operating instructions, attention must also be paid to any generally applicable and local regulations regarding accident prevention and en­vironmental protection.
All safety and danger notices on the device
must be in a legible state,
-
must not be damaged,
-
must not be removed,
-
must not be covered, pasted or painted over.
-
For the location of the safety and danger notices on the device, refer to the sec­tion headed "General" in the operating instructions for the device. Before commissioning the device, rectify any faults that could compromise safety.
This is for your personal safety!
5
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.
Proper use includes:
carefully reading these operating instructions
-
following all the instructions and safety rules in these operating instructions
-
performing all stipulated inspection and maintenance work
-
The device is designed for use in industry and the workshop. The manufacturer accepts no responsibility for any damage caused through use in a domestic set­ting.
The manufacturer likewise accepts no liability for inadequate or incorrect results.
Environmental conditions
Obligations of the operator
Operation or storage of the device outside the stipulated area will be deemed as not in accordance with the intended purpose. The manufacturer shall not be held liable for any damage arising from such usage.
Ambient temperature range:
during operation: 0 °C to + 40 °C (32 °F to 104 °F)
-
during transport and storage: -25 °C to +55 °C (-13 °F to 131 °F)
-
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)
The operator must only allow persons to work with the device who:
are familiar with the fundamental instructions regarding safety at work and
-
accident prevention and have been instructed in how to use the device have read and understood these operating instructions, especially the sec-
-
tion "safety rules", and have confirmed as much with their signatures are trained to produce the required results.
-
Checks must be carried out at regular intervals to ensure that operators are working in a safety-conscious manner.
Obligations of personnel
Specific hazards
6
Before using the device, all persons instructed to do so undertake:
to observe the basic instructions regarding safety at work and accident pre-
-
vention to read these operating instructions, especially the "Safety rules" section and
-
sign to confirm that they have understood them and will follow them.
Before leaving the workplace, ensure that people or property cannot come to any harm in your absence.
Stay out of the working area of the robot.
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. as the result of a
-
control fault.
If untrained operators have access to the device, its compressed air supply must be disconnected for the duration of work in accordance with "Performance Level d" of the ISO 13849-1 standard.
In addition to these operating instructions, the safety rules issued by the robot manufacturer must also be observed.
Keep your body, especially your hands, face, hair, clothing and all tools away from moving parts, such as:
rotating cleaning cutter
-
lifting device moving up/down
-
extending/retracting gas nozzle clamping device
-
wire cutter
-
Do not touch cleaning cutters immediately after use - risk of burns. Observe the special safety rules in the operating instructions for handling cleaning cutters.
EN
Protecting your­self and others
Protect hands, face and eyes against flying parts (shavings, etc.) and compressed air/parting agent mixture escaping from the parting-agent injection nozzles.
Covers may only be opened/removed for the duration of any maintenance, in­stallation or repair work.
During operation
Ensure that all covers are closed and fitted properly
-
Keep all covers closed
-
Anyone working with the device exposes themselves to numerous risks. In addi­tion to these Operating Instructions, the safety rules of the manufacturer of the entire welding system must also be observed.
Keep all persons, especially children, out of the working area while any devices are in operation or welding is in progress. If, however, there are people in the vi­cinity:
Make them aware of all the dangers and health risks (crushing from mechan-
-
ically-powered parts, injury from cleaning cutter, flying shavings and similar matter, escaping compressed air/parting agent mixture, flying sparks, dazzling by arc, inhaling of harmful welding fumes, noise, possible danger from mains or welding current, etc.) Provide suitable protective equipment
-
Alternatively, erect suitable safety screens/curtains
-
EMC Device Classifications
Devices in emission class A:
Are only designed for use in industrial settings
-
Can cause line-bound and radiated interference in other areas
-
7
Devices in emission class B:
Satisfy the emissions criteria for residential and industrial areas. This is also
-
true for residential areas in which the energy is supplied from the public low­voltage mains.
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). If this is the case, then the operator is obliged to take appropriate action to recti­fy the situation.
Check for possible problems, and check and evaluate neighbouring devices' res­istance to interference according to national and international requirements:
Safety devices
-
Power, signal and data transfer lines
-
IT and telecommunications devices
-
Measuring and calibrating devices
-
Supporting measures for avoidance of EMC problems:
Mains supply
1. If electromagnetic interference arises despite correct mains connection,
-
additional measures are necessary (e.g. use a suitable line filter).
Control lines
2. must be kept as short as possible
-
must run close together (to avoid EMF problems)
-
must be kept well apart from other leads
-
Equipotential bonding
3.
Shield, if necessary
4. Shield off other nearby devices
-
Shield off entire welding installation
-
EMF measures Electromagnetic fields may pose as yet unknown risks to health:
Effects on the health of persons in the vicinity, e.g. those with pacemakers
-
and hearing aids Individuals with pacemakers must seek advice from their doctor before ap-
-
proaching the device or any welding that is in progress For safety reasons, maintain as large a distance as possible between the
-
welding power-leads and the head/torso of the welder Do not carry welding power-leads and hosepacks over the shoulders or wind
-
them around any part of the body
Safety measures at the installa­tion location and during transport
A device toppling over could easily kill someone. Place the device horizontally on a level, firm and solid surface and anchor it securely to prevent it toppling over.
Special regulations apply in rooms at risk of fire or explosion
Observe relevant national and international regulations.
-
Use internal directives and checks to ensure that the workplace environment is always clean and clearly laid out.
When transporting the device, observe the relevant national and local guidelines and accident prevention regulations. This applies especially to guidelines regard­ing the risks arising during transport.
8
After transporting the device, it must be visually inspected for damage before commissioning. Any damage must be repaired by trained service technicians be­fore commissioning the device.
EN
Safety measures in normal opera­tion
Only operate the device if all safety devices are fully functional. If the safety devices are not fully functional, there is a risk of
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.
-
Any safety devices that are not functioning properly must be repaired before switching on the device.
Never bypass or disable safety devices.
Before switching on the device, ensure that no one is likely to be endangered.
Check the device at least once a week for obvious damage and proper function­ing of safety devices.
Only use suitable original parting agent from the manufacturer.
-
Observe the information on the parting agent safety data sheet when hand-
-
ling parting agent. The parting agent safety data sheet may be obtained from your service centre or downloaded from the manufacturer's website. Do not mix the manufacturer's parting agent with other parting agents.
-
If damage results from using a different parting agent, the manufacturer ac-
-
cepts no liability. In addition, no warranty claims will be entertained. Used parting agent must be disposed of properly in accordance with the rel-
-
evant national and international regulations.
Commissioning, maintenance and repair
Safety inspec­tion
It is impossible to guarantee that bought-in parts are designed and manufac­tured to meet the demands made of them, or that they satisfy safety require­ments.
Use only original spare and wearing parts (also applies to standard parts).
-
Do not carry out any modifications, alterations, etc. to the device without the
-
manufacturer's consent. Components that are not in perfect condition must be replaced immediately.
-
When ordering, please give the exact designation and part number as shown
-
in the spare parts list, as well as the serial number of your device.
The housing screws provide the ground conductor connection for earthing the housing parts. Only use original housing screws in the correct number and tightened to the spe­cified torque.
The manufacturer recommends that a safety inspection of the device is per­formed at least once every 12 months.
A safety inspection should be carried out by a qualified electrician
after any changes are made
-
after any additional parts are installed, or after any conversions
-
after repair, care and maintenance has been carried out
-
at least every twelve months.
-
For safety inspections, follow the appropriate national and international stand­ards and directives.
9
Further details on safety inspection and calibration can be obtained from your service centre. They will provide you on request with any documents you may re­quire.
Disposal Waste electrical and electronic equipment must be collected separately and re-
cycled in an environmentally-friendly way, in accordance with the European Dir­ective and national legislation. Used equipment must be returned to the distrib­utor or disposed of via an approved local collection and disposal facility. Correct disposal of used equipment promotes the sustainable recycling of material re­sources. Failing to dispose of used equipment correctly can lead to adverse health and/or environmental impacts.
Packaging materials
Separate collection according to material. Check your local authority regulations. Crush containers to reduce size.
Safety symbols Devices with the CE mark satisfy the essential requirements of the applicable
directives (e.g. low-voltage and electromagnetic compatibility directives, ma­chinery directive).
Devices with the CSA test mark satisfy the requirements of the relevant stand­ards in Canada and the USA.
Copyright Copyright of these operating instructions remains with the manufacturer.
The text and illustrations are all technically correct at the time of printing. We reserve 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 instructions, we will be most grateful for your comments.
10
General information
11
12
General
Principle The Robacta Reamer is a welding torch
cleaning device that is used for the automatic cleaning of MIG/MAG weld­ing torches. This device can be relied upon to clean the interior and front of gas nozzles on torches of many differ­ent shapes, thereby significantly ex­tending the service life of these wear­ing parts. With the Robacta Reamer, applying parting agent evenly prevents dirt from building up again.
Device concept A lifting cylinder for the lifting device, as well as all pneumatic components, are
located in the robust steel housing. On the outside are the cleaning motor and the clamping device for the gas nozzle on the welding torch. The parting agent container is attached to the outside of the steel housing.
EN
Application areas
The Robacta Reamer can optionally be fitted with a wire cutter. During the clean­ing process, the wire electrode is shortened to a defined length for the next weld­ing process.
A stable fitting base is available for professional assembly of the device.
The Robacta Reamer is intended exclusively for use in robot and other automated applications and can be used for processing steel and aluminium materials. The Robacta Reamer was designed for use in the automobile and component supply industry, equipment construction, chemical plant construction and ma­chinery and rail vehicle manufacturing.
13
Scope of supply and options
(1)
(2)
(3)
(4) (5)
Robacta Reamer scope of supply
NOTE!
The "Robacta Reamer" parting agent (item number 42,0411,8042) and the cleaning cutter are not part of the scope of supply.
(1) Robacta Reamer cleaning
device (2) Spatter tray retainer (3) Spatter tray (4) Tightening key for cleaning mo-
tor (5) Compressed air relief valve
not shown:
(6) Standard I/O connecting plug (X1) without cable (7) Operating instructions (8) Filling funnel for parting agent (9) Fixings for assembling the cleaning device:
4 screws
-
4 washers
-
4 lock washers
-
4 nuts
-
Robacta Reamer options
Fitting base
-
Wire cutter
-
14
Warning notices on the device
Type
Art.No.
Chargen No.
U1
I1
Wels - Austria
p
max
24 V
0.25 A
6 bar (87PSI)
EN
Warning notices on the cleaning device
NOTE!
The cleaning device is fitted with warning notices and a rating plate.
The warning notices and rating plate must not be removed or painted over.
Warning notices on the cleaning device
WARNING! Risk of serious injury from:
mechanically-powered parts
-
compressed air/parting agent mixture escaping from the part-
-
ing agent spray nozzles flying parts (shavings, etc.)
-
Keep device free from current and pressure during maintenance and servicing.
Do not use the functions described here until you have thoroughly read and understood the following documents:
these operating instructions
-
all the operating instructions for the system components, es-
-
pecially the safety rules
15
For indoor use only
Wear eye protection
Notice warning of automatic start-up of the device
16
Transport
EN
Transport devices
Transport no­tices on the packaging
The device is to be transported by the following 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.
Secure the device to prevent it from falling over when transporting on a fork-
▶
lift truck or lift truck. Avoid sudden changes in direction, braking or acceleration.
▶
CAUTION!
Danger due to improper transport.
This can result in damage to property.
Observe the transport notices on the device packaging.
▶
17
18
Controls, connections and mechan-
ical components
19
20
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:
these operating instructions
▶
all the operating instructions for the system components, especially the
▶
safety rules
EN
21
Robacta Reamer control elements, connections
(1)
(3) (4)
(2)
(9)
(5)
(6)
(7)
(8)
and mechanical components
Control ele­ments, connec­tions and mech­anical compon­ents
Side view
(1) Parting agent adjuster
for setting the spray amount on the parting agent spray nozzles
(2) "Cleaning" screw
for manually checking the following functions:
Cleaning motor ON/OFF
-
Supply of compressed air and parting agent to parting agent spray
-
nozzles (compressed air/parting agent mixture is sprayed out of the parting agent spray nozzles) Lifting device UP/DOWN
-
Gas nozzle clamping device extends/retracts
-
(3) Compressed air connection
for a dry compressed air supply at 6 bar (86.99 psi) Thread identification compressed air connection: G ¼“
(4) 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.
Secure supply against overcurrent with a 500 mA slow-blow fuse.
Front view
22
(5) Gas nozzle clamping device
Holds the gas nozzle in place during cleaning
(6) Protective covering
(7) Cleaning motor
Drives the cleaning cutter
Loading...
+ 50 hidden pages
Buy Points How it Works FAQ Contact Us Questions and Suggestions Privacy Policy Cookie Policy Terms of Use