Operating
Instructions
Robacta Reamer Single/Twin
EN-US
Operating instructions
42,0426,0447,EA 002-09032023
Table of contents
Safety Instructions 5
Explanation of safety instructions 5
General 5
Intended Use 6
Environmental Conditions 6
Obligations of the Operating Company 6
Obligations of Personnel 6
Particular Hazard Areas 6
Personal Protection and Protection of Others 7
EMC Device Classifications 7
EMC Measures 8
EMF measures 8
Safety Measures at the Setup Location and during Transport 8
Safety Measures in Normal Operation 9
Maintenance and repair 9
Safety Inspection 9
Safety Symbols 10
Copyright 10
General 11
General 13
Device concept 13
Functionality of the cleaning device 13
Application areas 13
Warning notices on the cleaning device 13
Transport 16
Transport equipment 16
Transport Instructions on the packaging 16
Scope of Supply and Options 17
Scope of supply 17
Available options 17
EN-US
Operating controls, connections and mechanical components 19
Safety 21
Safety 21
Operating controls, connections and mechanical components 22
Operating controls, connections, and mechanical components 22
Harting Han12P (X1) connecting plug configuration for the robot control 24
General 24
Harting Han12P (X1) connecting plug configuration 24
Installation and Startup 25
Safety 27
Safety 27
Ensuring that the cleaning device is depressurized 28
Before installation 29
Intended Use 29
Operating personnel, maintenance personnel 29
Setup regulations 29
Measures to ensure safe operation of the device when operating personnel are untrained 29
Screwing the Cleaning Device to the Solid Surface 30
Screwing the cleaning device to the base 30
Screwing the cleaning device and work stand to the surface 31
Installing/removing the protective cover 33
Fitting the protective cover 33
Removing the protective cover 33
Mounting the gas nozzle clamping device 34
Mounting the gas nozzle clamping device 34
3
Welding Torch Cleaning Position 35
Twin welding torch cleaning position 35
Cleaning position of the single welding torch 36
Fitting the Cleaning Cutter 38
Fitting the cleaning cutter 38
Adjusting the Position of the Cleaning Motor 39
Setting the position of the cleaning motor for twin welding torches 39
Setting the position of the cleaning motor for single welding torches 40
Compressed air supply 41
Specifications for the compressed air supply 41
Mounting the compressed air relief valve 41
Operation of the compressed air relief valve 42
Starting Up the Parting Agent Atomizer 43
Filling the parting agent container (1 liter) and connecting it to the cleaning device 43
Connecting the parting agent container (10 liter) to the cleaning device 44
Positioning of the parting agent container (10 liters) 45
OPT/i TSS TCP Touch Sense 47
Mount OPT/i TSS TCP Touch Sense 47
Manually Checking the Cleaning Device Functions 48
Safety 48
Manually checking the cleaning device functions 48
Start up the Cleaning Device 51
Requirements for commissioning 51
Commissioning 51
Program sequence 52
Safety 52
Cleaning program sequence for twin welding torches 53
Program sequence of cleaning for single welding torches 61
Cleaning signal sequence 67
Signal input 67
Signal input and output 67
Signal output 68
Service, maintenance and disposal 69
Safety 71
Safety 71
Ensuring that the cleaning device is depressurized 72
Service, maintenance and disposal 73
Before every start-up 73
Daily 73
Weekly 73
Every 6 months 73
Whenever required: 73
Disposal 73
Troubleshooting 75
Safety 77
Safety 77
Ensuring that the cleaning device is depressurized 78
Troubleshooting 79
Errors in the Program Sequence 79
Technical data 81
Technical data 83
Robacta Reamer Single/Twin 83
Appendix 85
Declaration of conformity 87
4
Safety Instructions
EN-US
Explanation of
safety instructions
Indicates a potentially dangerous situation.
▶
Indicates a potentially harmful situation.
▶
Indicates a possibility of flawed work results and possible damage to the equipment.
Please pay special attention when one of the symbols from the "Safety rules"
chapter appears in these instructions.
General The device has been manufactured using state-of-the-art technology and ac-
cording to recognized safety standards. If used incorrectly or misused, however,
it can cause
-
-
-
WARNING!
Death or serious injury may result if appropriate precautions are not taken.
CAUTION!
Minor injury or damage to property may result if appropriate precautions are
not taken.
NOTE!
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 the commissioning, operation, maintenance, and servicing
of the device must
be suitably qualified,
-
have knowledge of automated welding and
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have read these Operating Instructions and any system component operating
-
instructions in full and follow them carefully.
The Operating Instructions must always be at hand wherever the device is being
used. In addition to the Operating Instructions, all applicable local rules and regulations regarding accident prevention and environmental protection must also
be followed.
All safety and danger notices on the device must
must be kept in a legible state
-
not be damaged/marked
-
not be removed
-
not be covered, pasted, or painted over
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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 switching on the device, remove any faults that could compromise safety.
Your personal safety is at stake!
5
Intended Use The device is to be used exclusively for its intended purpose.
The device is intended exclusively for the mechanical cleaning of Fronius robot
welding torches in automatic mode.
Utilization for any other purpose, or in any other manner, shall be deemed to be
"not in accordance with the intended purpose." The manufacturer is not responsible for any damage resulting from improper use.
Proper use also means
Reading these Operating Instructions in their entirety
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Following all instructions and safety rules in these Operating Instructions
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Carrying out all the specified inspection and servicing work
-
The device is designed for operation in industry and business. The manufacturer
shall not be liable for any damage resulting from use in a living area.
The manufacturer shall also not be liable for faulty or incorrect work results.
Environmental
Conditions
Obligations of
the Operating
Company
Operation or storage of the device outside the stipulated area will be deemed as
not in accordance with the intended purpose. The manufacturer is not responsible for any damage resulting from improper use.
Temperature range of the ambient air:
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)
-
Ambient air: free of dust, acids, corrosive gases or substances, etc.
Altitude above sea level: up to 2000 m (6500 ft.)
The operating company must only allow persons to work with the device if they
Are familiar with the basic occupational safety and accident prevention regu-
-
lations and are trained in handling the device
Have read and understood these Operating Instructions, especially the sec-
-
tion "Safety Rules," and have confirmed this with their signature
Are trained according to the requirements for the work results
-
The safety-conscious work of the personnel must be checked regularly.
Obligations of
Personnel
Particular Hazard Areas
6
All persons who are assigned to work with the device must do the following before beginning the work:
Follow the basic regulations for occupational safety and accident prevention
-
Read these Operating Instructions, especially the section "Safety Rules," and
-
confirm that they have understood and will follow them by signing
Before leaving the workplace, ensure that no personal injury or property damage
can occur in one's absence.
Do not linger in the operating area of the robot.
Always integrate the device into a higher-level safety system in a secured area.
If this area has to be accessed for preparatory or maintenance work, ensure that
the entire system is shut down for the duration of access to this area
-
and remains shut down to prevent unintended operation, e.g., as a result of a
-
control error.
If untrained operating personnel have access to the device, the compressed air
supply to the device must be disconnected for the duration of this access in accordance with "Performance Level d" of ISO 13849-1.
In addition to these Operating Instructions, the safety rules of the robot manufacturer must be followed.
The human body, and, in particular, hands, face and hair, plus items of clothing
and all tools, must be kept away from moving components, such as:
the rotating cleaning cutter
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the cleaning motor that moves up and down
-
the gas nozzle clamping device that moves in and out
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Wire cutter
-
Do not touch the cleaning cutter immediately after operation - burning hazard.
Follow the special safety regulations for handling the cleaning cutter in the Operating Instructions.
Protect hands, face and eyes from flying parts (chips, etc.) and compressed air/
parting agent mixture discharged from the parting-agent injection nozzle.
EN-US
Personal Protection and Protection of Others
Covers must only be opened/removed during maintenance, installation and repair work.
During operation:
ensure that all covers are closed, and all side parts have been mounted prop-
-
erly
keep all covers closed
-
You are exposed to numerous hazards while handling the device. In addition to
these Operating Instructions, the safety rules of the manufacturer of the entire
welding system must be followed.
Keep persons, especially children, away during the operation of the devices and
during the welding process. However, if persons are in the vicinity:
instruct them about all hazards (crush hazard posed by moving mechanical
-
parts, injury hazard from the cleaning cutter, flying chips or similar, discharged compressed air/parting agent mixture, injury hazard due to flying
sparks, blinding hazard due to arcs, welding fume hazardous to health, noise
exposure, possible hazard due to mains current or welding current, etc.)
Provide suitable protective equipment, or
-
construct suitable protective walls and 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 grid.
7
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 operating company is obliged to take appropriate action to rectify the situation.
Check and evaluate possible problems and the interference immunity of equipment in the vicinity according to national and international regulations:
Safety devices
-
Grid power lines, signal lines, and data transfer lines
-
EMC and telecommunications equipment
-
Devices for measuring and calibrating
-
Supporting measures to avoid EMC problems:
Grid power supply
1.
If electromagnetic interference occurs despite a grid connection that
-
complies with regulations, take additional measures (e.g., use a suitable
grid filter).
Control lines
2.
Keep them as short as possible
-
Route them close together (also to avoid EMF problems)
-
Route them far from other lines
-
Equipotential bonding
3.
Shield, if necessary
4.
Shield other devices in the vicinity
-
Shield the entire welding installation
-
EMF measures Electromagnetic fields may cause health problems that are not yet known:
Effects on the health of persons close by, e.g., those with pacemakers and
-
hearing aids
Persons with pacemakers must seek advice from their doctor before staying
-
in the immediate vicinity of the device and the welding process
Keep distances between welding power-leads and the head/torso of the
-
welder as great as possible for safety reasons
Do not carry welding power-leads and hosepacks over your shoulder or wrap
-
them around your body or body parts
Safety Measures
at the Setup
Location and
during Transport
A toppling device can be deadly! Install the device horizontally on a flat, stable
surface free of vibration, anchor it securely on the surface, and secure against
toppling.
Special regulations apply in areas at risk of fire or explosion
Follow the appropriate national and international regulations.
-
Use instructions and checks within the company to ensure that the vicinity of the
workplace is always clean and organized.
Take care to ensure that the applicable national and regional guidelines and accident prevention regulations are observed when transporting the device, especially guidelines concerning hazards during transport and shipment.
8
It is essential to conduct a visual inspection of the device to check for damage
after it has been transported but before it is commissioned. Have any damage repaired by trained service technicians before commissioning the device.
EN-US
Safety Measures
in Normal Operation
Only operate the device when 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 operating
-
company,
inefficient operation of the device.
-
Safety devices that are not fully functional must be repaired before the device is
started up.
Never bypass or disable safety devices.
Before starting up the device, ensure that no one can be put in danger.
The device must be examined at least once a week for externally detectable damage and functionality of the safety devices.
Only use appropriate original parting agents from the manufacturer.
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When handling parting agent, observe the information on the parting agent
-
safety data sheet. The parting agent safety data sheet can be obtained from
your service center or via the manufacturer's website.
Do not mix parting agents from the manufacturer with other parting agents.
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If damage occurs due to the use of other parting agents, the manufacture is
-
not liable for this and all warranty claims are forfeited.
Properly dispose of used parting agent according to national and internation-
-
al regulations.
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).
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Do not carry out any modifications, alterations, etc. to the device without the
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manufacturer's consent.
Components that are not in perfect condition must be replaced immediately.
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When ordering, please give the exact designation and part number as shown
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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 be performed at least every 12 months.
A safety inspection by a certified electrician is recommended:
after changes
-
after alterations
-
after repair, care, and maintenance
-
at least every 12 months.
-
9
For the safety inspection, follow the appropriate national and international
standards and guidelines.
You can obtain more information about the safety inspection and calibration
from your service center. The service center will provide the necessary documents upon request.
Safety Symbols Devices with CE marking satisfy the essential requirements of the relevant dir-
ectives (e.g. the low-voltage, electromagnetic compatibility, and machinery directives).
Devices marked with the CSA test mark satisfy the requirements of the relevant
standards for Canada and the USA.
Copyright Copyright of these Operating Instructions remains with the manufacturer.
Text and illustrations were accurate at the time of printing. Fronius reserves 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 Operating Instructions, we will be most grateful for your comments.
10
General
11
12
General
Device concept The cleaning device is intended to
automatically clean MIG/MAG welding
torches. The cleaning device can be
used to reliably clean the inside of gas
nozzles and the face of the gas nozzles
in a range of welding torch geometries.
This significantly increases the service
life of wearing parts. At the same time,
the even application of parting agent
prevents the build-up of new dirt.
EN-US
Functionality of
the cleaning
device
Application
areas
Warning notices
on the cleaning
device
The gas nozzle clamping device on the front of the cleaning device holds the
-
gas nozzle in place during the cleaning process.
A cleaning cutter is used for cleaning.
-
After cleaning, the parting-agent injection nozzle parting agent is sprayed in-
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to the gas nozzle and onto the face of the gas nozzle.
The cleaning device is exclusively suited for operation in automation and robot
applications and can be used for a range of materials.
Main applications:
Automotive and supply industry
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Equipment engineering
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Chemical plant construction
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Mechanical engineering, rail vehicle construction
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Construction machinery and special-purpose vehicle construction
-
The cleaning device has warning notices and a rating plate fitted. These warning
notices and the rating plate must not be removed or painted over.
13
Robacta Reamer Single/Twin
4,044,068
Warning notices on the cleaning device
PLEASE NOTE! Risk of serious injury from mechanically moving
parts.
Keep the device de-energized and depressurized during maintenance and servicing.
Do not use the functions described here until you have fully
read and understood the following documents:
These Operating Instructions
-
All Operating Instructions for system components, espe-
-
cially the safety rules.
For indoor use only.
CE marking - confirms compliance with applicable EU directives
and regulations.
14
WEEE marking - waste electrical and electronic equipment must
be collected separately and recycled in an environmentally
sound manner in accordance with the European Directive and
national law.
Wear eye protection.
Warning before the device switches on automatically.
Warning of hand injuries.
EN-US
15
Transport
Transport equipment
Transport Instructions on the
packaging
Transport the device using the following transport equipment:
On a pallet using a counterbalanced lift truck
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On a pallet using a lift truck
-
Manually
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WARNING!
Danger from devices and objects falling.
This can result in severe personal injury and damage to property.
When transporting the device by counterbalanced lift truck or lift truck, se-
▶
cure the device to prevent it from falling.
Do not turn, brake, or accelerate in a sudden, jerking manner.
▶
CAUTION!
Danger due to improper transport.
This can result in damage to property.
Follow the transport instructions on the device packaging.
▶
16
Scope of Supply and Options
Scope of supply
(1) Robacta Reamer Single/Twin cleaning device
(2) 2x parting agent containers
EN-US
Available options
(3) Collection container with mounting bracket
(4) Harting Han12P (X1) without cable
(5) Compressed air relief valve
(6) Operating Instructions
(7) Wrench for cleaning motor
(8) Mounting material to assemble the cleaning device:
4x M8x20 hexagonal bolts
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4x A8 washers
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4x M8 lock washer
-
4x M8 hexagonal nuts
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The “Robacta Reamer” parting agent (item number 42.0411.8042) and the cleaning cutter are not included in the scope of supply. Find the right cleaning cutter
in the Spare Parts List for the welding torch used: https://spareparts.froni-
us.com/
The following options are available for the cleaning device:
Work stand
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Suction pipe for parting agent container
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OPT/i TSS TCP Touch Sense
-
Cleaning cutter
-
Clamping device gas nozzle (TPS, TPS/i)
-
GVC (gas volume control)
-
Impulse compressed air blowout
-
17
18
Operating controls, connections
and mechanical components
19
20
Safety
Safety Please follow the safety rules below when using all the functions described in the
"Operating controls, connections, and mechanical components" chapter.
WARNING!
Danger from incorrect operation and work that is not carried out properly.
This can result in severe personal injury and damage to property.
All the work and functions described in this document must only be carried
▶
out by trained and qualified personnel.
Read and understand this document.
▶
Read and understand all the Operating Instructions for the system compon-
▶
ents, especially the safety rules.
EN-US
21
Operating controls, connections and mechanical
components
Operating controls, connections, and mechanical components
(1) Knife / wire cutter (available option)
2x knives for cutting the welding wire (max. 2 welding wires à 1.6 mm diameter).
(2) Clamping device gas nozzle (available option)
fixes the gas nozzle during the cleaning process.
The clamping device must be selected depending on the gas nozzle used.
(3) Cleaning cutter (available option)
(4) Parting agent injection device
includes the parting-agent injection nozzle.
The parting-agent injection nozzle ensures that the parting agent only
reaches the inside/face of the gas nozzle.
(5) Cleaning motor
drives the cleaning cutter.
(6) Lifting device
Lifts the cleaning motor with the cleaning cutter into the gas nozzle during the cleaning process.
(7) Touch sense (available option)
Gauge for the wear of the contact tip and the exit angle of the wire electrode.
(8) TCP (ToolCenterPoint) with protective cover
(9) Manually check the “Clamp gas nozzle / Cut wire” function.
22
(10) Manually check the “Spray in release agent” function.
(11) Manually check the “Cleaning motor on / Lifting device up” function.
(12) Actuator/sensor connection
(13) Compressed air connection socket
For supplying dry compressed air at 6 bar (86.99 psi).
For more information on compressed air quality, see chapter Specifica-
tions for the compressed air supply on page 41.
Thread identification for compressed air connection: G ¼”
(14) Harting Han12P (X1) connection socket
+ 24 V DC power supply
EN-US
(15) Protective cover
(16) Parting agent container
(17) Capacity of the parting agent container (storage capacity: 1l)
(18) Connection elbow
(19) Closure cap
(20) Suction hose
(21) Intake filter
23
Harting Han12P (X1) connecting plug configuration for the robot control
General
Harting Han12P
(X1) connecting
plug configuration
CAUTION!
Danger from overcurrent.
Damage to the Harting Han12P (X1) connection power supply may result.
Provide the power supply with 500 mA fuse protection against overcurrent.
▶
CAUTION!
Danger due to long control line.
Malfunctions in the signal transmission may result.
Keep the control line between the robot control and the cleaning device as
▶
short as possible.
The Harting Han12P (X1) connecting plug for connecting the cleaning device to
the robot control is included in the scope of supply. The cable harness has to be
adjusted for the robot control connection technology.
24
Harting Han12P (X1) connecting plug configuration – cable-side view
Input/output signals:
“Cleaning motor on / lifting device up” input signal
1.
“Spray parting agent” input signal
2.
GND actuator
3.
+ 24 V DC
4.
“Upper cleaning motor” output signal
5.
“Lower cleaning motor” output signal
6.
Input/output signal actuator/sensor
7.
Input/output signal actuator/sensor
8.
“Clamp gas nozzle / Cut wire” input signal
9.
“Gas nozzle clamped / wire cut” output signal
10.
“Gas nozzle free / wire cutter open” output signal
11.
GND sensor
12.
Installation and Startup
25
26
Safety
EN-US
Safety
WARNING!
Danger from incorrect operation and work that is not carried out properly.
This can result in severe personal injury and damage to property.
All the work and functions described in this document must only be carried
▶
out by trained and qualified personnel.
Read and understand this document.
▶
Read and understand all the Operating Instructions for the system compon-
▶
ents, especially the safety rules.
WARNING!
Danger due to machines starting automatically.
This can result in severe personal injury and damage to property.
In addition to these Operating Instructions, observe the safety rules of the
▶
robot manufacturer and welding system manufacturer. Before entering the
robot work area, ensure that all protective measures in the robot work area
are in place and remain in place for the duration of the access.
WARNING!
Danger due to moving mechanical parts, flying debris (chips, etc.), and compressed air/parting agent mixture discharged from the parting-agent injection
nozzle.
This can result in severe personal injury and damage to property.
Before carrying out any work, disconnect the compressed air and power sup-
▶
ply from the cleaning device and the associated system components and
make sure that the compressed air and power supply remain disconnected
until all work has been completed.
Before carrying out any work, ensure that the cleaning device is depressur-
▶
ized - the necessary steps for this can be found in the following chapter En-
suring that the cleaning device is depressurized from page 28.
WARNING!
If the cleaning device is supplied with voltage and/or compressed air, there is a
risk of serious injury from: rotating cleaning cutter, cleaning motor moving up/
down, gas nozzle clamping device moving out/in, activated wire cutter, flying
parts (chips, etc.), compressed air/parting agent mixture escaping from the
parting-agent injection nozzle.
This can result in severe personal injury and damage to property.
If work is required on the cleaning device while the cleaning device is being supplied with voltage and/or compressed air, take the following safety measures.
Keep your body, especially hands, face and hair, as well as objects and all
▶
items of clothing away from the cleaning cutter, cleaning motor, lifting
device, gas nozzle clamping device, wire cutter, and parting-agent injection
nozzle.
Wear hearing protection.
▶
Wear protective goggles with side protection.
▶
27
Ensuring that
the cleaning
device is depressurized
To ensure that the cleaning device is depressurized, try to briefly activate the
cleaning device without the compressed air supply. To do this, proceed as follows:
Take protective measures:
1
The cleaning cutter, lifting device, gas nozzle clamping device, wire cut-
-
ter, and parting-agent injection nozzle could be activated. Therefore,
keep your body, especially hands, face and hair, as well as objects and all
items of clothing, away from the aforementioned parts.
Wear hearing protection.
-
Wear protective goggles with side protection.
-
Ensure that the cleaning device is disconnected from the compressed air
2
supply.
Set the “Start cleaning” screw on the cleaning device to position “1” (activ-
3
ated) for max. 2 seconds and then return to the starting position “0” (deactivated).
If the cleaning device does not respond to the activation of the “Start
-
cleaning” function, the cleaning device is free of compressed air.
If the cleaning device responds to the activation of the “Start cleaning”
-
function, the cleaning device is still connected to the compressed air
supply.
In this case, the cleaning device must be disconnected from the compressed air supply before starting any work. Finally, ensure that the
cleaning device is depressurized.
28
Before installation
Intended Use The cleaning device is used exclusively to mechanically clean Fronius robot weld-
ing torches in automatic mode within the limits of technical data, especially to
clean the gas nozzle and gas nozzle internal space. Any other use does not constitute proper use. The manufacturer shall not be liable for any damage resulting
from such improper use.
Proper use also means
Reading these Operating Instructions in their entirety
-
Following all instructions and safety rules in these Operating Instructions
-
Carrying out all the specified inspection and servicing work
-
EN-US
Operating personnel, maintenance personnel
Setup regulations
WARNING!
Danger due to machines starting automatically.
This can result in severe personal injury and damage to property.
The device must only ever be operated/maintained by one person.
▶
Ensure that there is only one person in the device’s operating area while it is
▶
being worked on.
The cleaning device has been tested according to protection class IP 21. This
means:
Protection against solid foreign bodies larger than Ø 12.5 mm (0.49 in.)
-
No protection against penetrating water
-
The device should not be set up and operated outdoors. The installed electrical
components should be protected against direct exposure to moisture.
WARNING!
Danger from devices falling or toppling over.
This can result in severe personal injury and damage to property.
Always screw the cleaning device to the surface.
▶
Measures to ensure safe operation of the
device when operating personnel are untrained
If untrained operating personnel have access to the device, the compressed air
supply to the device must be disconnected for the duration of this access in accordance with “Performance Level d” of ISO 13849-1.
We recommend FESTO’s MS6-SV soft-start and quick exhaust valve for interrupting the compressed air supply as required.
29
Screwing the Cleaning Device to the Solid Surface
Screwing the
cleaning device
to the base
WARNING!
Danger from devices falling or toppling over.
This can result in severe personal injury and damage to property.
Always screw the cleaning device to the base.
▶
The supplied mounting material only for bases up to max. 5 mm (0.197 in.)
▶
Use material thickness.
For bases with a material thickness greater than 5 mm (0.197 in.), suitable
▶
and appropriately dimensioned fastening material must be used.
Install the cleaning device and the mounting bracket on a flat, stable solid surface (base) free of vibration.
IMPORTANT!
Position the cleaning device so that the robot’s approach route to the cleaning
position is as short as possible.
30
Place the mounting bracket of the collection container and the cleaning
1
device on the base in the order shown.
Screw the cleaning device and the mounting bracket of the collection con-
2
tainer to the base using the supplied fastening material.
Hook the collecting vessel from left to right into the mounting bracket of the
3
collecting vessel.
EN-US
Screwing the
cleaning device
and work stand
to the surface
WARNING!
Danger from devices falling or toppling over.
This can result in severe personal injury and damage to property.
Always secure the assembly stand to the base.
▶
Only use screws suitable for the base (not included in the scope of delivery)
▶
to fasten the assembly stand.
Always screw the cleaning device to the work stand.
▶
Set up the work stand (available as an option) on a level, solid, and vibration-free
base (foundation).
IMPORTANT!
Position the work stand so that the robot’s approach route to the cleaning device
on the work stand is as short as possible.
Screw the assembly stand to the
1
base using suitable fastening material.
31
Place the collecting vessel mounting bracket and the cleaning device on the
2
mounting stand in the order shown.
Screw down the cleaning device, the mounting bracket of the collection con-
3
tainer and the mounting stand with the supplied fastening material.
Hook the collecting vessel from left to right into the mounting bracket of the
4
collecting vessel.
32
Installing/removing the protective cover
EN-US
Fitting the protective cover
Removing the
protective cover
Place the protective cover on the
1
cleaning device in position.
Tighten the fastening screws of the
2
protective cover.
Loosen the fixing screws of the
1
protective cover.
Pull the protective cover off the
2
cleaning device towards the front.
33
Mounting the gas nozzle clamping device
Mounting the gas
nozzle clamping
device
Only fasten the gas nozzle clamp-
1
ing device to the gas nozzle clamping device holder using the screws
supplied (strength class 12.9) and
a torque of 11 Nm.
34
Welding Torch Cleaning Position
EN-US
Twin welding
torch cleaning
position
CAUTION!
Danger due to incorrectly adjusted cleaning position of the welding torch.
The welding torch may be damaged.
Only position the contact tips centrally and vertically over the cleaning mo-
▶
tor.
The gas nozzle locking screws are only used for the rough positioning of the
contact tip. The gas nozzle locking screw is more or less visible in the bore of
the gas nozzle clamping device, depending on the angle of the contact tip.
Before start-up, make sure that the cleaning position is set correctly.
▶
The respective contact tip of the twin welding torch must be positioned centrally
and vertically above the cleaning cutter.
Cleaning position of contact tip 1
Align the gas nozzle locking screw centrally in the first hole (1) of the clamp-
1
ing device.
Set the exact position of the cleaning motor according to the chapter Adjust-
2
ing the Position of the Cleaning Motor on page 39 .
35
Cleaning position of contact tip 2
Align the gas nozzle locking screw centrally in the second hole (2) of the
1
clamping device.
Set the exact position of the cleaning motor according to the chapter Adjust-
2
ing the Position of the Cleaning Motor on page 39 .
Cleaning position of the single
welding torch
CAUTION!
Danger due to incorrectly adjusted cleaning position of the welding torch.
The welding torch may be damaged.
Position the contact tip only centrally and vertically above the cleaning mo-
▶
tor.
Before start-up, make sure that the cleaning position is set correctly.
▶
36
Position the contact tip of the single welding torch centrally and vertically
1
above the cleaning cutter.
IMPORTANT!
The position of the cleaning motor may only be adjusted for the twin welding
torch. If single and twin welding torches are to be cleaned with the Robacta
Reamer Single/Twin, the distance to the cleaning cutter and the immersion
depth in the contact tip for the respective single welding torch used must be
set with the torch position in the clamping device.
Set the exact position of the cleaning motor according to the chapter Set-
2
ting the position of the cleaning motor for single welding torches on page
40 .
EN-US
37
Fitting the Cleaning Cutter
Fitting the
cleaning cutter
CAUTION!
Danger due to hot cleaning cutter.
Serious burns may result.
Before handling the cleaning cutter, allow it to cool to room temperature
▶
(+25°C, +77°F).
CAUTION!
Danger due to incompatible wearing parts.
Property damage and malfunctions may result.
Only use original Fronius spare parts (contact tips, gas nozzles and cleaning
▶
cutters).
IMPORTANT!
No liability is accepted for damage caused by the use of contact tips, gas
nozzles, or cleaning cutters from other manufacturers.
Remove the protective cover from the cleaning device (see chapter Remov-
1
ing the protective cover on page 33).
Insert the supplied clamping key
2
of the cleaning motor into the
chuck.
Tighten the cleaning cutter clock-
3
wise using a suitable flat spanner.
38
Fit the protective cover to the cleaning device (see chapter Fitting the pro-
4
tective cover on page 33).
To disassemble the cleaning cutter, follow the steps in reverse order.
Adjusting the Position of the Cleaning Motor
Setting the position of the cleaning motor for
twin welding
torches
Remove the protective cover of the clamping device (see chapter Removing
1
the protective cover on page 33).
Remove the gas nozzle from the torch body.
2
Loosen the fixing screw (2) on the lifting device.
3
Make sure that the lifting device (1) is in the bottom-most lift position.
4
Move the welding torch into the cleaning position (see chapter Twin welding
5
torch cleaning position on page 35).
Manually slide the lifting device (1) to the top-most lift position and hold it in
6
this position.
Manually slide the cleaning motor (3) with cleaning cutter into the cleaning
7
position.
Ensure that the cleaning cutter does not touch any components of the weld-
8
ing torch.
Welding torch with spatter guard, see detail (4).
-
Welding torch with insulating sleeve, see detail (5).
-
Mount the cleaning motor (3) in this position in the lifting device (1), using the
9
fixing screw (2).
Perform a function test with the gas nozzle removed. To do this, push the lift-
10
ing device (1) to the uppermost lifting position by hand.
The cleaning cutter must surround the contact tip without colliding with
-
it. If the cleaning cutter touches components of the welding torch, the
position of the cleaning motor must be adjusted again (from step 3).
Fit the gas nozzle onto the torch body.
11
Perform a function test with the gas nozzle fitted. To do this, push the lifting
12
device (1) to the uppermost lifting position by hand.
The cleaning cutter must plunge into the gas nozzle without colliding
-
with it. If the cleaning cutter touches components of the welding torch,
the position of the cleaning motor must be adjusted again (from step 3).
Mount the protective cover of the clamping device (see chapter Fitting the
13
protective cover on page 33).
EN-US
IMPORTANT!
For twin welding torches, the function test (steps 10 - 12) must be performed individually for each contact tip.
39
Setting the position of the cleaning motor for
single welding
torches
Remove the protective cover of the clamping device (see chapter Removing
1
the protective cover on page 33).
Remove the gas nozzle from the torch body.
2
Make sure that the lifting device (1) is in the bottom-most lift position.
3
Move the welding torch into the cleaning position (see chapter Cleaning posi-
4
tion of the single welding torch on page 36).
Manually slide the lifting device (1) to the top-most lift position and hold it in
5
this position.
Manually slide the cleaning motor (3) with cleaning cutter into the cleaning
6
position.
Ensure that the cleaning cutter does not touch any components of the weld-
7
ing torch.
Welding torch with spatter guard, see detail (4).
-
Welding torch with insulating sleeve, see detail (5).
-
Perform a function test with the gas nozzle removed. To do this, push the lift-
8
ing device (1) to the uppermost lifting position by hand.
The cleaning cutter must surround the contact tip without colliding with
-
it. If the cleaning cutter touches components of the welding torch, the
position of the welding torch must be adjusted again (step 4).
Fit the gas nozzle onto the torch body.
9
Perform a function test with the gas nozzle fitted. To do this, push the lifting
10
device (1) to the uppermost lifting position by hand.
The cleaning cutter must plunge into the gas nozzle without colliding
-
with it. If the cleaning cutter touches components of the welding torch,
the position of the welding torch must be adjusted again (step 4).
Mount the protective cover of the clamping device (see chapter Fitting the
11
protective cover on page 33).
40
Compressed air supply
EN-US
Specifications
for the compressed air supply
Mounting the
compressed air
relief valve
To ensure the proper functioning of the cleaning device, fulfill the following specifications for the compressed air supply:
Set up a compressed air supply using the pressure relief valve and com-
-
pressed air filter
Guarantee the compressed air quality in accordance with ISO 8573-1:2001,
-
class 7 4 3, instrument air
-
Solid particle concentration £ 10 mg/m
Pressure dew point steam £ + 3 °C
-
-
Oil concentration £ 1 mg/m
WARNING!
Danger due to mechanically moving parts.
This can result in severe personal injury and damage to property.
The torch neck changeover station must not be supplied with compressed air
▶
until the installation has been completed.
3
3
Unscrew the connection piece
1
from the compressed air relief
valve.
Slide the outer of the two sealing
2
rings onto the opposite side of the
connection piece.
Fasten the connection piece to the
3
compressed air relief valve with a
torque of 14 Nm.
Attach the compressed air relief
1
valve to the compressed air connection of the cleaning device using the connection piece and a
torque of 14 Nm.
41
* Attach the compressed air sup-
ply line to the compressed air
relief valve.
Thread identification Compressed air connection: G ¼”
Operation of the
compressed air
relief valve
You can interrupt and restore the compressed air supply to the cleaning device
by moving the compressed air relief valve back and forth.
(1) Cleaning device is supplied with
compressed air.
(2) Compressed air supply to the
cleaning device is interrupted.
The cleaning device is free of
compressed air.
42
Starting Up the Parting Agent Atomizer
EN-US
Filling the parting agent container (1 liter)
and connecting
it to the cleaning
device
1
2
IMPORTANT!
Only use the water-based “Robacta Reamer” parting agent (item number
42.0411.8042) provided by the manufacturer. Its composition is specifically
tailored for use with the cleaning device. Correct operation is not ensured when
other products are used.
3
43
4
Connecting the
parting agent
container (10
liter) to the
cleaning device
1
Remove the parting agent container (1
liter) from the cleaning device and terminate the parting agent hose.
IMPORTANT!
The parting agent hose must not be extended. For proper operation, use only original parting agent hoses.
IMPORTANT!
Only use the water-based “Robacta Reamer” parting agent (item number
42.0411.8042) provided by the manufacturer. Its composition is specifically
44
tailored for use with the cleaning device. Correct operation is not ensured when
other products are used.
Positioning of
the parting
agent container
(10 liters)
2
* “Long parting agent hose” option (item number 42.0300.3007)
Connect the release agent hose to the cleaning device and fasten the cap of the
parting agent container.
IMPORTANT!
For proper functioning of the injection device, observe the following information
on positioning the parting agent container.
EN-US
45
46
OPT/i TSS TCP Touch Sense
EN-US
Mount OPT/i TSS
TCP Touch
Sense
NOTE!
Ensure proper routing and connection of the ground cable. Damage to the
ground cable of the OPT/i TSS TCP Touch Sense option can impair its function.
Lay the ground cable in the cable guide on the underside of the OPT/i TSS
▶
TCP Touch Sense option.
Do not crush the ground cable or damage the insulation.
▶
Position the OPT/i TSS TCP Touch
1
Sense option on top of the
Robacta Reamer Single/Twin.
Insert the 2 screws supplied (M4 x
2
10 mm) into the hole and fasten
with a torque of 1.5 Nm.
IMPORTANT!
For the function of the OPT/i TSS TCP
Touch Sense option, a ground earth
connection to the workpiece is required.
47
Manually Checking the Cleaning Device Functions
Safety
Manually checking the cleaning
device functions
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 severe personal injury and damage to property.
Keep your body, especially hands, face and hair, as well as objects and all
▶
items of clothing away from the cleaning cutter, cleaning motor, lifting
device, gas nozzle clamping device, wire cutter, and parting-agent injection
nozzle.
Wear hearing protection.
▶
Wear protective goggles with side protection.
▶
The individual functions are checked manually with the respective adjusting
screw.
0 = disabled
-
1 = activated
-
Before manually checking the individual functions, the following activities must
be performed:
Move the welding torch into the cleaning position (see chapter Welding
1
Torch Cleaning Position on page 35).
Establish the compressed air supply for the cleaning device (see chapter
2
Compressed air supply on page 41).
Clamp the gas nozzle in the clamping device.
3
“Cut wire” function
1
Activate the function with the set screw and a 90° clockwise turn.
2
After the function has been completed, check whether the welding wire has
3
been cut to the correct length.
48
“Clamp gas nozzle” function
1
Activate the function with the set screw and a 90° clockwise turn.
2
Check that the gas nozzle is correctly held in the clamping device.
3
“Cleaning motor on / lifting device up” function
1
EN-US
Activate the function with the set screw and a 90° clockwise turn.
2
Check the function of the clamping device for the gas nozzle.
3
Check the insertion depth of the cleaning cutter into the gas nozzle.
4
Check the function of the cleaning motor.
5
49
“Spray parting agent” function
1
Activate the function with the set screw and a 90° clockwise turn.
2
After the function has been completed, check whether the gas nozzle is
3
moistened with parting agent.
IMPORTANT!
The quantity of parting agent is controlled by the injection time (see chapter
Program sequence from page 52).
50
Start up the Cleaning Device
EN-US
Requirements
for commissioning
Commissioning An active signal from the robot control starts up the cleaning device.
The following requirements must be met in order to start up the cleaning device:
Cleaning device screwed to the base (see chapter Screwing the Cleaning
1.
Device to the Solid Surface on page 30).
Clamping device gas nozzle mounted (see chapter Mounting the gas nozzle
2.
clamping device on page 34).
Cleaning cutter mounted (see chapter Fitting the Cleaning Cutter on page
3.
38).
Position of the cleaning motor set (see chapter Adjusting the Position of the
4.
Cleaning Motor on page 39).
Parting agent atomizer put into operation (see chapter Starting Up the Part-
5.
ing Agent Atomizer on page 43).
Compressed air supply established (see chapter Compressed air supply on
6.
page 41).
Functions checked manually (see chapter Manually Checking the Cleaning
7.
Device Functions on page 48).
Cleaning device connected to the robot control unit.
8.
All covers installed and all safety devices in good order and installed in the
9.
location intended (see chapter Fitting the protective cover on page 33).
51
Program sequence
Safety
CAUTION!
Danger due to improper installation and commissioning.
This can result in damage to property.
The cleaning device’s functions must be manually checked before starting
▶
automatic operation.
Only start automatic mode once the cleaning device has been installed and
▶
commissioned properly.
NOTE!
If wetting agent has not been applied to the inside of the welding torch, this may
lead to the permanent contamination of the welding torch when welding begins.
Always wet the inside of the welding torch with the manufacturer’s parting
▶
agent before starting automatic mode.
52
Cleaning program sequence
for twin welding
torches
Start
Move to position A
Position: 50 mm over wire cutter
Speed: High speed mode
EN-US
Gas nozzle free?
Wire cutter open?
High
Move to position B
Position: Move into wire cutter
Speed: 10 cm/s (236.22 ipm)
Low
High
Set
External signal: Clamp gas nozzle / Cut
wire
Wait 0.5 seconds
Reset
External signal: Clamp gas nozzle / Cut
wire
Gas nozzle free?
Wire cutter open?
Low
Stop
Error
Set
External signal: Clamp gas nozzle / Cut
wire
53
Wait 0.7 seconds
Move to position A
Position: 25 mm over wire cutter
Speed: 10 cm/s (236.22 ipm)
Reset
External signal: Clamp gas nozzle / Cut
wire
Gas nozzle free?
Wire cutter open?
High
Move to position C
Position: 25 mm above cleaning position
1 (contact tip 1)
Low
High
Set
External signal: Clamp gas nozzle / Cut
wire
Wait 0.5 seconds
Reset
External signal: Clamp gas nozzle / Cut
wire
Gas nozzle free?
Wire cutter open?
Low
Stop
Error
54
Retract wire
Wait 2–3 seconds
Lower cleaning motor?
High
Low
EN-US
Set
External signal: Motor on / Lifting device
up
Move to position D
(cleaning position KR1)
Position: Move into clamping device
Speed: 10 cm/s (236.22 ipm)
Set
External signal: Clamp gas nozzle / Cut
wire
Wait 0.5 seconds
Reset
External signal: Motor on / Lifting device
up
High
Wait 0.3 seconds
Lower cleaning motor?
Low
Stop
Error
Wait 0.5 seconds
55
Gas nozzle clamped?
Set
External signal: Compressed air gas
purging with welding torch
Low
High
Set
External signal: Clamp gas nozzle
Gas nozzle clamped?
Low
Set
External signal: Cleaning motor on /
Lifting device up
Wait 2–3 seconds
Upper cleaning motor?
High
Reset
External signal: Cleaning motor on /
Lifting device up
Reset
External signal: Compressed air gas
purging with welding torch
Low
Stop
Error
Stop
Error
56
Set
External signal: Inject parting agent
Wait 0.5 seconds
Reset
External signal: Inject parting agent
Lower cleaning motor?
High
Reset
External signal: Clamp gas nozzle /
Wire cutter closed
Low
Stop
Error
EN-US
Gas nozzle free?
Wire cutter open?
High
Move to position E
(Cleaning position KR2)
Speed: 10 cm/s (236.22 ipm)
Low
High
Set
External signal: Clamp gas nozzle /
Wire cutter closed
Wait 0.3 seconds
Reset
External signal: Clamp gas nozzle /
Wire cutter closed
Gas nozzle free?
Wire cutter open?
Low
Stop
Error
Set
External signal: Clamp gas nozzle /
Wire cutter closed
Wait 0.5 seconds
57
Gas nozzle clamped?
Set
External signal: Compressed air gas
purging with welding torch
Low
High
Set
External signal: Clamp gas nozzle
Gas nozzle clamped?
Low
Set
External signal: Cleaning motor on /
Lifting device up
Wait 2–3 seconds
Upper cleaning motor?
High
Reset
External signal: Cleaning motor on /
Lifting device up
Reset
External signal: Compressed air gas
purging with welding torch
Low
Stop
Error
Stop
Error
58
Set
External signal: Inject parting agent
Wait 0.5 seconds
Reset
External signal: Inject parting agent
Lower cleaning motor?
High
Reset
External signal: Clamp gas nozzle /
Wire cutter closed
Low
Stop
Error
EN-US
Gas nozzle free?
Wire cutter open?
High
Move to position F
Position: 25 mm above cleaning position
KR2
Speed: 10 cm/s (236.22 ipm)
Low
Stop
Error
Extend wire
59
Move to position B
Position: Move into wire cutter
Speed: 10 cm/s (236.22 ipm)
Set
External signal: Clamp gas nozzle / Cut
wire
Wait 0.5 seconds
Move to position A
Position: 25 mm over wire cutter
Speed: High speed mode
Reset
External signal: Clamp gas nozzle / Cut
wire
60
Cleaning
completed
Program sequence of cleaning for single
welding torches
If the diameter of the gas nozzle is too small, the gas nozzle may not be clamped
properly in the clamping device. No signal is output that the clamping device is
closed.
Start
Move to position A
Position: 50 mm over wire cutter
Speed: High speed mode
EN-US
Gas nozzle free?
Wire cutter open?
High
Move to position B
Position: Move into wire cutter
Speed: 10 cm/s (236.22 ipm)
Low
High
Set
External signal: Clamp gas nozzle / Cut
wire
Wait 0.5 seconds
Reset
External signal: Clamp gas nozzle / Cut
wire
Gas nozzle free?
Wire cutter open?
Low
Stop
Error
Set
External signal: Clamp gas nozzle / Cut
wire
61
Wait 0.7 seconds
Move to position A
Position: 50 mm over wire cutter
Speed: 10 cm/s (236.22 ipm)
Reset
External signal: Clamp gas nozzle / Cut
wire
Gas nozzle free?
Wire cutter open?
High
Move to position C
Position: 25 mm above the cleaning
position
Low
High
Set
External signal: Clamp gas nozzle / Cut
wire
Wait 0.5 seconds
Reset
External signal: Clamp gas nozzle / Cut
wire
Gas nozzle free?
Wire cutter open?
Low
Stop
Error
62
Retract wire
Wait 2–3 seconds
Lower cleaning motor?
High
Low
EN-US
Set
External signal: Motor on / Lifting device
up
Move to position D
Position: Move into clamping device
Speed: 10 cm/s (236.22 ipm)
Set
External signal: Clamp gas nozzle / Cut
wire
Wait 0.5 seconds
Reset
External signal: Motor on / Lifting device
up
High
Wait 0.3 seconds
Lower cleaning motor?
Low
Stop
Error
Wait 0.5 seconds
63
Gas nozzle clamped?
Set
External signal: Compressed air gas
purging with welding torch
Low
High
Set
External signal: Clamp gas nozzle
Gas nozzle clamped?
Low
Set
External signal: Cleaning motor on /
Lifting device up
Wait 2–3 seconds
Upper cleaning motor?
High
Reset
External signal: Cleaning motor on /
Lifting device up
Reset
External signal: Compressed air gas
purging with welding torch
Low
Stop
Error
Stop
Error
64
Set
External signal: Inject parting agent
Wait 0.5 seconds
Reset
External signal: Inject parting agent
Lower cleaning motor?
High
Reset
External signal: Clamp gas nozzle /
Wire cutter closed
Low
Stop
Error
EN-US
Gas nozzle free?
Wire cutter open?
High
Move to position F
Position: 25 mm above the cleaning
position
Speed: 10 cm/s (236.22 ipm)
Low
Stop
Error
Extend wire
65
Move to position B
Position: Move into wire cutter
Speed: 10 cm/s (236.22 ipm)
Set
External signal: Clamp gas nozzle / Cut
wire
Wait 0.5 seconds
Move to position A
Position: 50 mm over wire cutter
Speed: High speed mode
Reset
External signal: Clamp gas nozzle / Cut
wire
66
Cleaning
completed
Cleaning signal sequence
Signal input Cleaning motor on / lifting device up signal:
= Pin 1 at the Harting Han12P connecting plug (X1)
Contact tip 1
Contact tip 2
Spray in parting agent signal:
= Pin 2 on the Harting Han12P connecting plug (X1)
EN-US
Signal input and
output
Contact tip 1
Contact tip 2
Clamp gas nozzle / cut wire signal:
= Pin 9 on Harting Han12P connector (X1)
Actuator/sensor signal (Pin 7):
= Pin 7 on the Harting Han12P connecting plug (X1)
67
Actuator/sensor signal (Pin 8):
= Pin 8 on the Harting Han12P connecting plug (X1)
Signal output Upper cleaning motor signal:
= Pin 5 at the Harting Han12P connecting plug (X1)
Lower cleaning motor signal:
= Pin 6 at the Harting Han12P connecting plug (X1)
Gas nozzle free signal:
= Pin 11 on the Harting Han12P connecting plug (X1)
Gas nozzle clamped / wire cutter closed signal:
= Pin 10 at Harting Han12P connecting plug (X1)
68
Service, maintenance and disposal
69
70
Safety
EN-US
Safety
WARNING!
Danger from incorrect operation and work that is not carried out properly.
This can result in severe personal injury and damage to property.
All the work and functions described in this document must only be carried
▶
out by trained and qualified personnel.
Read and understand this document.
▶
Read and understand all the Operating Instructions for the system compon-
▶
ents, especially the safety rules.
WARNING!
Danger due to machines starting automatically.
This can result in severe personal injury and damage to property.
In addition to these Operating Instructions, observe the safety rules of the
▶
robot manufacturer and welding system manufacturer. Before entering the
robot work area, ensure that all protective measures in the robot work area
are in place and remain in place for the duration of the access.
WARNING!
Danger due to moving mechanical parts, flying debris (chips, etc.), and compressed air/parting agent mixture discharged from the parting-agent injection
nozzle.
This can result in severe personal injury and damage to property.
Before carrying out any work, disconnect the compressed air and power sup-
▶
ply from the cleaning device and the associated system components and
make sure that the compressed air and power supply remain disconnected
until all work has been completed.
Before carrying out any work, ensure that the cleaning device is depressur-
▶
ized - the necessary steps for this can be found in the following chapter En-
suring that the cleaning device is depressurized from page 78.
WARNING!
If the cleaning device is supplied with voltage and/or compressed air, there is a
risk of serious injury from: rotating cleaning cutter, cleaning motor moving up/
down, gas nozzle clamping device moving out/in, activated wire cutter, flying
parts (chips, etc.), compressed air/parting agent mixture escaping from the
parting-agent injection nozzle.
This can result in severe personal injury and damage to property.
If work is required on the cleaning device while the cleaning device is being supplied with voltage and/or compressed air, take the following safety measures.
Keep your body, especially hands, face and hair, as well as objects and all
▶
items of clothing away from the cleaning cutter, cleaning motor, lifting
device, gas nozzle clamping device, wire cutter, and parting-agent injection
nozzle.
Wear hearing protection.
▶
Wear protective goggles with side protection.
▶
71
Ensuring that
the cleaning
device is depressurized
To ensure that the cleaning device is depressurized, try to briefly activate the
cleaning device without the compressed air supply. To do this, proceed as follows:
Take protective measures:
1
The cleaning cutter, lifting device, gas nozzle clamping device, wire cut-
-
ter, and parting-agent injection nozzle could be activated. Therefore,
keep your body, especially hands, face and hair, as well as objects and all
items of clothing, away from the aforementioned parts.
Wear hearing protection.
-
Wear protective goggles with side protection.
-
Ensure that the cleaning device is disconnected from the compressed air
2
supply.
Set the “Start cleaning” screw on the cleaning device to position “1” (activ-
3
ated) for max. 2 seconds and then return to the starting position “0” (deactivated).
If the cleaning device does not respond to the activation of the “Start
-
cleaning” function, the cleaning device is free of compressed air.
If the cleaning device responds to the activation of the “Start cleaning”
-
function, the cleaning device is still connected to the compressed air
supply.
In this case, the cleaning device must be disconnected from the compressed air supply before starting any work. Finally, ensure that the
cleaning device is depressurized.
72
Service, maintenance and disposal
EN-US
Before every
start-up
Daily
Weekly
Check the fill level in the parting agent container and top up if necessary.
-
Check for wear of the cleaning cutter and replace the cleaning cutter if ne-
-
cessary.
Drain the cleaning device’s collecting container.
-
In general, you should visually inspect the cleaning device and ensure that
-
any damage is repaired immediately (before commissioning).
CAUTION!
Danger due to cleaning agents containing solvents.
This can result in damage to property.
Only clean the cleaning device with cleaning products that are free of
▶
solvents.
Remove deposited parting agent and contamination from the device.
1
CAUTION!
Danger due to cleaning agents containing solvents.
This can result in damage to property.
Only clean the parting agent container with cleaning products that are free
▶
of solvents.
Check the parting agent container for contamination and clean if necessary.
1
Blow out the intake filter in the parting agent container from the inside out
2
with compressed air using the intake hose (see chapter Starting Up the Part-
ing Agent Atomizer from page 43).
Every 6 months
Whenever required:
Disposal Waste electrical and electronic equipment must be collected separately and re-
Open the device and check the pneumatic valves to ensure:
1
no leaks
-
all screws are screwed tightly in place
-
all screw joints are fixed firmly in place on the pneumatic valves.
-
Open the device and
blast the inside of the device clean with dry and reduced compressed air
1
lightly oil the guides on the lifting device’s lifting cylinder
2
restore the operational state of the device.
3
cycled in an environmentally sound manner in accordance with the European Directive and national law. Used equipment must be returned to the distributor or
through a local authorized collection and disposal system. Proper disposal of the
used device promotes sustainable recycling of material resources. Failure to ob-
73
serve this may lead to potential health/environmental impacts.
Packaging materials
Separate collection. Check your municipality’s regulations. Reduce the volume of
the box.
74
Troubleshooting
75
76
Safety
EN-US
Safety
WARNING!
Danger from incorrect operation and work that is not carried out properly.
This can result in severe personal injury and damage to property.
All the work and functions described in this document must only be carried
▶
out by trained and qualified personnel.
Read and understand this document.
▶
Read and understand all the Operating Instructions for the system compon-
▶
ents, especially the safety rules.
WARNING!
Danger due to machines starting automatically.
This can result in severe personal injury and damage to property.
In addition to these Operating Instructions, observe the safety rules of the
▶
robot manufacturer and welding system manufacturer. Before entering the
robot work area, ensure that all protective measures in the robot work area
are in place and remain in place for the duration of the access.
WARNING!
Danger due to moving mechanical parts, flying debris (chips, etc.), and compressed air/parting agent mixture discharged from the parting-agent injection
nozzle.
This can result in severe personal injury and damage to property.
Before carrying out any work, disconnect the compressed air and power sup-
▶
ply from the cleaning device and the associated system components and
make sure that the compressed air and power supply remain disconnected
until all work has been completed.
Before carrying out any work, ensure that the cleaning device is depressur-
▶
ized - the necessary steps for this can be found in the following chapter En-
suring that the cleaning device is depressurized from page 78.
WARNING!
If the cleaning device is supplied with voltage and/or compressed air, there is a
risk of serious injury from: rotating cleaning cutter, cleaning motor moving up/
down, gas nozzle clamping device moving out/in, activated wire cutter, flying
parts (chips, etc.), compressed air/parting agent mixture escaping from the
parting-agent injection nozzle.
This can result in severe personal injury and damage to property.
If work is required on the cleaning device while the cleaning device is being supplied with voltage and/or compressed air, take the following safety measures.
Keep your body, especially hands, face and hair, as well as objects and all
▶
items of clothing away from the cleaning cutter, cleaning motor, lifting
device, gas nozzle clamping device, wire cutter, and parting-agent injection
nozzle.
Wear hearing protection.
▶
Wear protective goggles with side protection.
▶
77
Ensuring that
the cleaning
device is depressurized
To ensure that the cleaning device is depressurized, try to briefly activate the
cleaning device without the compressed air supply. To do this, proceed as follows:
Take protective measures:
1
The cleaning cutter, lifting device, gas nozzle clamping device, wire cut-
-
ter, and parting-agent injection nozzle could be activated. Therefore,
keep your body, especially hands, face and hair, as well as objects and all
items of clothing, away from the aforementioned parts.
Wear hearing protection.
-
Wear protective goggles with side protection.
-
Ensure that the cleaning device is disconnected from the compressed air
2
supply.
Set the “Start cleaning” screw on the cleaning device to position “1” (activ-
3
ated) for max. 2 seconds and then return to the starting position “0” (deactivated).
If the cleaning device does not respond to the activation of the “Start
-
cleaning” function, the cleaning device is free of compressed air.
If the cleaning device responds to the activation of the “Start cleaning”
-
function, the cleaning device is still connected to the compressed air
supply.
In this case, the cleaning device must be disconnected from the compressed air supply before starting any work. Finally, ensure that the
cleaning device is depressurized.
78
Troubleshooting
EN-US
Errors in the
Program Sequence
Parting agent is not injected
Parting agent container is full
Cause:
Remedy:
Cause:
Remedy:
Cause:
Remedy:
Cause:
Remedy:
Cause:
Remedy:
Injection quantity too low.
Extend the injection time.
The intake filter of the parting agent hose in the parting agent container is contaminated.
Clean the suction filter of the parting agent hose with compressed air
(for more information, see chapter Starting Up the Parting Agent At-
omizer from page 43).
No signal from robot.
Check robot program.
Parting-agent injection nozzle blocked.
Clean the parting-agent injection nozzle.
Notify the service team (have parting-agent injection nozzle replaced).
Vacuum pump defective.
Contact service team (have vacuum pump replaced).
Cause:
Remedy:
Welding torch has been poorly cleaned or is damaged
Cause:
Remedy:
Cause:
Remedy:
Cause:
Remedy:
Cause:
Remedy:
Solenoid valve has mechanical fault.
Contact service team (have solenoid valve replaced).
Position of the cleaning motor incorrectly set.
Set the position of the cleaning motor correctly (see chapterAdjust-
ing the Position of the Cleaning Motor from page 39).
Cleaning position of the welding torch incorrectly set.
Set the cleaning position of the welding torch again (see chapter
Welding Torch Cleaning Position from page 35).
Cleaning cutter does not fit the welding torch geometry.
Fit a correct cleaning cutter.
Cleaning cutter worn.
Replace cleaning cutter.
79
Lifting device does not move up or down
Cause:
Remedy:
Compressed air supply missing.
Set up the compressed air supply.
Cause:
Remedy:
Cause:
Remedy:
Cause:
Remedy:
Cause:
Remedy:
Cleaning motor not working
Cause:
Remedy:
Cause:
Remedy:
Cause:
Remedy:
No signal from robot.
Check robot program.
Solenoid valve has mechanical fault.
Contact service team (have solenoid valve replaced).
Throttle valve cannot be adjusted or is faulty.
Contact service team (have throttle valve replaced).
Seal on lifting cylinder is faulty.
Contact service team (have lifting cylinder replaced).
Compressed air supply missing.
Set up the compressed air supply.
No signal from robot.
Check robot program.
Cleaning motor has mechanical fault.
Contact service team (have cleaning motor replaced).
Cause:
Remedy:
Solenoid valve has mechanical fault.
Contact service team (have solenoid valve replaced).
80
Technical data
81
82
Technical data
EN-US
Robacta Reamer
Single/Twin
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 for compressed air
connection
Standard I/O (X1) Input: + 24 V DC/max. 100 mA
Cleaning time 4.5 - 6.5 s
Overall cycle time 5.0 - 9.0 s
Capacity of the parting agent container 1 l
Protection class Protection class 21
Mark of conformity CE
Safety symbols S
“Performance Level” c
G ¼”
Output: + 24 V DC/max. 30 mA
.26 gal. (US)
Maximum noise emission (LWA) 82 dB (A)
EMC emission class
Dimensions l x w x h 345 x 245 x 400 mm
Weight
(not including parting agent and optional
wire cutter)
1)
A device in emissions class A is not intended for use in residential areas in
which the electrical power is supplied via a public low-voltage grid. The electromagnetic compatibility may be influenced by conducted or radiated radio frequencies.
1)
A
13.58 x 9.64 x 15.74 in.
14.5 kg
31.96 lb.
83
84
Appendix
85
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EN-US
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88
EN-US
89
90
EN-US
91
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