General5
Proper use5
Environmental conditions5
Obligations of the operator6
Obligations of personnel6
Specific hazards6
Protecting yourself and others7
EMC Device Classifications7
EMC measures7
EMF measures8
Safety measures at the installation location and during transport8
Safety measures in normal operation8
Commissioning, maintenance and repair9
Safety inspection9
Disposal9
Safety symbols10
Copyright10
General11
General13
Principle13
Functionality of the cleaning device13
Application areas13
Warning notices on the cleaning device13
Transport16
Transport devices16
Transport notices on the packaging16
Scope of supply and options17
Scope of supply17
Available options17
EN
Controls, connections and mechanical components19
Safety21
Safety21
Controls, connections and mechanical components22
Control elements, connections and mechanical components 22
Harting Han12P connecting plug (X1) pin assignment for robot control24
Safety27
Ensuring that the cleaning device is depressurised28
Before commissioning29
Proper use29
Operators, maintenance personnel29
Setup regulations29
Compressed air supply specifications29
Measures for the safe operation of the device with untrained personnel30
Screwing the cleaning device to the underlying surface31
Screwing the cleaning device and installation stand to the underlying surface31
Screwing the cleaning device to the underlying surface32
Torch cleaning position34
Welding torch cleaning position34
Adjust gas nozzle clamping device35
Adjusting the gas nozzle clamping device35
3
Fitting the cleaning cutter36
Fitting the cleaning cutter36
Adjusting the position of the cleaning motor37
Adjusting the position of the cleaning motor37
Configuring the spray device38
Configuring the spray device38
Installing the electrically controlled wire cutter (optional)39
How the electrically-controlled wire cutter works39
Maximum wire diameter39
Installing the electrically controlled wire cutter39
To establish the compressed air supply:41
Establishing the compressed air supply for the cleaning device, function of the compressed air relief valve
Starting up the parting agent nebuliser42
Filling the parting agent container (1 litre) and connecting it to the cleaning device42
Connecting the parting agent container (10 litres) to the cleaning device43
Adjusting the parting agent nebuliser spray amount43
Manually checking the cleaning device functions45
Safety45
Manually checking the cleaning device functions45
Starting up the cleaning device47
Prerequisites for start-up47
Start-up47
Cleaning programme48
Safety48
Cleaning program sequence49
Signal waveform for cleaning53
Signal inputs53
Signal outputs53
Signal waveform optional wire cutter (input)53
41
Care, maintenance and disposal55
Safety57
Safety57
Ensuring that the cleaning device is depressurised58
Care, maintenance and disposal59
General59
Before each start-up59
Daily59
Weekly59
Every 6 months59
As necessary59
Disposal60
Troubleshooting61
Safety63
Safety63
Ensuring that the cleaning device is depressurised64
Troubleshooting65
Errors in program sequence65
Technical data67
Technical data69
Robacta Reamer V 70 Han12P69
Appendix71
Robacta Reamer V 70 Han12P Circuit Diagram73
Robacta Reamer V 70 Han12P pneumatic diagram74
Declaration of conformity75
4
Safety rules
GeneralThe 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.
-
EN
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 useThe 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.
5
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 hazardsStay 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 cleaning cutter
-
upwards/downwards travelling cleaning motor
-
extending/retracting gas nozzle clamping device
-
wire cutter
-
6
Do not touch cleaning cutters immediately after use - risk of burns. Observe the
special safety rules in the Operating Instructions for handling cleaning cutters.
Protect hands, face and eyes against flying parts (shavings, etc.) and compressed
air/parting agent mixture escaping from the parting-agent injection nozzle.
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
-
EN
Protecting yourself and others
EMC Device
Classifications
Anyone working with the device exposes themselves to numerous risks. In addition to these Operating Instructions, the safety rules of the manufacturer of the
entire welding system must also be observed.
Keep all persons, especially children, out of the working area while any devices
are in operation or welding is in progress. If, however, there are people in the vicinity:
Make them aware of all the dangers and health risks (crushing from mechan-
-
ically-powered parts, injury from cleaning cutter, flying shavings and similar
matter, escaping compressed air/parting agent mixture, flying sparks,
dazzling by arc, inhaling of harmful welding fumes, noise, possible danger
from mains or welding current, etc.)
Provide suitable protective equipment
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 measuresIn 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
-
7
Supporting measures for avoidance of EMC problems:
Mains supply
1.
If electromagnetic interference arises despite correct mains connection,
-
additional measures are necessary (e.g. use a suitable line filter).
Control lines
2.
must be kept as short as possible
-
must run close together (to avoid EMF problems)
-
must be kept well apart from other leads
-
Equipotential bonding
3.
Shield, if necessary
4.
Shield off other nearby devices
-
Shield off entire welding installation
-
EMF measuresElectromagnetic 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.
8
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.
EN
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.
DisposalWaste 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.
9
Safety symbolsDevices with the CE mark satisfy the essential requirements of the applicable
directives (e.g. low-voltage and electromagnetic compatibility directives, machinery directive).
Devices with the CSA test mark satisfy the requirements of the relevant standards in Canada and the USA.
CopyrightCopyright of these operating instructions remains with the manufacturer.
The text and illustrations are all technically correct at the time of printing. We
reserve the right to make changes. The contents of the operating instructions
shall not provide the basis for any claims whatsoever on the part of the purchaser. If you have any suggestions for improvement, or can point out any mistakes that you have found in the instructions, we will be most grateful for your
comments.
10
General
11
12
General
PrincipleThe cleaning device is used to auto-
matically clean MIG/MAG welding
torches. This cleaning device allows
you to thoroughly clean the inside and
front of the gas nozzle on a wide range
of welding torch shapes. The result is a
significant increase in the service life
of wearing parts. At the same time,
evenly applying parting agent prevents
the build-up of dirt.
EN
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 cleaning
A cleaning cutter is used to clean the nozzle
-
After the cleaning process, a parting agent is applied to the inside and front
-
of the gas nozzle through the parting-agent injection nozzle
The cleaning device is exclusively intended for use in robot and other automated
applications, and can be used for a wide range of materials.
The main application areas are:
Automotive and component supply industry
-
Equipment construction
-
Chemical plant construction
-
Machine and tracked vehicle manufacturing
-
Construction machinery and special vehicles
-
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.
13
Type
Art.No.
Chargen No.
U1
I1
p
max
24 V
6 bar (87psi.)
www.fronius.com
Warning notices on the cleaning device
WARNING! Risk of serious injury from:
Mechanically powered components
-
Compressed air/parting agent mixture escaping from the parting-agent injec-
-
tion nozzle
Flying parts (shavings, etc.)
-
Keep the device free from current and pressure during maintenance and servicing.
14
Do not use the functions described here 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
For indoor use only
Wear eye protection
Warning of automatic start-up of the device
EN
15
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.
▶
16
Scope of supply and options
(1)
(2)
(3)
(4)
(5)
(6)
EN
Scope of supply
(1)Robacta Reamer V 70 Han12P
(2)Leather seal for the parting
(3)Spatter tray retainer
(4)Spatter tray
(5)Tightening key for cleaning mo-
(6)Compressed air relief valve
Included in scope of supply, but not shown:
Harting Han12P connecting plug (X1) without cable
-
Operating instructions
-
Fixings for assembling the cleaning device:
-
4 screws
-
4 washers
-
4 lock washers
-
4 nuts
-
cleaning device
agent spray device
tor
Available options
The "Robacta Reamer" parting agent (item number 42,0411,8042) and the cleaning cutter are not included in the scope of supply.
The following options are available for the cleaning device:
Installation stand
-
Wire cutter
-
Fill-level control sensor
-
17
18
Controls, connections and mechan-
ical components
19
20
Safety
SafetyObserve the following safety rules for all work described in the "Control ele-
ments, connections and mechanical components" section.
WARNING!
Danger due to incorrect operation and incorrectly performed work.
This can result in serious 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
21
Controls, connections and mechanical compon-
(3)
(2)
(1)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(16)
(15)
(13)
(14)
(12)
(11)
ents
Control elements, connections and mechanical components
Side view
No.Function
(1)Parting agent adjuster
For adjusting the amount of parting agent sprayed inside the gas nozzle
(2)Compressed air connection
For a dry compressed air supply at 6 bar (86.99 psi)
Thread identification compressed air connection: G ¼ ″
(3)Harting Han12P connection socket (X1)
For a + 24 V DC supply
CAUTION!
Danger from overcurrent.
Damage to the Harting Han12P (X1) connection supply may result.
Secure supply against overcurrent with a 500 mA slow-blow fuse.
▶
(4)Parting agent spatter tray
(5)Parting agent container
(6)Gas nozzle clamping device
holds the gas nozzle in place during cleaning
Front view
22
(7)Parting agent spray device
Includes the parting-agent injection nozzle
Ensures that the parting agent is only applied to the inside and front of
the gas nozzle
(8)Parting-agent injection nozzle
Applies the parting agent to the inside and front of the gas nozzle
(9)Cleaning cutter
(10)Protective covering
(11)"Start cleaning" screw
Manually checks the following:
Function of the gas nozzle clamping device (clamping device piston
-
extends)
The insertion depth of the cleaning cutter in the gas nozzle (lifting
-
device moves the cleaning motor upwards)
Function of the cleaning motor (cleaning motor starts)
-
(12)"Spray in parting agent" screw
For manually checking the spray device (compressed air or compressed
air/parting agent mixture is sprayed out of the parting-agent injection
nozzle)
(13)Compressed air connection for the wire cutter option
(14)Electrical connection for the wire cutter option
(15)Cleaning motor
Drives the cleaning cutter
(16)Lifting device
Lifts the cleaning motor and the cleaning cutter when cleaning the inside
of the gas nozzle
EN
23
Harting Han12P connecting plug (X1) pin assignment for robot control
Damage to the Harting Han12P (X1) connection supply may result.
Secure supply against overcurrent with a 500 mA slow-blow fuse.
▶
CAUTION!
Danger due to long control line.
Interference in signal transmission may result.
Keep the control line between the robot control and the cleaning device as
▶
short as possible.
The Harting Han12P 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:
Start cleaning input signal (clamp
1.
gas nozzle, cleaning motor on,
cleaning motor off)
Spray in parting agent input signal
SafetyObserve the following safety rules for all work described in the "Installation and
start-up" section.
WARNING!
Danger due to incorrect operation and incorrectly performed work.
This can result in serious 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!
Risk of machines starting automatically.
This can result in serious injury and damage to property.
In addition to these Operating Instructions, also observe the safety rules is-
▶
sued by the manufacturer of the robot and welding system. 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.
EN
WARNING!
Danger from mechanically powered parts, flying parts (shavings, etc.), compressed air/parting agent mixture escaping from the parting-agent injection
nozzle.
This can result in serious injury and damage to property.
Before carrying out any work, 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.
Before carrying out any work, make sure that the cleaning device is depres-
▶
surised - for the necessary steps, see the following section Ensuring that the
cleaning device is depressurised from page 28.
WARNING!
Whenever the cleaning device is supplied with voltage and/or compressed air, a
risk of serious injury exists from: rotating cleaning cutter, cleaning motor moving up/down, extending/retracting gas nozzle clamping device, activated wire
cutter, flying parts (shavings, etc.), compressed air/parting agent mixture escaping from the parting-agent injection nozzle.
This can result in serious injury and damage to property.
If work has to be performed on the cleaning device while it is being supplied with
voltage and/or compressed air, take the following protective measures:
Keep your body, especially your hands, face, hair, any objects and all clothing
▶
away from 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.
▶
27
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. To do this, proceed as
follows:
Take protective measures:
1
The cleaning cutter, lifting device, gas nozzle clamping device, wire cutter
-
and parting-agent injection nozzle could start up. It is therefore important that you keep your body, especially your hands, face and hair, any objects and all clothing away from the components referred to above
Wear ear protection
-
Wear protective goggles with side protection
-
Ensure that the cleaning device has been disconnected from the compressed
2
air supply
Briefly turn the "Start cleaning" screw on the cleaning device 90° to the right,
3
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
28
Before commissioning
Proper useThe 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
-
EN
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,
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.
30
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-
1
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
2
to the surface (foundation) using
the selected mounting materials
EN
Screw on the cleaning device and the spatter tray retainer using the fixings supplied with the cleaning device.
3
Place components on the installation stand and secure
31
4
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-
1
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.
2
32
Place components on the underlying surface and secure
3
Attach the spatter tray retainer as shown
EN
33
Torch cleaning position
Welding torch
cleaning position
The welding torch (gas nozzle) must be
located centrally above the cleaning
motor / cleaning cutter, at a distance
of 1-2 mm (0.039 - 0.079 inch) to the
protective cover
34
Adjust gas nozzle clamping device
(1)
(3)
(2)
(4)
EN
Adjusting the
gas nozzle
clamping device
CAUTION!
Danger due to incorrectly adjusted gas nozzle clamping device.
This may result in damage to the welding torch.
Adjust the gas nozzle clamping device in such a way that no reaction forces
▶
can be transferred to the robot.
The gas nozzle must only be clamped onto the cylindrical surface.
▶
Only clamp the gas nozzle centrally above the cleaning motor.
▶
Loosen the Allen screws on the
1
guide bolts (1) and (2)
Move the welding torch to the
2
cleaning position
centrally with respect to the
-
cleaning motor
Using the adjusting screw (3), posi-
3
tion the clamping device (4) so that
the clamping device is touching the
gas nozzle
Tighten the Allen screws on the
4
guide bolts (1) and (2)
35
Fitting the cleaning cutter
Fitting the
cleaning cutter
CAUTION!
Danger due to cleaning cutter that has become very hot through use.
This can result in severe burns.
Before handling cleaning cutters, allow cleaning cutter to cool to room tem-
▶
perature (+25 °C, +77 °F).
CAUTION!
Danger from incompatible wearing parts.
This can result in damage to property and malfunctions.
Only use the device manufacturer's contact tips, gas nozzles and cleaning
▶
cutters. No liability is accepted for damage caused by the use of contact tips,
gas nozzles or cleaning cutters from third-party manufacturers.
The cleaning cutter is not part of the scope of suppl.. Consult the manufacturer's
spare parts list for the appropriate cleaning cutter: https://spareparts.froni-
us.com/
Remove the protective covering from the cleaning device
1
2
36
Fit the protective covering to the cleaning device in its original position
3
Adjusting the position of the cleaning motor
(1)
(2)
(3)
(4)(6)(5)
EN
Adjusting the
position of the
cleaning motor
Remove the protective covering (1)
1
Remove the gas nozzle from the
2
torch body
Loosen the screw (2) on the lifting
3
device
Ensure that the lifting device (3) is
4
in its lowest lift position
Move the welding torch to the
5
cleaning position (approx. 1 - 2
mm / 0.039 - 0.079 in. above the
protective covering, centrally with
respect to the cleaning motor)
Manually push the lifting device (3) into its highest lift position and hold in
6
place
Manually push cleaning motor (4) and cleaning cutter to the cleaning position
7
Ensure that the cleaning cutter does not touch any welding torch com-
-
ponents
See diagram (5) for welding torch with insulating sleeve
-
See diagram (6) for welding torch with spatter guard
-
Fix the cleaning motor (4) in this position in the lifting device (3) - tighten the
8
screw (2) on the lifting device
Complete a function test without the gas nozzle fitted: move the cleaning
9
motor manually to the uppermost position
The cleaning cutter must close around the contact tip without touching
-
it. If the cleaning cutter touches the welding torch components, readjust
the position of the cleaning motor
Fit the gas nozzle to the torch body
10
Complete a function test with the gas nozzle fitted: move the cleaning motor
11
manually to the uppermost position
The cleaning cutter must be inserted into the gas nozzle gently, without
-
touching it. If the cleaning cutter touches the welding torch components,
readjust the position of the cleaning motor
Fit the protective covering to the cleaning device in its original position
12
37
Configuring the spray device
Configuring the
spray device
If the opening on the standard leather seal is too large for the gas nozzle used,
fit the second leather seal included in the scope of supply as shown below.
The available leather seals can be found in the Spare Parts List: https://spare-
parts.fronius.com/
Replace leather seal:
1
Remove existing leather seal
2
Fit leather seal with smaller diameter
38
Installing the electrically controlled wire cutter
(optional)
How the electrically-controlled wire cutter works
Maximum wire
diameter
Installing the
electrically controlled wire cutter
EN
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.
12
3
Use the adapter previously removed
from the wire cutter.
39
4
Use the fixings supplied with the wire
cutter.
Ensure that the recesses in the
spacers face the cleaning device.
5
The wire cutter is controlled electrically by the robot control.
40
To establish the compressed air supply:
EN
Establishing the
compressed air
supply for the
cleaning device,
function of the
compressed air
relief valve
To establish the compressed air supply:
Depressurise the compressed air supply line of the cleaning device and en-
1
sure that it remains depressurised for the duration of the following work on
the device
Screw the supplied compressed air relief valve into the compressed air con-
2
nection on the cleaning device
Connect the compressed air supply line to the compressed air relief valve
3
The compressed air supply to the cleaning device can be broken and re-established by moving the compressed air relief valve forwards and backwards - see
description below.
The diagram below shows the compressed air relief valve in the closed position =
no compressed air supply to the device:
Compressed air relief valve closed
The diagram below shows the compressed air relief valve in the open position =
compressed air is being supplied to the device:
Compressed air relief valve open
41
Starting up the parting agent nebuliser
Filling the parting agent container (1 litre)
and connecting
it to the cleaning
device
Only use "Robacta Reamer" parting agent (item number 42,0411,8042) supplied
by the manufacturer. The composition of this parting agent is designed specifically for the cleaning device. If other manufacturers' products are used, troublefree operation cannot be guaranteed.
12
34
42
5
Connecting the
1
*
1
4
2
3
parting agent
container (10
litres) to the
cleaning device
Only use "Robacta Reamer" parting agent (item number 42,0411,8042) supplied
by the manufacturer. The composition of this parting agent is designed specifically for the cleaning device. If other manufacturers' products are used, troublefree operation cannot be guaranteed.
1
2
EN
Adjusting the
parting agent
nebuliser spray
amount
* Option (long parting agent hose)
3
Move the welding torch to the cleaning position
1
Establish a compressed air supply to the cleaning device
2
Connect the cleaning device to the robot control
3
Start the spraying process using the robot control and check that sufficient
4
spray is being applied
43
If the spray amount is not sufficient, increase it as required
5
by adjusting the spray time using the robot control - a spray time of ~ 0.7
-
seconds is recommended
or by using the parting agent adjuster - see figure below
-
6
Finely adjusting the spray amount on parting agent adjuster
44
Manually checking the cleaning device functions
EN
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 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!
When the slot for the "Start cleaning" and "Spray in parting agent" screws is positioned horizontally, the respective function is deactivated.
Move the welding torch to the cleaning position
1
Disconnect the cleaning device from the robot control
2
Establish a compressed air supply to the cleaning device
3
Start cleaning function
The following must be checked when the function is being performed:
Function of the gas nozzle clamping device (clamping device piston extends)
-
The insertion depth of the cleaning cutter in the gas nozzle (lifting device
-
moves the cleaning motor upwards)
Function of the cleaning motor (cleaning motor starts)
-
4
Start cleaning
5
Deactivating the function
Spray in parting agent function
The following must be checked once the function has been performed:
whether the gas nozzle is coated with a sufficient layer of parting agent
-
45
6
7
Spraying in parting agent
Deactivating the function
46
Starting up the cleaning device
EN
Prerequisites for
start-up
Start-upThe cleaning device starts up when there is an active signal from the robot con-
The following requirements must be met before starting up the cleaning device:
If present, the cleaning device installation stand is screwed to the underlying
-
surface
The cleaning device is screwed to the underlying surface
-
Gas nozzle clamping device is adjusted
-
Cleaning cutter is fitted
-
Position of the cleaning motor has been set
-
If present, the wire cutter has been installed
-
Parting agent nebuliser has been started up
-
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.
47
Cleaning programme
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.
Do not start in automated mode until the cleaning device has been properly
▶
installed and started up.
NOTE!
Not coating the interior of the welding torch may result in permanent soiling of
the torch when welding begins.
Always wet the interior of the welding torch with the manufacturer's parting
▶
agent before starting automatic operation.
48
Cleaning program sequence
Start
Start from position C
- approx. 25 mm (0.98 in.) next to wire
cutter
- Speed: high speed
Start from position D
- Enter wire cutter
- Speed: 10 cm/s
(236.22 ipm)
Set
- External signal "Cut wire electrode"
Wait 0.5 sec.
Start from position G
- approx. 50 mm (1.97 in.) centrally
above the wire cutter
- Speed: 10 cm/s
(236.22 ipm)
Wire cutter option
EN
Reset
- External signal "Cut wire electrode"
49
Start from position A
- approx. 50 mm (1.97 in.) centrally
above the cleaning device
- Speed: high speed
Query output (Gas nozzle free output
signal)
- Low or High
Query = Low
(Gas nozzle clamped)
Query = High
(Gas nozzle free)
Start from position B (cleaning
position)
- Enter gas nozzle clamping device
- Speed: 10 cm/s
(236.22 ipm)
Set
- Blow-compressed air through
welding torch
Set
- Input "Begin cleaning"
Query output (cleaning motor UP
output signal)
- Low or High
Stop
Query = Low
(Cleaning motor not raised)
50
Query = High
(Cleaning motor raised)
Stop
Reset
- Input "Begin cleaning"
Wait 1.5 sec.
Reset
- Blow compressed air through
welding torch
Query output (Gas nozzle free output
signal)
- Low or High
Query output = High
(Gas nozzle free)
Start from position A
- approx. 50 mm (1.97 in.) centrally
above the cleaning device
SafetyObserve the following safety rules for all work described in the "Care, mainten-
ance and disposal" section.
WARNING!
Danger due to incorrect operation and incorrectly performed work.
This can result in serious 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!
Risk of machines starting automatically.
This can result in serious injury and damage to property.
In addition to these Operating Instructions, also observe the safety rules is-
▶
sued by the manufacturer of the robot and welding system. 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.
EN
WARNING!
Danger from mechanically powered parts, flying parts (shavings, etc.), compressed air/parting agent mixture escaping from the parting-agent injection
nozzle.
This can result in serious injury and damage to property.
Before carrying out any work, 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.
Before carrying out any work, make sure that the cleaning device is depres-
▶
surised - for the necessary steps, see the following section Ensuring that the
cleaning device is depressurised from page 58.
WARNING!
Whenever the cleaning device is supplied with voltage and/or compressed air, a
risk of serious injury exists from: rotating cleaning cutter, cleaning motor moving up/down, extending/retracting gas nozzle clamping device, activated wire
cutter, flying parts (shavings, etc.), compressed air/parting agent mixture escaping from the parting-agent injection nozzle.
This can result in serious injury and damage to property.
If work has to be performed on the cleaning device while it is being supplied with
voltage and/or compressed air, take the following protective measures:
Keep your body, especially your hands, face, hair, any objects and all clothing
▶
away from 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.
▶
57
CAUTION!
Danger due to cleaning cutter that has become very hot through use.
This can result in severe burns.
Before handling cleaning cutters, allow cleaning cutter to cool to room tem-
▶
perature (+25 °C, +77 °F).
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. To do this, proceed as
follows:
Take protective measures:
1
The cleaning cutter, lifting device, gas nozzle clamping device, wire cutter
-
and parting-agent injection nozzle could start up. It is therefore important that you keep your body, especially your hands, face and hair, any objects and all clothing away from the components referred to above
Wear ear protection
-
Wear protective goggles with side protection
-
Ensure that the cleaning device has been disconnected from the compressed
2
air supply
Briefly turn the "Start cleaning" screw on the cleaning device 90° to the right,
3
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
58
Care, maintenance and disposal
GeneralThe 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.
EN
Before each
start-up
Daily
Weekly
Check fill level in parting agent container and top up if necessary
-
Check fill level in parting agent spatter tray and empty if necessary
-
Check cleaning cutter for wear and replace if necessary
-
Empty the cleaning device spatter tray
-
If fitted, empty the wire cutter tray
-
Carry out a general visual inspection of the cleaning device and make sure
-
that any damage is repaired immediately (before start-up)
CAUTION!
Danger from cleaning agents containing solvents.
This can result in damage to property.
Only use solvent-free cleaning products on the cleaning device.
▶
Remove parting agent deposits and dirt from device
1
CAUTION!
Danger from cleaning agents containing solvents.
This can result in damage to property.
Only use solvent-free cleaning products on the parting agent container.
▶
Check the parting agent container for soiling and clean if necessary
1
Blow through suction filter in parting agent container using compressed air
2
from the inside outwards through the suction hose (for more detailed information see section Starting up the parting agent nebuliser from page 42)
Every 6 months
As necessaryOpen the device and
Open the device and check the pneumatic valves for
1
Leaks
-
The secure seating of all screws
-
The secure seating of all screw joints on the pneumatic valves
-
Clean inside of device using dry reduced compressed air
1
Lightly oil the lifting device cylinder guides
2
Restore the original condition of the device
3
59
DisposalDispose of in accordance with the applicable national and local regulations.
60
Troubleshooting
61
62
Safety
SafetyObserve the following safety rules for all work described in the "Troubleshooting"
section.
WARNING!
Danger due to incorrect operation and incorrectly performed work.
This can result in serious 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!
Risk of machines starting automatically.
This can result in serious injury and damage to property.
In addition to these Operating Instructions, also observe the safety rules is-
▶
sued by the manufacturer of the robot and welding system. 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.
EN
WARNING!
Danger from mechanically powered parts, flying parts (shavings, etc.), compressed air/parting agent mixture escaping from the parting-agent injection
nozzle.
This can result in serious injury and damage to property.
Before carrying out any work, 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.
Before carrying out any work, make sure that the cleaning device is depres-
▶
surised - for the necessary steps, see the following section Ensuring that the
cleaning device is depressurised from page 64.
WARNING!
Whenever the cleaning device is supplied with voltage and/or compressed air, a
risk of serious injury exists from: rotating cleaning cutter, cleaning motor moving up/down, extending/retracting gas nozzle clamping device, activated wire
cutter, flying parts (shavings, etc.), compressed air/parting agent mixture escaping from the parting-agent injection nozzle.
This can result in serious injury and damage to property.
If work has to be performed on the cleaning device while it is being supplied with
voltage and/or compressed air, take the following protective measures:
Keep your body, especially your hands, face, hair, any objects and all clothing
▶
away from 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.
▶
63
CAUTION!
Danger due to cleaning cutter that has become very hot through use.
This can result in severe burns.
Before handling cleaning cutters, allow cleaning cutter to cool to room tem-
▶
perature (+25 °C, +77 °F).
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. To do this, proceed as
follows:
Take protective measures:
1
The cleaning cutter, lifting device, gas nozzle clamping device, wire cutter
-
and parting-agent injection nozzle could start up. It is therefore important that you keep your body, especially your hands, face and hair, any objects and all clothing away from the components referred to above
Wear ear protection
-
Wear protective goggles with side protection
-
Ensure that the cleaning device has been disconnected from the compressed
2
air supply
Briefly turn the "Start cleaning" screw on the cleaning device 90° to the right,
3
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
64
Troubleshooting
EN
Errors in program sequence
The parting agent does not spray
Parting agent container is full
Cause:
Remedy:
Cause:
Remedy:
Cause:
Remedy:
Cause:
Remedy:
Cause:
Remedy:
Not enough spray
Adjust spray time
Parting agent hose suction filter in the parting agent container is
soiled
Clean the suction filter of the parting agent hose with compressed air
(for more detailed information, see section Starting up the parting
42 - Rückschlagventil ohne Feder
43 - Filter Ansaugung
30 - Kunststoffflasche für Antihaftmittel
31 - Kunststoffflasche für Antihaftmittel
15 - Schiebeeinheit
41 - Rückschlagventil mit Feder
25 - Venturidüse mit Rückschlagventil
24 - Drosselventil
27 - Einsprühdüse
40 - Aluminiumzylinder
74
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 V70 Han12P
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.