Operating
Instructions
Robacta Reamer Alu Edition
Robacta Reamer Alu 3000upm
Robacta Reamer Twin
Operating Instructions
EN
42,0426,0146,EN 019-03082022
Contents
Safety rules 6
Explanation of safety notices 6
General 6
Proper use 7
Environmental conditions 7
Obligations of the operator 7
Obligations of personnel 7
Specific hazards 7
Protecting yourself and others 8
EMC Device Classifications 8
EMC measures 9
EMF measures 9
Safety measures at the installation location and during transport 9
Safety measures in normal operation 10
Commissioning, maintenance and repair 10
Safety inspection 10
Disposal 11
Safety symbols 11
Copyright 11
General 13
General 15
Principle 15
Device concept 15
Application areas 15
Illustration of the various device types 16
Scope of supply and options 17
General 17
Robacta Reamer Alu Edition scope of supply 17
Robacta Reamer Alu Edition options 17
Robacta Reamer Alu 3000upm scope of supply 18
Robacta Reamer Alu 3000upm options 18
Robacta Reamer Twin scope of supply 18
Robacta Reamer Twin options 19
Warning notices on the device 20
Warning notices on the cleaning device 20
Transport 22
Transport devices 22
Transport notices on the packaging 22
EN
Controls, connections and mechanical components 23
Safety 25
Safety 25
Control elements, connections and mechanical components of the Robacta Reamer Alu Edition and Robacta Reamer Alu 3000upm
Control elements, connections and mechanical components 26
Robacta Reamer Twin control elements, connections and mechanical components 27
Control elements, connections and mechanical components 27
Harting Han6P connecting plug pin assignment (X1) for robot control 29
General 29
Harting Han6P connecting plug pin assignment (X1) 29
Installation and commissioning 31
Safety 33
Safety 33
Ensuring that the cleaning device is depressurised 34
Before commissioning 36
Proper use 36
26
3
Operators, maintenance personnel 36
Setup regulations 36
Compressed air supply specifications 36
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 39
Torch cleaning position 41
Welding torch cleaning position - Robacta Reamer Alu Edition 41
Welding torch cleaning position - Robacta Reamer Alu 3000upm 41
Welding torch cleaning position - Robacta Reamer Twin 41
Adjusting the gas nozzle clamping device on the Robacta Reamer Alu Edition and Robacta
Reamer Alu 3000upm
Adjusting the gas nozzle clamping device 42
Fitting the cleaning brush on the Robacta Reamer Alu Edition 43
Fitting the cleaning brush 43
Fitting the cleaning cutter on the Robacta Reamer Alu 3000upm 44
Fitting the cleaning cutter 44
Fitting the cleaning cutter on the Robacta Reamer Twin 45
Fitting the cleaning cutter 45
Adjusting the Robacta Reamer Alu Edition lifting device 46
Adjusting the lifting device 46
Adjusting the Robacta Reamer Alu 3000upm lifting device 47
Adjusting the lifting device 47
Adjusting the Robacta Reamer Twin lifting device 48
Adjusting the lifting device 48
Starting up the Robacta Reamer Twin parting agent nebuliser 49
Starting up the parting agent nebuliser 49
Correct adjustment of the parting agent spray nozzles on the Robacta Reamer Twin 50
Installing mechanically-controlled wire cutter on the Robacta Reamer Alu Edition and
Robacta Reamer Alu 3000upm (optional)
Installing the mechanically-controlled wire cutter 51
Installing the electrically-controlled wire cutter on the Robacta Reamer Alu Edition and
Robacta Reamer Alu 3000upm (optional)
Installing the electrically-controlled wire cutter 55
Wire cutter function 57
Maximum wire diameter 57
How the mechanically controlled wire cutter works 57
How the electrically-controlled wire cutter works 57
Installing the compressed air supply 58
Establishing the compressed air supply for the cleaning device, function of the com-
pressed air relief valve
Starting up the cleaning device 59
Prerequisites for start-up 59
Start-up 59
Programme sequence and signal waveform on the Robacta Reamer Alu Edition and Robacta
Reamer Alu 3000upm
Cleaning programme sequence 60
Signal waveform 62
Robacta Reamer Twin programme sequence and signal waveform 63
Cleaning programme sequence 63
Signal waveform 66
42
51
55
58
60
Care, maintenance and disposal 67
Safety 69
Safety 69
Ensuring that the cleaning device is depressurised 70
Care, maintenance and disposal 72
General 72
Before each start-up 72
Daily 72
Weekly 72
4
Every 6 months 72
As necessary 72
Disposal 72
Troubleshooting 73
Safety 75
Safety 75
Ensuring that the cleaning device is depressurised 76
Troubleshooting 78
Errors in program sequence 78
Technical data 81
Technical data 83
Robacta Reamer Alu Edition and Robacta Reamer Alu 3000upm 83
Robacta Reamer Twin 83
Appendix 85
EN
Circuit diagram Robacta Reamer, Robacta Reamer Alu Edition, Robacta Reamer Alu Edition
3000rpm
Circuit diagram Robacta Reamer Twin 88
Robacta Reamer Twin pneumatic diagram 89
Declarations of Conformity 90
87
5
Safety rules
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!
6
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.
EN
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
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.
7
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.
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
-
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 mechan-
-
ically-powered 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.
-
EMC Device
Classifications
8
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 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
-
EN
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.
9
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.
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.
-
10
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 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.
EN
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.
11
12
General
13
14
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 reaccumulation 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.
EN
Application
areas
For professional installation, a stable fitting base is available for all devices.
Devices from the Robacta Reamer series are intended exclusively for use in robot
and other 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.
15
Illustration of
the various
device types
Robacta Reamer Alu Edition, Robacta Reamer Alu 3000upm, Robacta Reamer Twin
16
Scope of supply and options
(1)
(2)
(3)
(4)
(5)
General The cleaning devices can be used in conjunction with various options. This makes
it possible to optimise various procedures in the welding process, as necessitated
by the particular field of application.
EN
Robacta Reamer
Alu Edition
scope of supply
NOTE!
The cleaning brush and adapter for
the cleaning brush are not included in
the scope of supply.
(1) Robacta Reamer Alu Edition
cleaning device
(2) Spatter tray retainer
(3) Spatter tray
(4) Tightening key for cleaning mo-
tor
(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 Edition options
Fitting base
-
Wire cutter
-
17
Robacta Reamer
(1)
(2)
(3)
(4)
(5)
((11))
((22))
((33))
((44))
((55))
Alu 3000upm
scope of supply
NOTE!
The cleaning cutter and adapter for
the cleaning cutter are not included in
the scope of supply.
(1) Robacta Reamer Alu 3000upm
cleaning device
(2) Spatter tray retainer
(3) Spatter tray
(4) Tightening key for cleaning mo-
tor
(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
-
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
device with wire cutter and
parting agent nebuliser
(2) Spatter tray retainer
(3) Spatter tray
(4) Tightening key for cleaning mo-
tor
(5) Compressed air relief valve
not shown:
(6) Harting Han6P connecting plug (X1) without cable
(7) Operating instructions
18
(8) Filling funnel for parting agent
(9) Fixings for assembling the cleaning device:
4 screws
-
4 washers
-
4 lock washers
-
4 nuts
-
EN
Robacta Reamer
Twin options
Fitting base
-
Cleaning cutter adjustment aid
-
Parting agent - spray unit
-
19
Warning notices on the device
Type
Art.No.
Chargen No.
U1
I1
Wels - Austria
p
max
24 V
0.25 A
6 bar (87PSI)
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.
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.
20
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
For indoor use only
Wear eye protection
Notice warning of automatic start-up of the device
EN
21
Transport
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.
▶
22
Controls, connections and mechan-
ical components
23
24
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
25
Control elements, connections and mechanical
(1)
(2)
(3)
(4)
(5)
(6)
(7)
components of the Robacta Reamer Alu Edition
and Robacta Reamer Alu 3000upm
Control elements, connections and mechanical components
Side view
(1) Compressed air connection
for a dry compressed air supply at 6 bar (86.99 psi)
Thread identification compressed air connection: G ¼“
(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
-
(4) Gas nozzle clamping device
holds the gas nozzle in place during cleaning
(5) Protective covering
Front view
26
(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
Robacta Reamer Twin control elements, connec-
(5)
(8)
(7)
(6)
(1)
(2)
(4)
(3)
tions and mechanical components
Control elements, connections and mechanical components
(1) Parting agent adjuster
for setting the spray amount on the parting agent spray nozzles
EN
(2) Compressed air connection
for a dry compressed air supply at 6 bar (86.99 psi)
Thread identification compressed air connection: G ¼“
(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
27
((1111))
(10)(10)
(9)(9)
((1111))
(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
28
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