Fronius Robacta Reamer brush head for aluminium applications Operating Instruction [EN]

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Operating Instructions

Robacta Reamer brush head for aluminium applications

Operating Instructions

42,0426,0100,EN 022-03082022

Contents

Safety rules 6

General 6 Proper use 6 Environmental conditions 6 Obligations of the operator 7 Obligations of personnel 7 Specific hazards 7 Protecting yourself and others 8 EMC Device Classifications 8 EMC measures 8 EMF measures 9 Safety measures at the installation location and during transport 9 Safety measures in normal operation 9 Commissioning, maintenance and repair 10 Safety inspection 10 Disposal 10 Safety symbols 11 Copyright 11

General 13

General 15

General 15 Device concept 15 Application areas 15 Scope of supply 16 Options 16 Warning notices on the cleaning device 16

Transport 18

Transport devices 18 Transport notices on the packaging 18

Controls, connections and mechanical components 19

Safety 21

Controls, connections and mechanical components 22

Control elements, connections and mechanical components 22

Harting Han6P connecting plug pin assignment (X1) for robot control 24

General 24 Harting Han6P connecting plug pin assignment (X1) 24

Installation and commissioning 25

Safety 27

Safety 27 Ensuring that the cleaning device is depressurised 28

Before commissioning 29

Proper use 29 Operators, maintenance personnel 29 Setup regulations 29 Compressed air supply specifications 29 Measures for the safe operation of the device with untrained personnel 30

Screwing the cleaning device to the underlying surface 31

Screwing the cleaning device and installation stand to the underlying surface 31 Screwing the cleaning device to the underlying surface 32

Adjusting and fitting the standard brush head 34

General 34 Adjusting the brush head 34 Fitting the brush head 35

Adjusting and fitting the Braze+ brush head 36

General 36 Adjusting the brush head 36 Fitting the brush head 37

Torch cleaning position 38

Cleaning position of the welding torch - standard brush head 38 Cleaning position of the welding torch - Braze+ brush head 38

Adjusting the position of the cleaning motor (with standard brush head) 39

Adjusting the position of the cleaning motor 39

Adjusting the position of the cleaning motor (with Braze+ brush head) 40

Adjusting the position of the cleaning motor 40

Installation and function of mechanically-controlled wire cutter (option) 41

How the mechanically controlled wire cutter works 41 Maximum wire diameter 41 Installing the mechanically-controlled wire cutter 41

Installation and function of electrically-controlled wire cutter (option) 43

How the electrically-controlled wire cutter works 43 Maximum wire diameter 43 Installing the electrically-controlled wire cutter 43

Installing the compressed air supply 44

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

Manually checking the cleaning device functions 45

Safety 45 Checking functions manually 45

Starting up the cleaning device 46

Prerequisites for start-up 46 Start-up 46

Cleaning program and signals 47

Sicherheit 47 Cleaning program sequence 48 Signal inputs and outputs 50

Care, maintenance and disposal 51

Safety 53

Safety 53 Ensuring that the cleaning device is depressurised 54

Care, maintenance and disposal 55

General 55 Before each start-up 55 Daily 55 Every 6 months 55 As necessary 55 Changing the end brushes (standard brush head only) 55 Changing the round brush 56 Changing the diagonal brushes 56 Disposal 57

Troubleshooting 59

Safety 61

Safety 61 Ensuring that the cleaning device is depressurised 62

Troubleshooting 63

Errors in program sequence 63

Technical data 65

Technical data 67

Robacta Reamer brush head for aluminium applications 67

Appendix 69

Circuit diagram: Robacta Reamer brush head for aluminium applications 71

Pneumatics diagram of Robacta Reamer brush head for aluminium applications 72 Circuit diagram: Wire cutter 73 Declaration of conformity 74

Safety rules

General The device is manufactured using state-of-the-art technology and according to

recognised safety standards. If used incorrectly or misused, however, it can cause:

injury or death to the operator or a third party,

damage to the device and other material assets belonging to the operating

company, inefficient operation of the device.

All persons involved in commissioning, operating, maintaining and servicing the device must:

be suitably qualified,

have sufficient knowledge of automated welding, and

read and carefully follow these operating instructions as well as the 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

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)

Obligations of the operator

Obligations of personnel

Specific hazards Stay out of the working area of the robot.

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.

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.

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 brush head

lifting device moving up/down

wire cutter

Protect hands, face and eyes against ﬂying parts (shavings, etc.) and compressed air escaping from the cleaning 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

Protecting yourself and others

EMC Device Classifications

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 brush head, ﬂying shavings and similar matter, escaping compressed air, ﬂying sparks, dazzling by arc, inhaling of harmful welding fumes, noise, possible danger from mains or welding current, etc.), provide suitable protective equipment or

erect suitable safety screens/curtains.

Devices in emission class A:

Are only designed for use in industrial settings

Can cause line-bound and radiated interference in other areas

Devices in emission class B:

Satisfy the emissions criteria for residential and industrial areas. This is also

true for residential areas in which the energy is supplied from the public 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

Safety measures in normal operation

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

Special regulations apply in rooms at risk of fire or explosion

Observe relevant national and international regulations.

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

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

After transporting the device, it must be visually inspected for damage before commissioning. Any damage must be repaired by trained service technicians before commissioning the device.

Only operate the device if all safety devices are fully functional. If the safety devices are not fully functional, there is a risk of

injury or death to the operator or a third party,

damage to the device and other material assets belonging to the operator,

inefficient operation of the device.

Any safety devices that are not functioning properly must be repaired before switching on the device.

Never bypass or disable safety devices.

Before switching on the device, ensure that no one is likely to be endangered.

Check the device at least once a week for obvious damage and proper functioning of safety devices.

Only use suitable original parting agent from the manufacturer.

Observe the information on the parting agent safety data sheet when 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 low-voltage

and electromagnetic compatibility directives (e.g. relevant product standards of the EN 60 974 series).

Fronius International GmbH hereby declares that the device is compliant with Directive 2014/53/EU. The full text on the EU Declaration of Conformity can be found at the following address: http://www.fronius.com

Devices marked with the CSA test mark satisfy the requirements of the relevant standards for 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

General The cleaning device automatically

cleans MIG/MAG welding torches, which are used to weld aluminium materials. This device allows you to clean the inside, front and outside of the gas nozzle across a wide range of torch geometries. The result is a significant increase in the service life of wearing parts.

Device concept A brush head is used to clean the welding torch. The brush head is equipped with

different brush types, giving optimal cleaning results. All brushes can be replaced without the need for any tools.

Application areas

Welding residues are blown away from the welding torch and brush head by two cleaning nozzles.

A stable installation stand is available for the cleaning device.

The cleaning device is ideal for use in robot and other automated applications.

The main application areas are:

Automobile and component supply industry

Equipment construction

Chemical plant construction

Machine and tracked vehicle manufacturing

Construction machinery and special vehicles

Scope of supply

(1)

(2)

(3) (4)

(5)

NOTE!

The brush head is not part of the scope of supply.

(1) Robacta Reamer brush head

cleaning device for aluminium

applications (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

Options The following options are available for the cleaning device:

Installation stand

Wire cutter

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.

Type

Art.No.

Chargen No.

Wels - Austria

max

24 V

0.13 A

6 bar (87PSI)

Warning notices on the cleaning device

WARNING! Risk of serious injury from:

mechanically powered parts

compressed air escaping from the cleaning 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

Controls, connections and mechanical compon-

(1)

(2)

(3)

(4)

(6)

(5)

(7)

(8)

ents

Control elements, connections and mechanical components

Side view

No. Function

(1) 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.

(2) Compressed air connection

for a dry compressed air supply at 6 bar (86.99 psi) Thread identification compressed air connection: G ¼ ″ For more details on compressed air conditions, see section Compressed

air supply specifications on page 29

(3) "Cleaning" screw

for manually checking the following functions:

Cleaning motor ON/OFF

Supply of compressed air to the cleaning nozzles (compressed air

emerges from cleaning nozzles) Lifting device UP/DOWN

Front view

(4) Protective covering

(5) Cleaning nozzles

for cleaning the brush head and welding torch using compressed air

(6) Compressed air connection for the wire cutter option

(7) Lifting device

lifts the cleaning motor with the brush head to the cleaning position ready to commence cleaning

(8) Cleaning motor

drives the brush head

Harting Han6P connecting plug pin assignment

5 4

(X1) for robot control

General

Harting Han6P connecting plug pin assignment (X1)

CAUTION!

Danger from overcurrent.

Damage to the Harting Han6P connection supply may result.

Secure the power supply of the cleaning device against overcurrent with a

▶

500 mA slow-blow fuse.

NOTE!

To avoid malfunction, keep the cable length between the cleaning device and robot control as short as possible.

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

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

Cleaning motor DOWN output sig-

nal 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 poorly executed work 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 manufacturer of the robot and welding system 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 components

▶

ﬂying parts (shavings, etc.)

▶

compressed air escaping from the cleaning nozzles

▶

Before performing work on the cleaning device or any connected system

▶

components: disconnect the customer's compressed air and power supplies from the

▶

cleaning 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 brush head

▶

lifting device moving up/down

▶

activated wire cutter

▶

ﬂying parts (shavings, etc.)

▶

compressed air escaping from the cleaning 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, tools and all clothing away

▶

from the brush head, brush head lifting device, wire cutter and cleaning 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 brush head, brush head lifting device, wire cutter and cleaning

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

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

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

Adjusting and fitting the standard brush head

General

NOTE!

The following information applies to the use of the manufacturer's contact tips, gas nozzles and brush head.

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

The brush head has two different settings (A and B) to modify the distance between the diagonal brushes according to the type of gas nozzle being used.

Adjusting the brush head

NOTE!

The following list of settings is intended as a guide only.

Setting A for: standard gas nozzles with an outer diameter up to 23 mm (0.91 inch)

Setting B for: standard gas nozzles with an outer diameter from 24 mm (0.95 inch) upwards

Adjust the brush head as follows:

1 2

Fitting the brush head

Remove the protective covering from the cleaning device

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

Adjusting and fitting the Braze+ brush head

General

NOTE!

The following information applies to the use of the manufacturer's contact tips, gas nozzles and brush head.

The brush head has two different settings (A and B) to modify the distance between the diagonal brushes according to the type of gas nozzle being used.

Adjusting the brush head

Adjust the brush head as follows:

1 2

Fitting the brush head

Remove the protective covering from the cleaning device

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

Torch cleaning position

45 mm

1.77 inch

Cleaning position of the welding torch standard brush head

Cleaning position of the welding torch - Braze + brush head

End of gas nozzle is approx. 45

mm (1.77 in.) beneath upper edge of cleaning device housing, positioned centrally with respect to the cleaning motor

End of gas nozzle is approx. 90

mm (3.54 in.) beneath upper edge of cleaning device housing, positioned centrally with respect to the cleaning motor

Adjusting the position of the cleaning motor (with

(5)

(6)

(2)

(1)

(3)

(4)

standard brush head)

Adjusting the position of the cleaning motor

Remove the protective covering from the cleaning device

Ensure that the lifting device (1) is in its lowest position

Move the welding torch to the cleaning position

Remove the gas nozzle from the torch body

Loosen screw (2) on the lifting

device (1)

Manually push the lifting device (1)

into its highest lift position and hold in place

Manually push the cleaning motor

(3) and brush head (4) into the cleaning position

see diagram (5) for welding

torch with spatter guard see diagram (6) for welding

torch with insulating sleeve

Fix the cleaning motor (3) in this position in the lifting device (1) - tighten the

screw (2) on the lifting device (1)

Fit the gas nozzle to the torch body

Press brush head together and pull off bracket

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

Adjusting the position of the cleaning motor (with

(2)

(1)

(3)

(4)

Braze+ brush head)

Adjusting the position of the cleaning motor

Remove the protective covering from the cleaning device

Ensure that the lifting device (1) is in its lowest position

Move the welding torch to the cleaning position

Loosen screw (2) on the lifting

device (1)

Manually push the lifting device (1)

into its highest lift position and hold in place

Manually push the cleaning motor

(3) and brush head (4) into the cleaning position

Fix the cleaning motor (3) in this position in the lifting device (1) - tighten the

screw (2) on the lifting device (1)

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

Installation and function of mechanically-con-

(1)

trolled wire cutter (option)

How the mechanically controlled wire cutter works

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.

Maximum wire diameter

Installing the mechanicallycontrolled wire cutter

Wire electrodes with a diameter of up to 1.6 mm (0.063 in.) can be cut by the wire cutter.

NOTE!

Use the fixings supplied with the wire cutter for the assembly shown.

NOTE!

Use the fixings supplied with the wire cutter for the assembly shown.

* Use a suitable adapter to con-

nect the wire cutter com-

pressed air hose to the cleaning

device.

Installation and function of electrically-con-

trolled wire cutter (option)

How the electrically-controlled wire cutter works

Maximum wire diameter

Installing the electrically-controlled wire cutter

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

Wire electrodes with a diameter of up to 1.6 mm (0.063 in.) can be cut by the wire cutter.

NOTE!

Use the fixings supplied with the wire cutter for the work described below.

Ensure that the recesses in the spacers face the cleaning device.

* Use supplied adapter to con-

nect the wire cutter com-

pressed air hose to the cleaning

device.

NOTE!

The wire cutter must be controlled electrically by the robot control.

Installing the compressed air supply

(1)

(3)

(2)

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

Function of the compressed air relief valve

To establish the compressed air sup-

ply:

Depressurise the compressed air

supply line (1) and ensure that it remains depressurised for the duration of the work on the device

Screw the supplied compressed

air relief valve tightly to the compressed air connection on the cleaning device

Connect the compressed air sup-

ply line (1) to the compressed air relief valve

Function of the compressed air relief valve:

Valve open (2):

compressed air is being supplied Valve closed (3):

compressed air is not being supplied

Manually checking the cleaning device functions

Safety

Checking functions manually

WARNING!

For the following tasks, the cleaning device must be supplied with compressed air. This results in danger from the rotating cleaning cutter, cleaning motor moving up/down, gas nozzle clamping device moving out/in, ﬂying parts (chips, etc.), compressed air/parting agent mixture escaping from the parting-agent injection nozzle.

This can result in serious injury and damage to property.

Keep your body, especially your hands, face, hair, any objects and all clothing

▶

awayfrom the cleaning cutter, cleaning motor, lifting device, gas nozzle clamping device,wire cutter and parting-agent injection nozzle.. Wear ear protection!

▶

Wear protective goggles with side protection.

▶

NOTE!

Functions are deactivated if the slot on the "Cleaning" screw is horizontal.

The following must be checked when the functions are being performed:

function of the cleaning motor (cleaning motor OFF/ON)

correct setting of the cleaning motor (lifting device moves UP/DOWN)

Standard brush head: for more details, see section Adjusting the posi-

tion of the cleaning motor (with standard brush head) from page 39

Braze+ brush head: for more details, see section Adjusting the position

of the cleaning motor (with Braze+ brush head) from page 40

function of the cleaning nozzles (compressed air emerges from cleaning

nozzles)

Establish the compressed air supply to the welding torch cleaning device

Checking functions manually

Deactivating the functions

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 screwed to the underlying

surface The cleaning device is screwed to the underlying surface

Brush head is fitted

Position of the cleaning motor has been set

Compressed air supply has been established

Functions have been checked manually

Cleaning device is connected to the robot control

All coverings are fitted and all safety devices are intact and in their proper

place

trol.

Cleaning program and signals

Sicherheit

VORSICHT!

Gefahr durch unsachgemäße Inbetriebnahme.

Sachschäden können die Folge sein.

Den automatisierten Betrieb erst starten, wenn das Reinigungsgerät ord-

▶

nungsgemäß installiert und in Betrieb genommen wurde.

Cleaning program sequence

Start

Wire cutter option

Move to pos. C

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

- Speed: high speed

Move to pos. D

- Enter

wire cutter

- Speed: 60 cm/min (23.62 ipm)

Wait 0.5 s

Move to pos. A

- approx. 50 mm (1.97 in.) centrally above brush head

- Speed: high speed

Query - cleaning

motor lowered

'High'

Move to pos. B

- Move to

cleaning position

- Speed: 60 cm/min (23.62 ipm)

Set

- 'Start cleaning' signal

Wait 3 - 5 seconds

'Low'

Stop program

- Cleaning motor not lowered

Reset

- ’Start cleaning‘ signal

Wait 1,5 s

Query

Cleaning

motor lowered

‘High‘

Move to pos. A

- approx. 50 mm (1.97 in.) above Centre of brush head

- Speed: high speed

End

‘Low‘

Stop program

- Cleaning motor not lowered

Signal inputs and outputs

Signal input „start cleaning (cleaning motor ON, lifting device UP, compressed air supply to cleaning nozzles ON)“:

Signal output „cleaning motor down“:

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 poorly executed work 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 components

▶

ﬂying parts (shavings, etc.)

▶

compressed air escaping from the cleaning nozzles

▶

Before performing work on the cleaning device or any connected system

▶

components: disconnect the customer's compressed air and power supplies from the

▶

cleaning 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 brush head

▶

lifting device moving up/down

▶

activated wire cutter

▶

ﬂying parts (shavings, etc.)

▶

compressed air escaping from the cleaning 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, tools and all clothing away

▶

from the brush head, brush head lifting device, wire cutter and cleaning 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 brush head, brush head lifting device, wire cutter and cleaning

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

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

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

Every 6 months

Check the cleaning brushes on the brush head and replace worn brushes

Empty the cleaning device spatter tray

If fitted, empty the wire cutter tray

Carry out a general visual inspection of the cleaning device and wire cutter

Remove any dirt deposits from device

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

As necessary Open the device and

Clean inside of device using dry reduced compressed air

Lightly oil the lifting device cylinder guides

Restore the original condition of the device

Changing the end brushes (standard brush head only)

Remove the protective covering from the cleaning device

2 3

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

Changing the round brush

NOTE!

In the process described below for changing the round brush, a standard brush head is shown.

The process is identical for aBraze+ brush head.

NOTE!

Before changing the brush, note the setting of the brush head (A or B) and be sure to use this setting during assembly.

This will ensure that the correct clearance is maintained between the diagonal brushes after the brush has been changed.

Remove the protective covering from the cleaning device

2 3

Changing the diagonal brushes

4 5

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

NOTE!

In the process described below for changing a diagonal brush, a standard brush head is shown.

The process is identical for aBraze+ brush head.

NOTE!

Before changing the brushes, note the setting of the brush head (A or B) and be sure to use this setting during assembly.

This will ensure that the correct clearance is maintained between the diagonal brushes after the brush has been changed.

Remove the protective covering from the cleaning device

2 3

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

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

Troubleshooting

Safety

Safety Observe the following safety rules for all work described in the "Troubleshooting"

section.

WARNING!

Incorrect operation or poorly executed work 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 components

▶

ﬂying parts (shavings, etc.)

▶

compressed air escaping from the cleaning nozzles

▶

Before performing work on the cleaning device or any connected system

▶

components: disconnect the customer's compressed air and power supplies from the

▶

cleaning 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 brush head

▶

lifting device moving up/down

▶

activated wire cutter

▶

ﬂying parts (shavings, etc.)

▶

compressed air escaping from the cleaning 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, tools and all clothing away

▶

from the brush head, brush head lifting device, wire cutter and cleaning 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 brush head, brush head lifting device, wire cutter and cleaning

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

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

Troubleshooting

Errors in program sequence

Welding torch is poorly cleaned or damaged

Cause: Remedy:

Lifting device is not moving up or down

Cause: Remedy:

Position of the cleaning motor has been set incorrectly Adjust the position of the cleaning motor

Worn cleaning brushes on cleaning head Replace cleaning brushes on cleaning head

Compressed air relief valve closed Open compressed air relief valve

No signal from robot Check connection to robot control

Mechanical fault on solenoid valve Contact After-Sales Service (arrange for solenoid valve to be re-

placed)

Choke valve not adjustable, or faulty Contact After-Sales Service (arrange for choke valve to be replaced)

Cause: Remedy:

Cleaning motor does not work

Cause: Remedy:

Faulty sealing in lifting cylinder Contact After-Sales Service (arrange for lifting cylinder to be re-

placed)

Compressed air relief valve closed Open compressed air relief valve

No signal from robot Check connection to robot control

Mechanical fault on cleaning motor Contact After-Sales Service (arrange for cleaning motor to be re-

placed)

Mechanical fault on solenoid valve Contact After-Sales Service (arrange for solenoid valve to be re-

placed)

Technical data

Robacta Reamer brush head for aluminium applications

Supply voltage + 24 V DC

Nominal output 2.4 W

Nominal pressure 6 bar

86.99 psi

Air consumption 420 l/min

443.81 qt./min

Thread identification compressed air connection

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

Standard I/O Input: + 24 V DC/ max. 100

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

Safety symbols S

Dimensions l x w x h 165 x 245 x 350 mm

G ¼ ″

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

6.50 x 9.65 x 13.78 in.

Weight (without optional wire cutter)

10 kg

22.05 lb.

Appendix

Circuit diagram: Robacta Reamer brush head for aluminium applications

Pneumatics diagram of Robacta Reamer brush head for aluminium applications

Circuit diagram: Wire cutter

Drahtelektrode abschneiden

Cut wire

Drahtabschneider oﬀen

Wire cutter open

Drahtabschneider geschlossen

Wire cutter closed

Declaration 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 Bürstenkopf Alu

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 Bürstenkopf Alu

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 Bürstenkopf Alu

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 brush head for aluminium applications Operating Instruction [EN]

Specifications and Main Features

Frequently Asked Questions

User Manual