Fronius Robacta Reamer Alu Edition/Alu Edition 3000rpm/Twin Operating Instruction [EN]

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Operating Instructions

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

Operating Instructions

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

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

Ensuring that the cleaning device is depressurised 34 Before commissioning 36

Proper use 36

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

Care, maintenance and disposal 67

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

Every 6 months 72

As necessary 72

Disposal 72

Troubleshooting 73

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

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

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!

Proper use The device is to be used exclusively for its intended purpose.

The device is intended solely for the mechanical cleaning of Fronius robot welding torches in automatic mode. Any use above and beyond this purpose is deemed improper. The manufacturer shall not be held liable for any damage arising from such usage.

Proper use includes:

carefully reading these operating instructions

following all the instructions and safety rules in these operating instructions

performing all stipulated inspection and maintenance work

The device is designed for use in industry and the workshop. The manufacturer accepts no responsibility for any damage caused through use in a domestic setting.

The manufacturer likewise accepts no liability for inadequate or incorrect results.

Environmental conditions

Obligations of the operator

Operation or storage of the device outside the stipulated area will be deemed as not in accordance with the intended purpose. The manufacturer shall not be held liable for any damage arising from such usage.

Ambient temperature range:

during operation: 0 °C to + 40 °C (32 °F to 104 °F)

during transport and storage: -25 °C to +55 °C (-13 °F to 131 °F)

Relative humidity:

up to 50 % at 40 °C (104 °F)

up to 90 % at 20 °C (68 °F)

Keep ambient air free from dust, acids, corrosive gases and substances, etc.

Can be used at altitudes of up to 2000 m (6500 ft)

The operator must only allow persons to work with the device who:

are familiar with the fundamental instructions regarding safety at work and

accident prevention and have been instructed in how to use the device have read and understood these operating instructions, especially the sec-

tion "safety rules", and have confirmed as much with their signatures are trained to produce the required results.

Checks must be carried out at regular intervals to ensure that operators are working in a safety-conscious manner.

Obligations of personnel

Specific hazards

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

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

vention to read these operating instructions, especially the "Safety rules" section and

sign to confirm that they have understood them and will follow them.

Before leaving the workplace, ensure that people or property cannot come to any harm in your absence.

Stay out of the working area of the robot.

The device must be incorporated into a higher-level safety system within a secured area.

If this area has to be accessed when setup and maintenance work is carried out, make sure that

the entire system is switched off for the duration of the work in this area

and that it is prevented from starting up accidentally, e.g. as the result of a

control fault.

If untrained operators have access to the device, its compressed air supply must be disconnected for the duration of work in accordance with "Performance Level d" of the ISO 13849-1 standard.

In addition to these operating instructions, the safety rules issued by the robot manufacturer must also be observed.

Keep your body, especially your hands, face, hair, clothing and all tools away from moving parts, such as:

rotating cleaning cutter / 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

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

Shield, if necessary

4. Shield off other nearby devices

Shield off entire welding installation

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

Effects on the health of persons in the vicinity, e.g. those with pacemakers

and hearing aids Individuals with pacemakers must seek advice from their doctor before ap-

proaching the device or any welding that is in progress For safety reasons, maintain as large a distance as possible between the

welding power-leads and the head/torso of the welder Do not carry welding power-leads and hosepacks over the shoulders or wind

them around any part of the body

Safety measures at the installation location and during transport

A device toppling over could easily kill someone. Place the device horizontally on a level, firm and solid surface and anchor it securely to prevent it toppling over.

Special regulations apply in rooms at risk of fire or explosion

Observe relevant national and international regulations.

Use internal directives and checks to ensure that the workplace environment is always clean and clearly laid out.

When transporting the device, observe the relevant national and local guidelines and accident prevention regulations. This applies especially to guidelines regarding the risks arising during transport.

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.

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.

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.

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.

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.

Illustration of the various device types

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

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.

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

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

(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

Warning notices on the device

Type

Art.No.

Chargen No.

Wels - Austria

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.

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

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.

▶

Controls, connections and mechan-

ical components

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

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

(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

(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

((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

Harting Han6P connecting plug pin assignment

5 4

(X1) for robot control

General

Danger from overcurrent.

Damage to the Harting Han6P connection supply may result.

▶

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 included in 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)

CAUTION!

Secure the power supply of the cleaning device against overcurrent with a 500 mA slow-blow fuse.

NOTE!

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

Start cleaning input signal (clean-

ing motor ON, lifting device UP, compressed air supply to cleaning nozzles ON) Not assigned

GND

+ 24 V DC

Gas nozzle free output signal

Earthing

(see circuit diagrams in appendix)

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

Installation and commissioning

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 injec-

▶

tion nozzles Before performing work on the cleaning device or any connected system

▶

components: disconnect the customer compressed air and power supplies from the clean-

▶

ing device and the connected system components, and ensure that they remain disconnected until 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 injec-

▶

tion nozzles

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 supply

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

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

WARNING!

Risk of machines starting automatically.

This can result in serious injury and damage to property.

The device must only be used by 1 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. The device must only be serviced by 1 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.

The cleaning device is tested to protection class IP 21, meaning:

Protection against penetration by solid foreign bodies with diameters > 12.5

mm (0.49 in.) No protection against the ingress of water

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

WARNING!

Compressed air supply specifications

Danger from machines falling or toppling over.

This can result in serious injury and damage to property.

Always secure the cleaning device to the underlying surface.

▶

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

Measures for the safe operation of the device with untrained personnel

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.

Screwing the cleaning device to the underlying surface

Screwing the cleaning device and installation stand to the underlying surface

WARNING!

Danger from machines falling or toppling over.

This can result in serious injury and damage to property.

Always secure the installation stand to the underlying surface.

▶

The screws for fastening the installation stand are not included in the scope

▶

of supply of the installation stand. The installer is responsible for selecting the right type of screws or bolts. Always secure the cleaning device to the installation stand.

▶

Place the optionally available in-

stallation stand on a level, firm and vibration-free surface (foundation)

Position the installation stand

in such a way that the distance the robot has to travel to the cleaning device on the installation stand is as short as possible

Tightly screw the installation stand

to the surface (foundation) using the selected mounting materials

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

Place components on the installation stand and secure

Attach the spatter tray retainer as shown

Screwing the cleaning device to the underlying surface

WARNING!

Danger from machines falling or toppling over.

This can result in serious injury and damage to property.

Always secure the cleaning device to the underlying surface.

▶

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

▶

ings supplied with the cleaning device for fastening. If the underlying surface thickness is greater than 5 mm (0.197 in.), do not

▶

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

Place the cleaning device and the spatter tray retainer on a level, firm and vi-

bration-free 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.

Place components on the underlying surface and secure

Attach the spatter tray retainer as shown

Torch cleaning position

228800 mmmm ((1111..0022 iinn..))

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

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

Welding torch cleaning position

- Robacta Reamer Alu Edition

Welding torch cleaning position

- Robacta Reamer Alu 3000upm

Welding torch cleaning position

- Robacta Reamer Twin

NOTE!

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

Adjusting the gas nozzle clamping device on the

(1)

(3)

(2) (4)

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), posi-

tion 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.

Fitting the cleaning brush on the Robacta Reamer Alu Edition

Fitting the cleaning brush

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).

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.

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.

CAUTION!

NOTE!

Remove the protective covering from the cleaning device

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

Fitting the cleaning cutter on the Robacta Reamer Alu 3000upm

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 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.

Remove the protective covering from the cleaning device

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

Fitting the cleaning cutter on the Robacta Reamer Twin

Fitting the cleaning cutter

CAUTION!

Danger due to cleaning cutter that has become very hot through use.

This can result in severe burns.

Before handling cleaning cutters, allow cleaning cutter to cool to room tem-

▶

perature (+25 °C, +77 °F).

CAUTION!

Danger from incompatible wearing parts.

This can result in damage to property and malfunctions.

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

▶

cutters. No liability is accepted for damage caused by the use of contact tips, gas nozzles or cleaning cutters from third-party manufacturers.

The cleaning cutter is not part of the scope of suppl.. Consult the manufacturer's spare parts list for the appropriate cleaning cutter: https://spareparts.froni-

us.com/

Remove the protective covering from the cleaning device

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

Adjusting the Robacta Reamer Alu Edition lifting

(1)(1)

(2)(2)

(4)(4)(4)(4)

(2)(2)(2)(2)

(5)(5)(5)(5)

(3)(3)(3)(3)

(6)(6)(6)(6)

1/31/31/31/3

2/32/32/32/3

device

Adjusting the lifting device

Remove protective covering (1)

Ensure that the lifting device is in

its lowest 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 brush to the cleaning posi-

tion

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

Adjusting the Robacta Reamer Alu 3000upm lift-

(4)(4)

(2)(2)

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

(3)(3)

ing device

Adjusting the lifting device

Remove protective covering (1)

Remove gas nozzle from torch

neck

Ensure that the lifting device is in

its lowest 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

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

Adjusting the Robacta Reamer Twin lifting device

(1)(1)

(2)(2)

(3)(3)

(5)(5)(5)

(4)(4)(4)

000

,,,

555

---

111

mmm

...

000

222

---

...

000

444

iii

nnn

...

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

An adjustment aid is not necessary when the gas nozzle is open, as the welding torch is clamped above the gas nozzle. The gas nozzle can be removed beforehand. The bracket must be back in the starting position. When the gas nozzle is mounted, the bracket must be closed.

Remove the protective cover (1)

Ensure that the lifting device is in

its lowest lift position

Loosen the screw (2) on the lifting

device

Move the welding torch to the

cleaning position (including fitted adjustment aid)

Push the lifting device (3) by hand

into its highest lift position and hold in place

Push the cleaning motor (4) and

cleaning cutter by hand into the cleaning position (5)

NOTE!

The cleaning cutter must not touch any welding torch components.

Fix the cleaning motor (4) in this

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

Fit the protective cover to the

cleaning device in its original position

Starting up the Robacta Reamer Twin parting

321

(1)

(4) (3)

(2)

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

▶

screwdriver 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

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.

Installing mechanically-controlled wire cutter on

(1)(2)

(3)

(4)

(3)

the Robacta Reamer Alu Edition and Robacta Reamer Alu 3000upm (optional)

Installing the mechanicallycontrolled 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

cover (4)

(5)

Remove screw (5)

(6) (6)

(6)

Undo screws and washers (6)

Keep the screws and washers

for future use

Screw the wire cutter to the clean-

ing device using the previously removed screws and washers (6)

(7)

Cut through the compressed air

(9)

(8)

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

Detach compressed air connection

(8) from compressed air connection (9)

(11)

(12) (13)

(10)

(9)

(8)

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

Installing the electrically-controlled wire cutter

(1)(2)

(3)

(4)

(3)

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

cover (4)

(5) (5)

Undo screws and washers (5)

(5)

Keep the screws and washers

for future use

Screw the wire cutter to the clean-

ing 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.

Wire cutter function

(1)

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.

NOTE!

If you change over to a new welding torch, the mechanically controlled wire cutter must be reset!

If a torch body pushes the valve lever (1) to the side by more than 15° with the gas nozzle, the wire cutter is activated and the wire electrode is cut.

NOTE!

The wire electrode is cut while the torch body 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.

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 en-

sure 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 con-

nection on the cleaning device

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

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

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

Compressed air relief valve closed

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

Compressed air relief valve open

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 con-

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

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

face 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

trol.

Programme sequence and signal waveform on the

Pos. C

Pos. D

Robacta Reamer Alu Edition and Robacta Reamer Alu 3000upm

Cleaning programme sequence

- approx. 25 mm (0.98 in.) next to wire cutter

Start from position C

- Speed: high speed mode

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!

Start

Wire cutter option

- approx. 25 mm (0.98 in.) Enter wire cutter

Start from position D

- Speed: 10 cm/s (236.22 ipm)

Wait 0.5 sec.

Pos. A

Pos. B

Start from position A

- approx. 50 mm (1.97 in.) above centre of cleaning motor

- Speed: high speed mode

Query output (Gas nozzle free output sig-

nal)

Query = Low

(Gas nozzle clamped)

- Low or High

Query = High

Stop

(Gas nozzle free)

Start from position B (cleaning position)

- Enter gas nozzle clamping device

- Speed: 10 cm/s (236.22 ipm)

Set

- Blow compressed air through welding torch

Set

- Input "Begin cleaning"

Wait 3 sec.

Reset

- Input "Begin cleaning"

Reset

- Blow compressed air through welding torch

Wait 1.5 sec.

Pos. A

(1)

(2)

(3)

(4)

Query output (Gas nozzle free output sig-

nal)

- Low or High

Query = Low

(Gas nozzle clamped)

Query = High

(Gas nozzle free)

Start from position A

- approx. 50 mm (1.97 in.) above centre of cleaning device

- Speed: 10 cm/s (236.22 ipm)

End

Signal waveform

Stop

No. Meaning

(1) Input "Begin cleaning"

(2) Output "Gas nozzle free"

(3) Gas nozzle free

(4) Cleaning time: 3.0 - 5.0 seconds

Robacta Reamer Twin programme sequence and

Pos. A

Pos. B

signal waveform

Cleaning programme sequence

- approx. 25 mm (0.98 in.) next to wire cutter

Start from position A

- Speed: high speed mode

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!

Start

- approx. 25 mm (0.98 in.) Enter wire cutter

- The wire cutter is actuated by the valve

Start from position B

- Speed: 10 cm/s (236.22 ipm)

lever of the wire cutter

Wait 0.5 sec.

Pos. C

Pos. D

Start from position C

- approx. 50 mm (1.97 in.) above centre of cleaning device

- Speed: high speed mode

Query output (Gas nozzle free output sig-

nal)

Query = Low

(Gas nozzle clamped)

- Low or High

Query = High

(Gas nozzle free)

Reset

- Input "Begin cleaning"

Query output (Gas nozzle free output sig-

nal)

- Low or High

Query = High

(Gas nozzle free)

Query = Low

(Gas nozzle

clamped)

Stop

Start from position D (cleaning position)

- Enter gas nozzle clamping device

- Speed: 10 cm/s (236.22 ipm)

Reset

- Blow compressed air through welding torch

Set

- Input "Begin cleaning"

Cleaning procedure

Input "Begin cleaning"

Gas nozzle clamping device clamps the gas nozzle

Cleaning cutter cleans the first side of the welding torch for approx. 3 sec.

Cleaning motor moves to the starting position

Gas nozzle clamping device opens for approx. 0.5 sec. to allow the cleaning motor to move

to the second side of the welding torch Gas nozzle clamping device clamps the gas nozzle again

Cleaning cutter cleans the second side of the welding torch for approx. 3 sec.

Cleaning motor moves to the starting position

Gas nozzle clamping device opens for approx. 0.5 sec. to allow the cleaning motor to move

to the first side of the welding torch - at this time the "Begin cleaning" signal must be reset

- Input "Begin cleaning"

- Blow compressed air through welding

Query output (Gas nozzle free output sig-

Wait 7 sec.

Reset

torch

Wait 1.5 sec.

nal)

- Low or High

Query = High

(Gas nozzle free)

Query = Low

(Gas nozzle clamped)

- Input "Begin cleaning"

Reset

Query output (Gas nozzle free output sig-

nal)

- Low or High

Query = High

(Gas nozzle free)

Query = Low

(Gas nozzle

clamped)

Stop

Pos. C

(1)

(2)

(3) (4)

(5)

Start from position C

- approx. 50 mm (1.97 in.) above centre of cleaning device

- Speed: 10 cm/s (236.22 ipm)

Signal waveform

End

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

Care, maintenance and disposal

Safety

Safety Observe the following safety rules for all work described in the "Care, mainten-

ance and disposal" section.

WARNING!

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

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.

WARNING!

Risk of serious injury from:

mechanically powered parts

▶

ﬂying parts (shavings, etc.)

▶

compressed air/parting agent mixture escaping from the parting-agent injec-

▶

tion nozzles Before performing work on the cleaning device or any connected system

▶

components: disconnect the customer compressed air and power supplies from the clean-

▶

ing device and the connected system components, and ensure that they remain disconnected until 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 injec-

▶

tion nozzles

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

▶

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:

The cleaning cutter / cleaning brush, lifting device, gas nozzle clamping

wear protective goggles with side protection

Ensure that the cleaning device has been disconnected from the compressed

air supply

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

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

Care, maintenance and disposal

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

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

Before each start-up

Daily

Weekly

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 neces-

sary Empty the cleaning device spatter tray

If fitted, empty the wire cutter tray

Perform a general visual inspection on the device

CAUTION!

Danger from cleaning agents containing solvents.

This can result in damage to property.

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 com-

pressed air from the inside outwards through the suction hose (see "Starting up the Robacta Reamer Twin parting agent nebuliser")

Every 6 months

As necessary Open the device and

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

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

Clean inside of device using dry reduced compressed air

Lightly oil the lifting device cylinder guides

Restore the original condition of the device

Troubleshooting

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.

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.

WARNING!

Risk of serious injury from:

mechanically powered parts

▶

ﬂying parts (shavings, etc.)

▶

compressed air/parting agent mixture escaping from the parting-agent injec-

▶

tion nozzles Before performing work on the cleaning device or any connected system

▶

components: disconnect the customer compressed air and power supplies from the clean-

▶

ing device and the connected system components, and ensure that they remain disconnected until 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 injec-

▶

tion nozzles

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

▶

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:

The cleaning cutter / cleaning brush, lifting device, gas nozzle clamping

wear protective goggles with side protection

Ensure that the cleaning device has been disconnected from the compressed

air supply

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

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

Troubleshooting

Errors in program sequence

Parting agent does not spray (Robacta Reamer Twin only)

Parting agent container is full

Cause: Remedy:

Welding torch is poorly cleaned or damaged

Cause: Remedy:

Not enough spray Adjust spray amount

Parting agent spray nozzles are blocked Clean parting agent spray nozzles

If cleaning does not rectify problem, contact After-Sales Service replace parting agent spray nozzles

No signal from robot Check connection to robot control

Lifting device not adjusted properly Adjust lifting device

Gas nozzle clamped in wrong position (not on Robacta Reamer Twin) Adjust gas nozzle clamping device (not on Robacta Reamer Twin)

Cleaning cutter / cleaning brush not suited to welding torch shape Fit the correct cleaning cutter / fit correct cleaning brush

Cause: Remedy:

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

Cause: Remedy:

Lifting device is not moving up or down

Cause: Remedy:

Cleaning cutter / cleaning brush worn Replace cleaning cutter / cleaning brush

Incorrect swivel mechanism stop angle Contact After-Sales Service - Adjust the swivel mechanism stop

angle

Compressed air relief valve closed Open compressed air relief valve

No signal from robot Check connection to robot control

Faulty sealing in lifting cylinder Contact After-Sales Service - replace lifting cylinder

Cleaning motor does not work

Cause: Remedy:

Compressed air relief valve closed Open compressed air relief valve

Cause: Remedy:

No signal from robot Check connection to robot control

Mechanical fault on cleaning motor Contact After-Sales Service - replace cleaning motor

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

Thread identification compressed air connection

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

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

G ¼“

mA Output: + 24 V DC / max. 30 mA

6.69 x 6.50 x 11.02 in.

Robacta Reamer Twin

Weight (without optional wire cutter)

Supply voltage + 24 V DC

Nominal output 6 W

Nominal pressure 6 bar

Air consumption 420 l/min

Thread identification compressed air connection

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

Cleaning time 7.0 - 7.5 s

Total cycle time 8.5 - 10 s

9 kg

19.84 lb.

86.99 psi

443.81 qt./min

G ¼“

mA Output: + 24 V DC / max. 30 mA

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.

Appendix

Circuit diagram Robacta Reamer, Robacta Reamer Alu Edition, Robacta Reamer Alu Edition 3000rpm

Circuit diagram Robacta Reamer Twin

motor right

-X1

-1V1

-1S1

- BLUE -

- BROWN -

- BLACK -

input start cleaning

GND 0VDC

+24V

output gas nozzle free

motor left

-X2

3456789

- BLUE -

- BROWN -

- BLACK -

-1S2

- BLUE -

- BROWN -

- BLACK -

-3S1

-K1

-S1

2 4

-2S2

-2S1

motor right clamping device

manual cleaning

motor up

motor down

- BLUE -

- BROWN -

- BLACK -

- BLUE -

- BROWN -

- BLUE -

- BROWN -

- BLUE -

- BLACK -

- BLUE -

- BROWN -

- BLACK -

- BLUE -

-1V2

-2V1

motor left motor up/down

Robacta Reamer Twin pneumatic diagram

-3X1

-2V3

6bar/87psi

-0X1

-3A2

-2V2

-2V1

-0V1

1 3

-4A1

-4V1

1 3

4 2

tappet valve is

operated if cleaning

motor is lowered

-3V2

1 3

-0X1.....compressed air connector

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

-1V1.....solenoid valve

-1V2.....choke fla p valve -3A2.....pne umatic motor

-3V2.....signal int erupter-2V1.....solenoid va lve

-2A1.....sliding un it

-4V1.....lever valve

-3Z1.....oiler

-3A1.....cylinder 32 mm

1 3

-1V3

-1A1

-1V2

-3V1

-1V1

4 2

3 5

4 2

3 5

-3Z1

-3X2

-3A1

-2A1

MOTOR

LEFT / RIGHT

MOTOR

UP / DOWN

SPRAYING

GAS NOZZLE CLAMP MOTOR

WIRE CUTTER

-1S1

-1S2

-2S1

-2S2

-3S1

-1V3.....choke flap valve

-1A1.....cylinder 25 mm

-2V2.....choke flap valve

-2V3.....choke flap valve

-3X1.....spraying nozzle

-3V1.....trapped valve

-3X2.....spraying nozzle

-4A1.....cylinder 63 mm

Declarations of Conformity

DE German Deutsch EN English English FR French Française

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

Wels-Thalheim, 2016-07-07

eingapmoc aLrerutcafunaMamriF eiD

FRONIUS INTERNATIONAL GMBH

Froniusstaße 1, A-4643 Pettenbach

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.

Dokumentationsverantwortlicher: (technische Dokumentation)

Ing. Josef Fe

ichtinger Günter Fronius Straße 1 A - 4600 Wels-Thalheim

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.

person responsible for documents: (technical documents)

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

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.

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

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

Wels-Thalheim, 2016-07-07

eingapmoc aLrerutcafunaMamriF eiD

FRONIUS INTERNATIONAL GMBH

Froniusstaße 1, A-4643 Pettenbach

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.

Dokumentationsverantwortlicher: (technische Dokumentation)

Ing. Josef Feic

htinger Günter Fronius Straße 1 A - 4600 Wels-Thalheim

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.

person responsible for documents: (technical documents)

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

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.

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

Fronius International GmbH

Froniusstraße 1

4643 Pettenbach

Austria

contact@fronius.com

www.fronius.com

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

of all Fronius Sales & Service Partners and locations.

spareparts.fronius.com

SPAREPARTS

ONLINE

Fronius Robacta Reamer Alu Edition/Alu Edition 3000rpm/Twin Operating Instruction [EN]

Specifications and Main Features

Frequently Asked Questions

User Manual