Fronius Robacta Reamer Alu Edition, Robacta Reamer Alu 3000upm, Robacta Reamer Twin User Manual

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Fronius prints on elemental chlorine free paper (ECF) sourced from certified sustainable forests (FSC).

/ Perfect Charging / Perfect Welding / Solar Energy

Robacta Reamer Alu Edition Robacta Reamer Alu 3000upm Robacta Reamer Twin

Operating Instructions Spare parts list

Welding torch cleaning

42,0426,0146,EN 015-04042019

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Dear reader,

Introduction Thank you for the trust you have placed in our company and congratulations on buying this

high-quality Fronius product. These instructions will help you familiarise yourself with the product. Reading the instructions carefully will enable you to learn about the many different features it has to offer. This will allow you to make full use of its advantages.

Please also note the safety rules to ensure greater safety when using the product. Careful handling of the product will repay you with years of safe and reliable operation. These are essential prerequisites for excellent results.

Explanation of safety symbols

DANGER!

Indicates immediate and real danger.

If it is not avoided, death or serious injury will result.

WARNING!

Indicates a potentially dangerous situation.

Death or serious injury may result if appropriate precautions are not taken.

CAUTION!

Indicates a situation where damage or injury could occur.

If it is not avoided, minor injury and/or damage to property may result.

NOTE!

Indicates a risk of flawed results and possible damage to the equipment.

IMPORTANT!

Indicates tips for correct operation and other particularly useful information.

It does not indicate a potentially damaging or dangerous situation.

If you see any of the symbols depicted in the "Safety rules" chapter, special care is required.

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Contents

Safety rules ................................................................................................................................................ 9

General ................................................................................................................................................. 9

Proper use ............................................................................................................................................ 9

Environmental conditions...................................................................................................................... 9

Obligations of the operator.................................................................................................................... 10

Obligations of personnel ....................................................................................................................... 10

Specific hazards.................................................................................................................................... 10

Protecting yourself and others .............................................................................................................. 11

EMC Device Classifications .................................................................................................................. 11

EMC measures ..................................................................................................................................... 11

EMF measures...................................................................................................................................... 12

Safety measures at the installation location and during transport ........................................................ 12

Safety measures in normal operation ................................................................................................... 12

Commissioning, maintenance and repair.............................................................................................. 13

Safety inspection................................................................................................................................... 13

Disposal ................................................................................................................................................ 13

Safety symbols...................................................................................................................................... 13

Copyright............................................................................................................................................... 13

General 15

General ...................................................................................................................................................... 17

Principle ................................................................................................................................................ 17

Device concept ..................................................................................................................................... 17

Application areas .................................................................................................................................. 17

Illustration of the various device types .................................................................................................. 17

Scope of supply and options...................................................................................................................... 18

General ................................................................................................................................................. 18

Robacta Reamer Alu Edition scope of supply....................................................................................... 18

Robacta Reamer Alu Edition options .................................................................................................... 18

Robacta Reamer Alu 3000upm scope of supply................................................................................... 19

Robacta Reamer Alu 3000upm options ................................................................................................ 19

Robacta Reamer Twin scope of supply ................................................................................................ 19

Robacta Reamer Twin options.............................................................................................................. 20

Warning notices on the device................................................................................................................... 21

Warning notices on the cleaning device ............................................................................................... 21

Transport.................................................................................................................................................... 23

Vehicles ................................................................................................................................................ 23

Transport notices on the packaging...................................................................................................... 23

Controls, connections and mechanical components 25

Safety......................................................................................................................................................... 27

Safety.................................................................................................................................................... 27

Control elements, connections and mechanical components of the Robacta Reamer Alu Edition and Ro-

bacta Reamer Alu 3000upm ......................................................................................................................

Control elements, connections and mechanical components............................................................... 28

Robacta Reamer Twin control elements, connections and mechanical components................................ 29

Control elements, connections and mechanical components .............................................................. 29

Harting Han6P connecting plug pin assignment (X1) for robot control ...................................................... 31

General ................................................................................................................................................. 31

Harting Han6P connecting plug pin assignment (X1) ........................................................................... 31

Installation and commissioning 33

Safety......................................................................................................................................................... 35

Safety.................................................................................................................................................... 35

Ensuring that the cleaning device is depressurised.............................................................................. 36

Before commissioning................................................................................................................................ 37

Proper use ............................................................................................................................................ 37

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Operators, maintenance personnel....................................................................................................... 37

Setup regulations .................................................................................................................................. 37

Compressed air supply specifications................................................................................................... 37

Measures for the safe operation of the device with untrained personnel.............................................. 37

Screwing the cleaning device to the underlying surface ............................................................................ 38

Screwing the cleaning device and installation stand to the underlying surface .................................... 38

Screwing the cleaning device to the underlying surface ....................................................................... 38

Torch cleaning position .............................................................................................................................. 40

Welding torch cleaning position - Robacta Reamer Alu Edition............................................................ 40

Welding torch cleaning position - Robacta Reamer Alu 3000upm........................................................ 40

Welding torch cleaning position - Robacta Reamer Twin ..................................................................... 40

Adjusting the gas nozzle clamping device on the Robacta Reamer Alu Edition and Robacta Reamer Alu

3000upm ....................................................................................................................................................

Adjusting the gas nozzle clamping device ............................................................................................ 41

Fitting the cleaning brush on the Robacta Reamer Alu Edition ................................................................. 42

Fitting the cleaning brush...................................................................................................................... 42

Fitting the cleaning cutter on the Robacta Reamer Alu 3000upm ............................................................. 43

Fitting the cleaning cutter...................................................................................................................... 43

Fitting the cleaning cutter on the Robacta Reamer Twin ........................................................................... 44

Fitting the cleaning cutter...................................................................................................................... 44

Adjusting the Robacta Reamer Alu Edition lifting device ........................................................................... 45

Adjusting the lifting device .................................................................................................................... 45

Adjusting the Robacta Reamer Alu 3000upm lifting device ....................................................................... 46

Adjusting the lifting device .................................................................................................................... 46

Adjusting the Robacta Reamer Twin lifting device..................................................................................... 47

Adjusting the lifting device .................................................................................................................... 47

Starting up the Robacta Reamer Twin parting agent nebuliser ................................................................. 48

Starting up the parting agent nebuliser ................................................................................................. 48

Correct adjustment of the parting agent spray nozzles on the Robacta Reamer Twin......................... 49

Installing mechanically-controlled wire cutter on the Robacta Reamer Alu Edition and Robacta Reamer

Alu 3000upm (optional)..............................................................................................................................

Installing the mechanically-controlled wire cutter.................................................................................. 50

Installing the electrically-controlled wire cutter on the Robacta Reamer Alu Edition and Robacta Reamer

Alu 3000upm (optional)..............................................................................................................................

Installing the electrically-controlled wire cutter...................................................................................... 54

Wire cutter function .................................................................................................................................... 56

Maximum wire diameter........................................................................................................................ 56

How the mechanically-controlled wire cutter works ..............................................................................56

How the electrically-controlled wire cutter works .................................................................................. 56

Installing the compressed air supply.......................................................................................................... 57

Establishing the compressed air supply for the cleaning device, function of the compressed air relief

valve......................................................................................................................................................

Starting up the cleaning device.................................................................................................................. 58

Prerequisites for start-up....................................................................................................................... 58

Start-up ................................................................................................................................................. 58

Programme sequence and signal waveform on the Robacta Reamer Alu Edition and Robacta Reamer

Alu 3000upm..............................................................................................................................................

Cleaning program sequence................................................................................................................. 59

Signal waveform ................................................................................................................................... 62

Robacta Reamer Twin programme sequence and signal waveform ......................................................... 63

Cleaning program sequence................................................................................................................. 63

Signal waveform ................................................................................................................................... 67

Care, maintenance and disposal 69

Safety......................................................................................................................................................... 71

Safety.................................................................................................................................................... 71

Ensuring that the cleaning device is depressurised.............................................................................. 72

Care, maintenance and disposal ............................................................................................................... 73

General ................................................................................................................................................. 73

Before each start-up ............................................................................................................................. 73

Daily ...................................................................................................................................................... 73

Weekly .................................................................................................................................................. 73

Every 6 months ..................................................................................................................................... 73

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If necessary........................................................................................................................................... 73

Disposal ................................................................................................................................................ 73

Troubleshooting 75

Safety......................................................................................................................................................... 77

Safety.................................................................................................................................................... 77

Ensuring that the cleaning device is depressurised.............................................................................. 78

Troubleshooting ......................................................................................................................................... 79

Errors in program sequence ................................................................................................................. 79

Technical data 81

Technical data............................................................................................................................................ 83

Robacta Reamer Alu Edition and Robacta Reamer Alu 3000upm ....................................................... 83

Robacta Reamer Twin .......................................................................................................................... 83

Appendix 85

Spare parts list: Robacta Reamer Alu Edition............................................................................................ 86

Spare parts list: Robacta Reamer Alu 3000upm........................................................................................ 87

Spare parts list: Robacta Reamer Twin ..................................................................................................... 88

Spare parts list: Robacta Reamer Twin ..................................................................................................... 89

Circuit diagrams: Robacta Reamer Alu Edition / Robacta Reamer Alu 3000upm ..................................... 90

Circuit diagrams: Robacta Reamer Twin ................................................................................................... 91

Robacta Reamer Twin pneumatic diagram................................................................................................ 92

Declarations of Conformity......................................................................................................................... 93

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Safety rules

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 operating 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!

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

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)

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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)

Obligations of the operator

Obligations of personnel

Specific hazards

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 section "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.

Before using the device, all persons instructed to do so undertake:

- to observe the basic instructions regarding safety at work and accident prevention

- 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 / rotating cleaning brushes

- lifting device moving up/down

- extending/retracting gas nozzle clamping device

- wire cutter

Do not touch cleaning cutter / cleaning brush immediately after use - risk of burns. Observe the special safety rules in the operating instructions for handling the cleaning cutter / cleaning brush.

Protect hands, face and eyes against flying parts (shavings, etc.) and compressed air/parting agent mixture escaping from the parting-agent injection nozzles.

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Covers may only be opened/removed for the duration of any maintenance, installation or repair work.

Protecting yourself and others

EMC Device Classifications

During operation

- Ensure that all covers are closed and fitted properly

- Keep all covers closed

When welding, you expose yourself to numerous dangers. 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 mechanicallypowered parts, injury from cleaning cutter / cleaning brush, 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 or

- erect suitable safety screens/curtains.

Devices in emission class A:

- Are only designed for use in industrial settings

- Can cause line-bound and radiated interference in other areas

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 low-voltage 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 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). 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:

1. Mains supply

- If electromagnetic interference arises despite correct mains connection, addition-

al measures are necessary (e.g. use a suitable line filter).

2. Control lines

- must be kept as short as possible

- must run close together (to avoid EMF problems)

- must be kept well apart from other leads

3. Equipotential bonding

4. Shield, if necessary

- Shield off other nearby devices

- Shield off entire welding installation

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EMF measures Electromagnetic fields may pose as yet unknown risks to health:

- effects on the health of others in the vicinity, e.g. wearers of pacemakers and hearing aids

- wearers of pacemakers must seek advice from their doctor before approaching the device or any welding that is in progress

- for safety reasons, keep distances between the welding cables and the welder's head/ torso as large as possible

- do not carry welding cables and hosepacks over the shoulders or wind them around any part of the body

Safety measures at the installation location and during transport

Safety measures in normal operation

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.

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.

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 handling 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 accepts no liability. In addition, no warranty claims will be entertained.

- Used parting agent must be disposed of properly in accordance with the relevant national and international regulations.

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Commissioning, maintenance and repair

Safety inspection The manufacturer recommends that a safety inspection of the device is performed at least

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.

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.

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 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. Any device that you no longer require must either be returned to your dealer or given to one of the approved collection and recycling facilities in your area. Ignoring this European Directive may have potentially adverse affects on the environment and your health!

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.

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.

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General

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General

Principle Robacta Reamer devices are welding torch cleaning devices that are used for automatic

cleaning of MIG/MAG welding torches. These devices 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 Twin, an even application of parting agent prevents re-accumulation of dirt.

Device concept A lifting cylinder for the lifting device, as well as all pneumatic components, form part of the

robust steel housing. On the outside are the cleaning motor and the clamping device for the gas nozzle on the welding torch.

The Robacta Reamer Twin is fitted with a wire cutter and parting agent nebuliser as standard. During the cleaning process, both wire electrodes are shortened to a defined length for the next welding process.

The wire cutter is an optional extra with the Robacta Reamer Alu Edition and Robacta Reamer Alu 3000upm.

For professional installation, a stable fitting base is available for all devices.

Application areas Devices from the Robacta Reamer series are intended exclusively for use in robot and oth-

er automated applications. The devices were designed for use in the automobile and component supply industry, equipment construction, chemical plant construction and machine and rail vehicle manufacturing.

The Robacta Reamer Twin can be used for processing steel and aluminium materials.

The Robacta Reamer Alu Edition and the Robacta Reamer Alu 3000upm are intended exclusively for aluminium applications.

Illustration of the various device types

Robacta Reamer Alu Edition, Robacta Reamer Alu 3000upm, Robacta Reamer Twin

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Scope of supply and options

General The cleaning devices can be used in conjunction with various options. This makes it pos-

sible to optimise various procedures in the welding process, as necessitated by the particular field of application.

Robacta Reamer Alu Edition scope of supply

(1)

(2)

(3) (4) (5)

NOTE!

The cleaning brush and adapter for the cleaning brush are not included in the scope of supply.

(1) Robacta Reamer Alu Edition clea-

ning device (2) Spatter tray retainer (3) Spatter tray (4) Tightening key for cleaning motor (5) Compressed air relief valve

Robacta Reamer Alu Edition options

not shown:

(6) Harting Han6P connecting plug (X1) without cable (7) Operating instructions (8) Fixings for assembling the cleaning device:

- 4 screws

- 4 washers

- 4 lock washers

- 4 nuts

- Fitting base

- Wire cutter

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Robacta Reamer Alu 3000upm scope of supply

NOTE!

(1)

The cleaning cutter and adapter for the cleaning cutter are not included in the scope of supply.

(1) Robacta Reamer Alu 3000upm cle-

aning device

(2)

(2) Spatter tray retainer (3) Spatter tray

(3) (4) (5)

(4) Tightening key for cleaning motor (5) Compressed air relief valve

not shown:

(6) Harting Han6P connecting plug (X1) without cable (7) Operating instructions (8) Fixings for assembling the cleaning device:

- 4 screws

- 4 washers

- 4 lock washers

- 4 nuts

Robacta Reamer Alu 3000upm options

Robacta Reamer Twin scope of supply

- Fitting base

- Wire cutter

((11))

((22))

((33))

((44))

((55))

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 Twin cleaning de-

vice with wire cutter and parting

agent nebuliser (2) Spatter tray retainer (3) Spatter tray (4) Tightening key for cleaning motor (5) Compressed air relief valve

not shown:

(6) Harting Han6P connecting plug (X1) without cable (7) Operating instructions

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(8) Filling funnel for parting agent (9) Fixings for assembling the cleaning device:

- 4 screws

- 4 washers

- 4 lock washers

- 4 nuts

Robacta Reamer Twin options

- Fitting base

- Cleaning cutter adjustment aid

- Parting agent - spray unit

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Warning notices on the device

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.

The locations of the warning notices are shown on the Robacta Reamer Twin as an example. On the Robacta Reamer Alu Edition and Robacta Reamer Alu 3000upm the warning notices are in the same location.

Type

Art.No.

max

6 bar (87PSI)

Chargen No.

24 V

0.25 A

Wels - Austria

Warning notices on the cleaning device

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WARNING! Risk of serious injury from:

- mechanically powered parts

- compressed air/parting agent mixture escaping from the parting 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, especially the safety rules

For indoor use only

Wear eye protection

Notice warning of automatic start-up of the device

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Transport

Vehicles The device is to be transported by the following vehicles:

- on pallets using a counterbalanced lift truck

- on pallets using a lift truck

- manually

WARNING!

Equipment that falls or topples over can cause serious or even fatal injury.

► When transporting the device on a counterbalanced lift truck or lift truck, secure it to

prevent it from falling over

► Do not suddenly change direction, brake or accelerate

Transport notices on the packaging

CAUTION!

Risk of damage due to incorrect transport.

Observe the transport notices on the device packaging.

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Controls, connections and mechani-

cal components

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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

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Control elements, connections and mechanical components of the Robacta Reamer Alu Edition and Robacta Reamer Alu 3000upm

Control elements, connections and mechanical components

(4)

(5)

(3)

(1) (2)

Side view Front view

No. Function

(1) Compressed air connection

for a dry compressed air supply at 6 bar (86.99 psi)

(2) Harting Han6P connection socket (X1)

for a + 24 V DC supply

CAUTION!

Risk of damage to Harting Han6P connection (X1) supply due to overcurrent.

Secure supply against overcurrent with a 500 mA slow-blow fuse.

(3) "Cleaning" screw

for manually checking the following functions:

- Cleaning motor ON/OFF

- Lifting device UP/DOWN

- Gas nozzle clamping device extending/retracting

(6)

(7)

(4) Gas nozzle clamping device

holds the gas nozzle in place during cleaning

(5) Protective covering

(6) Cleaning motor

drives the cleaning brush / cleaning cutter

(7) Lifting device

lifts the cleaning motor and the cleaning brush / cleaning cutter to the cleaning position ready to commence cleaning

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Robacta Reamer Twin control elements, connections and mechanical components

Control elements, connections and mechanical components

(1)

(2) (3)

(4)

No. Function

(1) Parting agent adjuster

for setting the spray amount on the parting agent spray nozzles

(5)

(6)

(7)

(8)

(2) Compressed air connection

for a dry compressed air supply at 6 bar (86.99 psi)

(3) Harting Han6P connection socket (X1)

for a + 24 V DC supply

CAUTION!

Risk of damage to Harting Han6P connection (X1) supply due to overcurrent.

Secure supply against overcurrent with a 500 mA slow-blow fuse.

(4) "Cleaning" button

for manually checking the following functions:

- Cleaning motor ON/OFF

- Compressed air and parting agent supply 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 extending/retracting

(5) Gas nozzle clamping device

holds the gas nozzle in place during cleaning

(6) Protective covering

(7) Cleaning motor

drives the cleaning cutter

(8) Lifting device

lifts the cleaning motor and the cleaning cutter to the cleaning position ready to commence cleaning

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No. Function

(9) Wire cutter valve lever

activates the wire cutter

(10) Wire cutter

(11) Parting agent spray nozzles

sprays the parting agent into the interior and onto the front of the gas nozzles using compressed air

(9)(9)

(10)(10)

((1111))

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Harting Han6P connecting plug pin assignment (X1) for robot control

General

CAUTION!

Risk of damage to Harting Han6P 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.

The Harting Han6P connecting plug (X1) for connecting the cleaning device to the robot control is part of the scope of supply. The cable harness must be adapted to the connection technology on the robot control.

Harting Han6P connecting plug pin assignment (X1)

Input and output signals on the Robacta Reamer Alu brush head:

1. Start cleaning input signal (cleaning motor ON, lifting device UP, compressed air supply to cleaning nozzles ON)

2. Not assigned

3. GND

4. + 24 V DC

5. Gas nozzle free output signal

6. Earthing

Harting Han6P connecting plug pin assignment (X1) cable-end view

(see circuit diagrams in appendix)

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Installation and commissioning

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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. All functions described in these operating instructions may only be used by trained and qualified personnel. Do not carry out any of the work or use any of the functions described until you have fully read and understood the following documents: ► these operating instructions ► all the operating instructions for the system components, especially the safety rules

WARNING!

Machines that start up automatically can cause serious injury and damage.

In addition to these operating instructions, the safety rules issued by the manufacturers of the robot and welding systems must also be observed. For your personal safety, ensure that all protective measures have been taken and will remain in place while you are in the working area of the robot.

WARNING!

Risk of serious injury from:

► mechanically powered parts ► flying parts (shavings, etc.) ► compressed air/parting agent mixture escaping from the parting-agent injection noz-

zles ► Before performing work on the cleaning device or any connected system components: ► disconnect the customer compressed air and power supplies from the cleaning device

and the connected system components, and ensure that they remain disconnected un-

til work is complete ► ensure that the cleaning device is depressurised - please see the "Ensuring that the

cleaning device is depressurised" section below for the relevant instructions

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 / rotating cleaning brush ► lifting device moving up/down ► extending/retracting gas nozzle clamping device ► activated wire cutter ► flying parts (shavings, etc.) ► compressed air/parting agent mixture escaping from the parting-agent injection noz-

zles

Page 36

If work has to be performed on the cleaning device while it is being supplied with voltage and/or compressed air: ► keep your body, especially your hands, face, hair, any objects and all clothing away

from the cleaning cutter / cleaning brush, lifting device, gas nozzle clamping device,

wire cutter and parting-agent injection nozzles ► wear ear protection ► wear protective goggles with side protection

Ensuring that the cleaning device is depressurised

Attempt to briefly activate the cleaning device without any compressed air supply to check whether the cleaning device is depressurised. Proceed as follows:

Take protective measures:

- The cleaning cutter / cleaning brush, lifting device, gas nozzle clamping device, wire cutter and parting-agent injection nozzles could start up. Therefore keep your body, especially your hands, face and hair, any objects and all clothing away from the parts referred to above

- wear ear protection

- wear protective goggles with side protection

Ensure that the cleaning device has been disconnected from the compressed air sup-

ply

On the Robacta Reamer Alu Edition, Robacta Reamer Alu 3000upm:

Briefly turn the "Cleaning" screw on the cleaning device 90° to the right, then turn it

straight back to its original position

- If the cleaning device does not respond to the turning of the screw, the cleaning device is depressurised

- If the cleaning device responds to the turning of the screw, the cleaning device is still connected to a compressed air supply. If this is the case, you must disconnect the cleaning device from the compressed air supply and check again that the cleaning device is depressurised before starting work

On the Robacta Reamer Twin:

Briefly press the valve lever on the cleaning device wire cutter to the side by more than

15° using a tool

- If the cleaning device wire cutter does not respond to the movement of the valve lever, the cleaning device (including the wire cutter) is depressurised

- If the wire cutter responds to the movement of the valve lever, the cleaning device (and therefore also the wire cutter) is still connected to a compressed air supply. If this is the case, you must disconnect the cleaning device from the compressed air supply and check again that the cleaning device is depressurised before starting work

Page 37

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 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

Operators, maintenance personnel

Setup regulations The cleaning device is tested to IP 21, meaning:

NOTE!

The device must only be used by one person at a time.

It is also necessary to ensure that no one else is within the working area of the device when the device is being used.

NOTE!

The device must only be serviced by one person at a time.

It is also necessary to ensure that no one else is within the working area of the device when the device is being serviced.

- Protection against penetration by solid foreign bodies with diameters > 12.5 mm (0.49 in.)

- protection against vertically falling drops of water

The device must not be set up and operated outdoors. The built in electrical parts must be protected from direct wetting.

Compressed air supply specifications

Measures for the safe operation of the device with untrained personnel

To ensure that the cleaning device functions correctly, the following compressed air supply specifications must be met:

- Establish compressed air supply using a pressure limiter and compressed air filter

- Provide compressed air quality conforming to ISO 8573-1:2001, class 7 4 3, instrument air

- Solid particle concentration  10 mg/m

- Vapour pressure dew point  + 3°C

- Oil concentration  1 mg/m

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.

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 38

Screwing the cleaning device to the underlying surface

Screwing the cleaning device and installation stand to the underlying surface

NOTE!

Different fixings may be required to set up the installation stand depending on the type of underlying surface (foundation).

Fixings are therefore not included in the scope of supply of the installation stand. The installer is responsible for selecting the right type of fixing.

Place the optional installation stand on a level, firm and vibration-free surface (foun-

dation)

- Position the installation stand in such a way that the distance the robot has to trav-

el to the cleaning device on the installation stand is as short as possible

Screw the installation stand to the underlying surface (foundation) using the appropri-

ate fixings

NOTE!

Screw on the cleaning device and the spatter tray retainer using the fixings supplied with the cleaning device.

Screwing the cleaning device to the underlying surface

NOTE!

Different fixings may be required to fasten the device, depending on the type of underlying surface (foundation).

► If the underlying surface (foundation) thickness is less than 5 mm (0.197 in.), use the

fixings supplied with the cleaning device for the work shown below.

► If the underlying surface (foundation) thickness is greater than 5 mm (0.197 in.), do not

use the fixings supplied for the work shown below. In this situation the installer is responsible for selecting the right type of fixing.

Page 39

NOTE!

Place the cleaning device and the spatter tray retainer on a level, firm and vibrationfree surface (foundation).

Position the cleaning device in such a way that the distance the robot has to travel to the cleaning position is as short as possible.

Page 40

Torch cleaning position

Welding torch cleaning position

- Robacta Reamer Alu Edition

Welding torch cleaning position

- Robacta Reamer Alu 3000upm

228800 mmmm ((11 11 .. 0022 iinn.. ))

Welding torch cleaning position

- Robacta Reamer Twin

2288 00 mmmm ((11 11.. 0022 iinn.. ))

NOTE!

Ensure that the coolant lines on the gas nozzle cannot be damaged by the extending/retracting gas nozzle clamping device.

1100 mmmm ((00.. 3399 iinn.. ))

Page 41

Adjusting the gas nozzle clamping device on the Robacta Reamer Alu Edition and Robacta Reamer Alu 3000upm

Adjusting the gas nozzle clamping device

NOTE!

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

position

- centrally with respect to the cleaning motor

Using the adjusting screw (3), position

(1) (3)

(2) (4)

the clamping device (4) so that the clamping device is on the gas nozzle

Tighten Allen screws on the guide bolts (1) and (2)

NOTE!

The gas nozzle must be clamped centrally over the cleaning motor.

Page 42

Fitting the cleaning brush on the Robacta Reamer Alu Edition

Fitting the cleaning brush

CAUTION!

A cleaning brush that has become very hot through use can cause severe burns.

Before handling the cleaning brush, allow cleaning brush to cool to room temperature (+25°C, +77 °F).

NOTE!

Only use the device manufacturer's contact tips, gas nozzles and cleaning brushes.

If other manufacturers' products are used, trouble-free operation of the device cannot be guaranteed. The manufacturer accepts no liability for damage resulting from the use of other manufacturers' contact tips, gas nozzles or cleaning brushes.

NOTE!

The cleaning brush and adapter are not included in the scope of supply.

Consult the device manufacturer's spare parts list for the appropriate cleaning brush.

Remove the protective covering from the cleaning device

Fit the protective covering to the cleaning device in its original position

Page 43

Fitting the cleaning cutter on the Robacta Reamer Alu 3000upm

Fitting the cleaning cutter

A cleaning cutter that has become very hot through use can cause severe burns.

Before handling cleaning cutters, allow cleaning cutter to cool to room temperature (+25°C, +77 °F).

NOTE!

Only use the device manufacturer's contact tips, gas nozzles and cleaning cutters.

NOTE!

The cleaning cutter and adapter are not included in the scope of supply.

Consult the device manufacturer's spare parts list for the appropriate cleaning cutter and adapter.

CAUTION!

Remove the protective covering from the cleaning device

Fit the protective covering to the cleaning device in its original position

Page 44

Fitting the cleaning cutter on the Robacta Reamer Twin

Fitting the cleaning cutter

CAUTION!

A cleaning cutter that has become very hot through use can cause severe burns.

Before handling cleaning cutters, allow cleaning cutter to cool to room temperature (+25°C, +77 °F).

NOTE!

Only use the device manufacturer's contact tips, gas nozzles and cleaning cutters.

NOTE!

The cleaning cutter is not part of the scope of supply.

Consult the manufacturer's spare parts list for the appropriate cleaning cutter.

Remove the protective covering from the cleaning device

Fit the protective covering to the cleaning device in its original position

Page 45

Adjusting the Robacta Reamer Alu Edition lifting device

Adjusting the lifting device

(1)(1)

(2)(2)

Remove protective covering (1)

Ensure that the lifting device is in its lo-

west position

Loosen screw (2) on the lifting device

Move the welding torch to the cleaning

position

2/32/3

1/31/3

(5)(5)

Push the lifting device (3) by hand into its highest position and hold in place

Manually push cleaning motor (4) and cleaning brush to the cleaning position

- see diagram (5) - correct adjustment

- see diagram (6) - incorrect adjustment

Fix cleaning motor (4) in this position in the lifting device (3) - tighten screw (2) on the

lifting device

Carry out function test - push lifting device by hand to its highest position

- Check that lifting device is adjusted correctly - see diagram (5). If the correct adjustment is not given, readjust the lifting device

Fit the protective covering to the cleaning device in its original position

(4)(4)

(2)(2)

(3)(3)

(6)(6)

Page 46

Adjusting the Robacta Reamer Alu 3000upm lifting device

Adjusting the lifting device

(4)(4)

(2)(2) (3)(3)

Remove protective covering (1)

Remove gas nozzle from torch neck

Ensure that the lifting device is in its lo-

west position

Loosen 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

Manually push cleaning motor (4) and

cleaning cutter to the cleaning position

- see diagram (5) for welding torch and spatter guard

- see diagram (6) for welding torch and insulating sleeve

(5)(5) (6)(6)

NOTE!

The cleaning cutter must not touch any welding torch components.

Fix cleaning motor (4) in this position in the lifting device (3) - tighten screw (2) on the

lifting device

Carry out function test on unfitted gas nozzle - push lifting device by hand to its highest

position

- The cleaning cutter must close around the contact tip without touching it. If the cleaning cutter touches welding torch components, readjust the lifting device

Fit gas nozzle to torch neck

Carry out function test on fitted gas nozzle - push lifting device by hand to its highest

position

- The cleaning cutter must be inserted into the gas nozzle gently, without touching it. If the cleaning cutter touches welding torch components, readjust the lifting device

Fit the protective covering to the cleaning device in its original position

Page 47

Adjusting the Robacta Reamer Twin lifting device

Adjusting the lifting device

It is recommended that one of the following adjustment aids is used to adjust the lifting device:

- Robacta Twin 900 adjustment aid, item no. 42,0001,5560

Remove protective covering (1)

Ensure that the lifting device is in its lo-

west position

Loosen screw (2) on the lifting device

Move welding torch to cleaning positi-

on (including fitted adjustment aid)

Push the lifting device (3) by hand into

(1)(1)

its highest position and hold in place

(2)(2)

(3)(3)

Manually push cleaning motor (4) and

cleaning cutter to the cleaning position

(5)(5)

(5)

(4)(4)

NOTE!

The cleaning cutter must not touch any

welding torch parts.

Fix cleaning motor (4) in this position in

the lifting device - tighten screw (2) on the lifting device

Fit the protective covering to the clea-

ning device in its original position

Page 48

Starting up the Robacta Reamer Twin parting agent nebuliser

Starting up the parting agent nebuliser

NOTE!

Only use "Robacta Reamer" parting agent (item number 42,0411,8042).

The composition of this parting agent is designed specifically for the cleaning device. If other manufacturers' products are used, trouble-free operation cannot be guaranteed.

NOTE!

Use the parting agent - spray unit option to achieve sufficient wetting of the entire Twin welding torch interior.

With the parting agent - spray unit option, the parting agent is sprayed through the blow out line directly into the welding torch interior.

Open the sealing plug (1)

Fill with "Robacta Reamer" parting agent using the filling funnel (2)

Close the sealing plug (1)

NOTE!

If the spray amount is not sufficient after starting up the cleaning device, increase it as required:

► by adjusting the spray time using the robot control - a spray time of ~ 0.7 seconds is

recommended

► or by using the parting agent adjuster (4): remove the safety clamp (3), use a screw-

driver to set the parting agent adjuster (4) so that the welding torch interior is coated with a thin layer of parting agent (0.2-0.5 ml) after the spraying action is complete

(1) (1)

(2)

(4) (3)

321

Page 49

Correct adjustment of the parting agent spray nozzles on the Robacta Reamer Twin

NOTE!

Both spray jets of parting agent must meet in front of the gas nozzle, so that they fully enter the nozzle.

Page 50

Installing mechanically-controlled wire cutter on the Robacta Reamer Alu Edition and Robacta Reamer Alu 3000upm (optional)

Installing the mechanically-controlled wire cutter

NOTE!

Installation of the wire cutter is shown for the Robacta Reamer Alu Edition.

The wire cutter is installed in exactly the same way on the Robacta Reamer Alu 3000upm.

Position the mounting bracket (1) on

the wire cutter (2) as shown and screw into place as described - using the fixings supplied

Undo 3 screws and washers (3)

Remove cleaning device housing co-

ver (4)

(3)

(1)(2)

(3)

(4)

(3)

Page 51

Remove screw (5)

(5)

(6) (6)

Undo screws and washers (6)

- Keep the screws and washers for future use

(6)

Screw the wire cutter to the cleaning

device using the previously removed screws and washers (6)

Page 52

(7)

Cut through the compressed air hose

(7) in the interior of the cleaning device housing in the position shown

Detach compressed air connection (8)

from compressed air connection (9)

(8)

(9)

Page 53

(8)

(9)

(10)

Attach the wire cutter compressed air

connection (9) to compressed air connection (8) on the cleaning device housing, as shown

Insert the compressed air hose (10)

firmly into the compressed air distributor (11)

Insert the two loose ends (12) and (13)

of the previously cut compressed air hose firmly into the compressed air distributor (11) as shown

Fit the cleaning device housing cover

(4) to the cleaning device in its original position

(11)

(12) (13)

Page 54

Installing the electrically-controlled wire cutter on the Robacta Reamer Alu Edition and Robacta Reamer Alu 3000upm (optional)

Installing the electrically-controlled wire cutter

NOTE!

Installation of the wire cutter is shown for the Robacta Reamer Alu Edition.

The wire cutter is installed in exactly the same way on the Robacta Reamer Alu 3000upm.

Position the mounting bracket (1) on

the wire cutter (2) as shown and screw into place as described - using the fixings supplied

Undo 3 screws and washers (3)

Remove cleaning device housing co-

ver (4)

(3)

(1)(2)

(3)

(4)

(3)

Page 55

(5) (5)

Undo screws and washers (5)

- Keep the screws and washers for future use

Screw the wire cutter to the cleaning

device using the previously removed screws and washers (5) as shown

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 a separate supply line.

NOTE!

The wire cutter electrical connection must be connected to the robot control.

Page 56

Wire cutter function

Maximum wire diameter

How the mechanically-controlled wire cutter works

Wire electrodes with a diameter of up to 1.6 mm (0.063 in.) can be cut with an electrically or mechanically-controlled wire cutter.

Two wire electrodes with a diameter of up to 1.6 mm (0.063 in.) can be cut in the case of twin applications.

If a torch neck pushes the valve lever (1) to the side by more than 15° with the gas

(1)

nozzle, the wire cutter is activated and the wire electrode is cut.

NOTE!

The wire electrode is cut while the torch neck is moving.

How the electrically-controlled wire cutter works

The electrically-controlled wire cutter opens and closes when there is an active signal from the robot control.

Page 57

Installing the compressed air supply

Establishing the compressed air supply for the cleaning device, function of the compressed air relief valve

To establish the compressed air supply:

Depressurise the compressed air supply line of the cleaning device and ensure that it

remains depressurised for the duration of the following work on the device

Screw the supplied compressed air relief valve into the compressed air connection on

the cleaning device

Connect the compressed air supply line to the compressed air relief valve

NOTE!

The compressed air supply to the cleaning device can be broken and re-established by moving the compressed air relief valve forwards and backwards.

The diagram on the left shows the compressed air relief valve in the closed position = no compressed air supply to the device

The diagram on the left shows the compressed air relief valve in the open position = compressed air is being supplied to the device

Page 58

Starting up the cleaning device

Prerequisites for start-up

Start-up The cleaning device starts up when there is an active signal from the robot control.

The following requirements must be met before the cleaning device is started up:

- If present, the cleaning device installation stand is bolted to underlying surface

- Cleaning device is bolted to underlying surface

- Only on the Robacta Reamer Alu Edition and Robacta Reamer Alu 3000upm: gas nozzle clamping device is adjusted

- Cleaning cutter / cleaning brush has been fitted

- Lifting device has been adjusted

- On the Robacta Reamer Twin: Parting agent nebuliser has been started up

- Compressed air supply has been established

- Cleaning device is connected to robot control

- All covers are fitted and all safety devices are intact and in their proper place

Page 59

Programme sequence and signal waveform on the Robacta Reamer Alu Edition and Robacta Reamer Alu 3000upm

Cleaning program sequence

Risk of damage.

Do not start in automated mode until the cleaning device has been properly installed and started up.

Not coating the interior of the welding torch may result in permanent soiling of the torch when welding begins.

Always wet the interior of the welding torch with the manufacturer's parting agent before starting automatic operation.

CAUTION!

NOTE!

Page 60

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Page 62

Signal waveform

(1)

(2)

(3)

(4)

No. Meaning

(1) Input "Begin cleaning"

(2) Output "Gas nozzle free"

(3) Gas nozzle free

(4) Cleaning time: 3.0 - 5.0 seconds

Page 63

Robacta Reamer Twin programme sequence and signal waveform

Cleaning program sequence

Risk of damage.

Do not start in automated mode until the cleaning device has been properly installed and started up.

Not wetting the interior of the welding torch may result in permanent soiling of the torch when welding begins.

Always wet the interior of the welding torch with the manufacturer's parting agent before starting automatic operation.

CAUTION!

NOTE!

Page 64

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Page 66

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Page 67

Signal waveform

(1)

(2)

(3) (4)

(5)

No. Meaning

(1) Input "Begin cleaning"

(2) Output "Gas nozzle released"

(3) Gas nozzle released (Cleaning, page 1)

(4) Gas nozzle released (Cleaning, page 2)

(5) Cleaning time: 7.0 - 7.5 seconds

Page 68

Page 69

Care, maintenance and disposal

Page 70

Page 71

Safety

Safety Observe the following safety rules for all work described in the "Care, maintenance and dis-

posal" section.

WARNING!

Incorrect operation or shoddy workmanship can cause serious injury or damage.

WARNING!

Machines that start up automatically can cause serious injury and damage.

WARNING!

Risk of serious injury from:

► mechanically powered parts ► flying parts (shavings, etc.) ► compressed air/parting agent mixture escaping from the parting-agent injection noz-

zles ► Before performing work on the cleaning device or any connected system components: ► disconnect the customer compressed air and power supplies from the cleaning device

and the connected system components, and ensure that they remain disconnected un-

til work is complete ► ensure that the cleaning device is depressurised - please see the "Ensuring that the

cleaning device is depressurised" section below for the relevant instructions

WARNING!

Whenever the cleaning device and connected system components are supplied with voltage and/or compressed air, a risk of serious injury exists from:

zles

Page 72

from the cleaning cutter / cleaning brush, lifting device, gas nozzle clamping device,

wire cutter and parting-agent injection nozzles ► wear ear protection ► wear protective goggles with side protection

CAUTION!

A cleaning cutter / cleaning brush that has become very hot through use can cause severe burns.

Before handling the cleaning cutter / cleaning brush, allow cleaning cutter / cleaning brush to cool to room temperature (+25°C, +77°F).

Ensuring that the cleaning device is depressurised

Attempt to briefly activate the cleaning device without any compressed air supply to check whether the cleaning device is depressurised. Proceed as follows:

Take protective measures:

- wear ear protection

- wear protective goggles with side protection

Ensure that the cleaning device has been disconnected from the compressed air sup-

ply

On the Robacta Reamer Alu Edition, Robacta Reamer Alu 3000upm:

Briefly turn the "Cleaning" screw on the cleaning device 90° to the right, then turn it

straight back to its original position

- If the cleaning device does not respond to the turning of the screw, the cleaning device is depressurised

On the Robacta Reamer Twin:

Briefly press the valve lever on the cleaning device wire cutter to the side by more than

15° using a tool

- If the cleaning device wire cutter does not respond to the movement of the valve lever, the cleaning device (including the wire cutter) is depressurised

Page 73

Care, maintenance and disposal

General The cleaning device generally needs no maintenance. However, to keep the cleaning de-

vice in good working condition for years to come, several points on care and maintenance must be observed.

Before each start-up- Only Robacta Reamer Twin: Check fill level in parting agent container and top up if

necessary

- Check the cleaning cutter / cleaning brushes for wear and replace if necessary

- Empty the cleaning device spatter tray

- If fitted, empty the wire cutter tray

- Perform a general visual inspection on the device

Daily

Weekly

NOTE!

Only use solvent-free cleaning products on the cleaning device.

- Remove parting agent deposits and dirt from device

NOTE!

Only use solvent-free cleaning products on the parting agent container.

Only Robacta Reamer Twin:

- Check parting agent container for soiling and clean if necessary

- Blow through the suction filter in the parting agent container using compressed air from the inside outwards through the suction hose (see "Starting up the Robacta Reamer Twin parting agent nebuliser")

Every 6 months Open the device and check the pneumatic valves for:

- leaks

- the secure seating of all screws

- the secure seating of all screw joints on the pneumatic valves

If necessary Open the device and

- clean the inside of the device using dry reduced compressed air

- lightly oil the lifting device cylinder guides

Disposal Dispose of in accordance with applicable national and local regulations.

Page 74

Page 75

Troubleshooting

Page 76

Page 77

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.

WARNING!

Machines that start up automatically can cause serious injury and damage.

WARNING!

Risk of serious injury from:

► mechanically powered parts ► flying parts (shavings, etc.) ► compressed air/parting agent mixture escaping from the parting-agent injection noz-

zles ► Before performing work on the cleaning device or any connected system components: ► disconnect the customer compressed air and power supplies from the cleaning device

and the connected system components, and ensure that they remain disconnected un-

til work is complete ► ensure that the cleaning device is depressurised - please see the "Ensuring that the

cleaning device is depressurised" section below for the relevant instructions

WARNING!

Whenever the cleaning device and connected system components are supplied with voltage and/or compressed air, a risk of serious injury exists from:

zles

Page 78

from the cleaning cutter / cleaning brush, lifting device, gas nozzle clamping device,

wire cutter and parting-agent injection nozzles ► wear ear protection ► wear protective goggles with side protection

CAUTION!

A cleaning cutter / cleaning brush that has become very hot through use can cause severe burns.

Before handling the cleaning cutter / cleaning brush, allow cleaning cutter / cleaning brush to cool to room temperature (+25°C, +77°F).

Ensuring that the cleaning device is depressurised

Attempt to briefly activate the cleaning device without any compressed air supply to check whether the cleaning device is depressurised. Proceed as follows:

Take protective measures:

- wear ear protection

- wear protective goggles with side protection

Ensure that the cleaning device has been disconnected from the compressed air sup-

ply

On the Robacta Reamer Alu Edition, Robacta Reamer Alu 3000upm:

Briefly turn the "Cleaning" screw on the cleaning device 90° to the right, then turn it

straight back to its original position

- If the cleaning device does not respond to the turning of the screw, the cleaning device is depressurised

On the Robacta Reamer Twin:

Briefly press the valve lever on the cleaning device wire cutter to the side by more than

15° using a tool

- If the cleaning device wire cutter does not respond to the movement of the valve lever, the cleaning device (including the wire cutter) is depressurised

Page 79

Troubleshooting

Errors in program sequence

Parting agent does not spray (Robacta Reamer Twin only)

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

Remedy: Check connection to robot control

Welding torch is poorly cleaned or damaged

Cause: Lifting device not adjusted properly

Remedy: Adjust lifting device

Cause: Gas nozzle clamped in wrong position (not on Robacta Reamer Twin)

Remedy: Adjust gas nozzle clamping device (not on Robacta Reamer Twin)

Cause: Cleaning cutter / cleaning brush not suited to welding torch shape

Remedy: Fit the correct cleaning cutter / fit correct cleaning brush

Cause: Cleaning cutter / cleaning brush worn

Remedy: Replace cleaning cutter / cleaning brush

Cleaning cutter collides with a contact tip or gas nozzle (Robacta Reamer Twin only)

Cause: Incorrect swivel mechanism stop angle

Remedy: Contact After-Sales Service - Adjust the swivel mechanism stop angle

Lifting device is not moving up or down

Cause: Compressed air relief valve closed

Remedy: Open compressed air relief valve

Cause: No signal from robot

Remedy: Check connection to robot control

Cause: Faulty sealing in lifting cylinder

Remedy: Contact After-Sales Service - replace lifting cylinder

Cleaning motor does not work

Cause: Compressed air relief valve closed

Remedy: Open compressed air relief valve

Cause: No signal from robot

Remedy: Check connection to robot control

Cause: Mechanical fault on cleaning motor

Remedy: Contact After-Sales Service - replace cleaning motor

Page 80

Page 81

Technical data

Page 82

Page 83

Technical data

Robacta Reamer Alu Edition and Robacta Reamer Alu 3000upm

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

Harting Han6P (X1) Input: + 24 V DC / max. 150 mA

Output: + 24 V DC / max. 30 mA

Cleaning time 3.0 - 5.0 s

Total cycle time 4.0 - 7.5 s

Degree of protection IP 21

Mark of conformity CE, CSA

Max. noise emission (LWA) 82 dB (A)

Dimensions l x w x h 170 x 165 x 280 mm

6.69 x 6.50 x 11.02 in.

Weight (without optional wire cutter)

9 kg

19.84 lb.

Robacta Reamer Twin

Supply voltage + 24 V DC

Nominal output 6 W

Nominal pressure 6 bar

86.99 psi

Air consumption 420 l/min

443.81 qt./min

Harting Han6P (X1) Input: + 24 V DC / max. 300 mA

Output: + 24 V DC / max. 30 mA

Cleaning time 7.0 - 7.5 s

Total cycle time 8.5 - 10 s

Parting agent container capacity 0.25 l

.07 gal. (US)

Degree of protection IP 21

Mark of conformity CE, CSA

Max. noise emission (LWA) 82 dB (A)

Dimensions l x w x h 325 x 220 x 350 mm

12.80 x 8.66 x 13.78 in.

Weight (without parting agent and optional wire cutter)

17 kg

37.48 lb.

Page 84

Page 85

Appendix

Page 86

Spare parts list: Robacta Reamer Alu Edition

Page 87

Spare parts list: Robacta Reamer Alu 3000upm

Page 88

Spare parts list: Robacta Reamer Twin

Page 89

Spare parts list: Robacta Reamer Twin

Robacta Reamer Twin - 44,0450,1145 Robacta Reamer Twin without Wire Cutter - 44,0450,1282 Robacta Reamer Twin without Injection - 44,0450,1229

44,0450,1174

44,0450,1366

44,0450,1174

44,0450,1179

44,0450,1174

44,0450,1193

44,0450,1204

44,0450,1199

44,0450,1175

44,0450,1200

44,0450,1192

44,0450,1193

44,0450,1187

44,0450,1173

44,0450,1178

44,0450,1177

Page 90

Circuit diagrams: Robacta Reamer Alu Edition / Robacta Reamer Alu 3000upm

Page 91

Circuit diagrams: Robacta Reamer Twin

-X1

input start cleaning

GND 0VDC

+24V

output gas nozzle free

- BLACK -

- BLUE -

- BROWN -

- BLUE -

- BROWN -

- BLUE -

- BLACK -

- BROWN -

- BLACK -

- BROWN -

- BLUE -

123456789

- BLACK -

- BLUE -

-X2

- BLUE -

- BROWN -

- BLACK -

- BLUE -

- BROWN -

- BLACK -

- BLUE -

- BROWN -

- BLACK -

1 2 3

manual cleaning

-S1

-1S1

-1S2

-3S1

motor left

motor right clamping device

-2S2

motor up

1243

motor down

-2S1

-K1

motor right

-1V1

motor left motor up/down

-1V2

-2V1

Page 92

Robacta Reamer Twin pneumatic diagram

WIRE CUTTER

GAS NOZZLE CLAMP MOTOR

-4A1

-3A1

-3A2

-3S1

-4V1

-3X1.....spraying nozzle

-3X2.....spraying nozzle

-3V2.....signal interupter-2V1.....solenoid valve

-4A1.....cylinder 63mm

-4V1.....lever valve

-3Z1.....oiler-3A1.....cylinder 32mm

-2V2.....choke flap valve

-2V3.....choke flap valve

-3V1.....trapped valve

-3V2

-3Z1

tappet valve is

motor is lowered

operated if cleaning

SPRAYING

-3X2

-3X1

-0X1.....compressed air connector

-0V1.....start/stop valve

-1V3.....choke flap valve

-1A1.....cylinder 25mm

-1V1.....solenoid valve

-1V2.....choke flap valve -3A2.....pneumatic m otor

-2A1.....sliding unit

-3V1

MOTOR

UP / DOWN

MOTOR

LEFT / RIGHT

-2A1

-1A1

-2S2

-2S1

-1S2

-1S1

-2V3

-2V2

-1V3

1 5

-2V1

35 1

-1V2

-1V1

-0V1

-0X1

6bar/87psi

Page 93

Declarations of Conformity

EU-KONFORMITÄTSERKLÄRUNG 2016 EU-DECLARATION OF CONFORMITY 2016 DÉCLARATION UE DE CONFORMITÉ, 2016

FRONIUS INTERNATIONAL GMBH

Froniusstaße 1, A-4643 Pettenbach

Wels-Thalheim, 2016-07-07

eingapmoc aLrerutcafunaMamriF eiD

erklärt in alleiniger Verantwortung, dass folgendes Produkt:

Robacta Reamer Alu 3000upm

Gasdüsenreinigungsgerät

auf das sich diese Erklärung bezieht, mit folgenden Richtlinien bzw. Normen übereinstimmt:

Richtlinie 2014/30/EU Elektromag. Verträglichkeit

Richtlinie 2006/42/EG Maschinenrichtlinie

Europäische Normen inklusive zutreffende Änderungen EN ISO 12100:2010 EN 61000-6-2:2005+AC:2005 EN 61000-6-4:2007+A1:2011

Die oben genannte Firma hält Dokumentationen als Nachweis der Erfüllung der Sicherheitsziele und die wesentlichen Schutzanforderungen zur Einsicht bereit.

Hereby certifies on its sole responsibility that the following product:

Robacta Reamer Alu 3000upm

Gas nozzle cleaner

which is explicitly referred to by this Declaration meet the following directives and standard(s):

Directive 2014/30/EU Electromag. compatibility

Directive 2006/42/EC Machinery Directive

European Standards including relevant amendments EN ISO 12100:2010 EN 61000-6-2:2005+AC:2005 EN 61000-6-4:2007+A1:2011

Documentation evidencing conformity with the requirements of the Directives is kept available for inspection at the above Manufacturer.

se déclare seule responsable du fait que le produit suivant:

Robacta Reamer Alu 3000upm

Appareil de nettoyage de buses gaz

qui est l’objet de la présente déclaration correspondent aux suivantes directives et normes:

Directive 2014/30/UE Électromag. Compatibilité

Directive 2006/42/CE Directive aux machines

Normes européennes avec amendements correspondants EN ISO 12100:2010 EN 61000-6-2:2005+AC:2005 EN 61000-6-4:2007+A1:2011

En tant que preuve de la satisfaction des demandes de sécurité la documentation peut être consultée chez la compagnie susmentionnée.

Dokumentationsverantwortlicher: (technische Dokumentation)

Ing. Josef Fe Günter Fronius Straße 1 A - 4600 Wels-Thalheim

ichtinger

person responsible for documents: (technical documents)

Ing. Josef Feichtinger Günter Fronius Straße 1 A - 4600 Wels-Thalheim

responsable documentation: (technique documentation)

Ing. Josef Feichtinger Günter Fronius Straße 1 A - 4600 Wels-Thalheim

2016 ppa. Mag.Ing.H.Hackl

Member of Board Chief Technology Officer

DE German Deutsch EN English English FR French Française

Page 94

EU-KONFORMITÄTSERKLÄRUNG 2016 EU-DECLARATION OF CONFORMITY 2016 DÉCLARATION UE DE CONFORMITÉ, 2016

Wels-Thalheim, 2016-07-07

FRONIUS INTERNATIONAL GMBH

Froniusstaße 1, A-4643 Pettenbach

eingapmoc aLrerutcafunaMamriF eiD

erklärt in alleiniger Verantwortung, dass folgendes Produkt:

Robacta Reamer Twin

Gasdüsenreinigungsgerät

auf das sich diese Erklärung bezieht, mit folgenden Richtlinien bzw. Normen übereinstimmt:

Richtlinie 2014/30/EU Elektromag. Verträglichkeit

Richtlinie 2006/42/EG Maschinenrichtlinie

Europäische Normen inklusive zutreffende Änderungen EN ISO 12100:2010 EN 61000-6-2:2005+AC:2005 EN 61000-6-4:2007+A1:2011

Die oben genannte Firma hält Dokumentationen als Nachweis der Erfüllung der Sicherheitsziele und die wesentlichen Schutzanforderungen zur Einsicht bereit.

Hereby certifies on its sole responsibility that the following product:

Robacta Reamer Twin

Gas nozzle cleaner

which is explicitly referred to by this Declaration meet the following directives and standard(s):

Directive 2014/30/EU Electromag. compatibility

Directive 2006/42/EC Machinery Directive

European Standards including relevant amendments EN ISO 12100:2010 EN 61000-6-2:2005+AC:2005 EN 61000-6-4:2007+A1:2011

Documentation evidencing conformity with the requirements of the Directives is kept available for inspection at the above Manufacturer.

se déclare seule responsable du fait que le produit suivant:

Robacta Reamer Twin

Appareil de nettoyage de buses gaz

qui est l’objet de la présente déclaration correspondent aux suivantes directives et normes:

Directive 2014/30/UE Électromag. Compatibilité

Directive 2006/42/CE Directive aux machines

Normes européennes avec amendements correspondants EN ISO 12100:2010 EN 61000-6-2:2005+AC:2005 EN 61000-6-4:2007+A1:2011

En tant que preuve de la satisfaction des demandes de sécurité la documentation peut être consultée chez la compagnie susmentionnée.

Dokumentationsverantwortlicher: (technische Dokumentation)

Ing. Josef Feic Günter Fronius Straße 1 A - 4600 Wels-Thalheim

htinger

person responsible for documents: (technical documents)

Ing. Josef Feichtinger Günter Fronius Straße 1 A - 4600 Wels-Thalheim

responsable documentation: (technique documentation)

Ing. Josef Feichtinger Günter Fronius Straße 1 A - 4600 Wels-Thalheim

2016 ppa. Mag.Ing.H.Hackl

Member of Board Chief Technology Officer

DE German Deutsch EN English English FR French Française

Page 95

Page 96

FRONIUS INTERNATIONAL GMBH

Vorchdorfer Straße 40, A-4643 Pettenbach, Austria

E-Mail: sales@fronius.com

www.fronius.com

Under www.fronius.com/contact you will find the addresses

of all Fronius Sales & Service Partners and locations

Fronius Robacta Reamer Alu Edition, Robacta Reamer Alu 3000upm, Robacta Reamer Twin User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual