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Robacta Reamer V Twin

Fronius Robacta Reamer V Twin Operating Instruction [EN]

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Operating Instructions
Robacta Reamer V Twin
Operating Instructions
EN
42,0426,0142,EN 025-30012023
Contents
Safety rules 6
General 13
General 15
Transport 19
EN
Controls, connections and mechanical components 21
Safety 23
Robacta Reamer V Twin control elements, connections and mechanical components 24
Control elements, connections and mechanical components 24
Standard I/O connecting plug (X1) pin assignment for robot control 26
Installation and commissioning 27
Safety 29
Before commissioning 31
Screwing the cleaning device to the underlying surface 33
Fitting the cleaning cutter 35
Fitting the cleaning cutter 35
Torch cleaning position 36
3
Cleaning position of the welding torch with externally routed coolant lines 36 Cleaning position of the welding torch with internally routed coolant lines 36
Fitting the clamping system for welding torches with internally routed coolant lines 37
Adjusting the lifting device 41
Installing the compressed air supply 43
Establishing the compressed air supply for the cleaning device, function of the com­pressed air relief valve
Starting up the parting agent nebuliser 44
Fill parting agent container (1 litre) and connect to the cleaning device 44 Connect the parting agent container (10 litres) to the cleaning device 45 Adjusting the parting agent nebuliser spray amount 46
Using the fill-level control sensor 47
Optional fill-level control sensor 47 Controls and indicators on the sensor 47 Installation adapter borehole dimensions 47 Fitting the fill-level control sensor 48 Calibrating the empty state 49 Calibrating the full state 49 Locking/unlocking the fill-level control sensor 50 Electrical connection 50
Manually checking the cleaning device functions 51
Starting up the cleaning device 53
Cleaning programme 54
3. "Cleaning motor lowered" query 58
4. "Gas nozzle free" query 59
Signal waveform for cleaning 65
43
Care, maintenance and disposal 67
Safety 69
Care, maintenance and disposal 71
General 71 Before each start-up 71 Daily 71 Weekly 71 Every 6 months 71 As necessary 71 Disposal 72
Adjust the swivel mechanism stop angle 73
General 73 Preparatory work 73 Adjust the swivel mechanism stop angle 74 And finally... 75
4
Troubleshooting 77
Safety 79
Safety 79
Troubleshooting 81
Technical data 83
Technical data 85
Robacta Reamer V Twin 85
Appendix 87
Circuit diagram Robacta Reamer V Twin 89 Robacta Reamer V Twin pneumatic diagram 90 Declaration of conformity 91
EN
5
Safety rules
Explanation of safety notices
DANGER!
Indicates immediate danger.
If not avoided, death or serious injury will result.
▶
WARNING!
Indicates a potentially hazardous situation.
If not avoided, death or serious injury may result.
▶
CAUTION!
Indicates a situation where damage or injury could occur.
If not avoided, minor injury and/or damage to property may result.
▶
NOTE!
Indicates a risk of flawed results and possible damage to the equipment.
General The device is manufactured using state-of-the-art technology and according to
recognised safety standards. If used incorrectly or misused, however, it can cause:
injury or death to the operator or a third party,
-
damage to the device and other material assets belonging to the operating
-
company, inefficient operation of the device.
-
All persons involved in commissioning, operating, maintaining and servicing the device must:
be suitably qualified,
-
have sufficient knowledge of automated welding, and
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read and carefully follow these operating instructions as well as the operat-
-
ing instructions for all system components.
The operating instructions must always be at hand wherever the device is being used. In addition to the operating instructions, attention must also be paid to any generally applicable and local regulations regarding accident prevention and en­vironmental protection.
All safety and danger notices on the device
must be in a legible state,
-
must not be damaged,
-
must not be removed,
-
must not be covered, pasted or painted over.
-
For the location of the safety and danger notices on the device, refer to the sec­tion headed "General" in the operating instructions for the device. Before commissioning the device, rectify any faults that could compromise safety.
This is for your personal safety!
6
Proper use The device is to be used exclusively for its intended purpose.
The device is intended solely for the mechanical cleaning of Fronius robot weld­ing torches in automatic mode. Any use above and beyond this purpose is deemed improper. The manufacturer shall not be held liable for any damage arising from such usage.
Proper use includes:
carefully reading these operating instructions
-
following all the instructions and safety rules in these operating instructions
-
performing all stipulated inspection and maintenance work
-
The device is designed for use in industry and the workshop. The manufacturer accepts no responsibility for any damage caused through use in a domestic set­ting.
The manufacturer likewise accepts no liability for inadequate or incorrect results.
EN
Environmental conditions
Obligations of the operator
Operation or storage of the device outside the stipulated area will be deemed as not in accordance with the intended purpose. The manufacturer shall not be held liable for any damage arising from such usage.
Ambient temperature range:
during operation: 0 °C to + 40 °C (32 °F to 104 °F)
-
during transport and storage: -25 °C to +55 °C (-13 °F to 131 °F)
-
Relative humidity:
up to 50 % at 40 °C (104 °F)
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up to 90 % at 20 °C (68 °F)
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Keep ambient air free from dust, acids, corrosive gases and substances, etc.
Can be used at altitudes of up to 2000 m (6500 ft)
The operator must only allow persons to work with the device who:
are familiar with the fundamental instructions regarding safety at work and
-
accident prevention and have been instructed in how to use the device have read and understood these operating instructions, especially the sec-
-
tion "safety rules", and have confirmed as much with their signatures are trained to produce the required results.
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Checks must be carried out at regular intervals to ensure that operators are working in a safety-conscious manner.
Obligations of personnel
Specific hazards Stay out of the working area of the robot.
Before using the device, all persons instructed to do so undertake:
to observe the basic instructions regarding safety at work and accident pre-
-
vention to read these operating instructions, especially the "Safety rules" section and
-
sign to confirm that they have understood them and will follow them.
Before leaving the workplace, ensure that people or property cannot come to any harm in your absence.
7
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
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extending/retracting gas nozzle clamping device
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wire cutter
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Do not touch cleaning cutters immediately after use - risk of burns. Observe the special safety rules in the Operating Instructions for handling cleaning cutters.
Protecting your­self and others
Protect hands, face and eyes against flying parts (shavings, etc.) and compressed air/parting agent mixture escaping from the parting-agent injection 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
-
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
-
Alternatively, erect suitable safety screens/curtains
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EMC Device Classifications
8
Devices in emission class A:
Are only designed for use in industrial settings
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Can cause line-bound and radiated interference in other areas
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Devices in emission class B:
Satisfy the emissions criteria for residential and industrial areas. This is also
-
true for residential areas in which the energy is supplied from the public low­voltage mains.
EMC device classification as per the rating plate or technical data.
EMC measures In certain cases, even though a device complies with the standard limit values for
emissions, it may affect the application area for which it was designed (e.g. when there is sensitive equipment at the same location, or if the site where the device is installed is close to either radio or television receivers). If this is the case, then the operator is obliged to take appropriate action to recti­fy the situation.
Check for possible problems, and check and evaluate neighbouring devices' res­istance to interference according to national and international requirements:
Safety devices
-
Power, signal and data transfer lines
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IT and telecommunications devices
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Measuring and calibrating devices
-
Supporting measures for avoidance of EMC problems:
Mains supply
1. If electromagnetic interference arises despite correct mains connection,
-
additional measures are necessary (e.g. use a suitable line filter).
Control lines
2. must be kept as short as possible
-
must run close together (to avoid EMF problems)
-
must be kept well apart from other leads
-
Equipotential bonding
3.
Shield, if necessary
4. Shield off other nearby devices
-
Shield off entire welding installation
-
EN
EMF measures Electromagnetic fields may pose as yet unknown risks to health:
Effects on the health of persons in the vicinity, e.g. those with pacemakers
-
and hearing aids Individuals with pacemakers must seek advice from their doctor before ap-
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proaching the device or any welding that is in progress For safety reasons, maintain as large a distance as possible between the
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welding power-leads and the head/torso of the welder Do not carry welding power-leads and hosepacks over the shoulders or wind
-
them around any part of the body
Safety measures at the installa­tion location and during transport
A device toppling over could easily kill someone. Place the device horizontally on a level, firm and solid surface and anchor it securely to prevent it toppling over.
Special regulations apply in rooms at risk of fire or explosion
Observe relevant national and international regulations.
-
Use internal directives and checks to ensure that the workplace environment is always clean and clearly laid out.
When transporting the device, observe the relevant national and local guidelines and accident prevention regulations. This applies especially to guidelines regard­ing the risks arising during transport.
After transporting the device, it must be visually inspected for damage before commissioning. Any damage must be repaired by trained service technicians be­fore commissioning the device.
9
Safety measures in normal opera­tion
Only operate the device if all safety devices are fully functional. If the safety devices are not fully functional, there is a risk of
injury or death to the operator or a third party,
-
damage to the device and other material assets belonging to the operator,
-
inefficient operation of the device.
-
Any safety devices that are not functioning properly must be repaired before switching on the device.
Never bypass or disable safety devices.
Before switching on the device, ensure that no one is likely to be endangered.
Check the device at least once a week for obvious damage and proper function­ing of safety devices.
Only use suitable original parting agent from the manufacturer.
-
Observe the information on the parting agent safety data sheet when hand-
-
ling parting agent. The parting agent safety data sheet may be obtained from your service centre or downloaded from the manufacturer's website. Do not mix the manufacturer's parting agent with other parting agents.
-
If damage results from using a different parting agent, the manufacturer ac-
-
cepts no liability. In addition, no warranty claims will be entertained. Used parting agent must be disposed of properly in accordance with the rel-
-
evant national and international regulations.
Commissioning, maintenance and repair
Safety inspec­tion
It is impossible to guarantee that bought-in parts are designed and manufac­tured to meet the demands made of them, or that they satisfy safety require­ments.
Use only original spare and wearing parts (also applies to standard parts).
-
Do not carry out any modifications, alterations, etc. to the device without the
-
manufacturer's consent. Components that are not in perfect condition must be replaced immediately.
-
When ordering, please give the exact designation and part number as shown
-
in the spare parts list, as well as the serial number of your device.
The housing screws provide the ground conductor connection for earthing the housing parts. Only use original housing screws in the correct number and tightened to the spe­cified torque.
The manufacturer recommends that a safety inspection of the device is per­formed at least once every 12 months.
A safety inspection should be carried out by a qualified electrician
after any changes are made
-
after any additional parts are installed, or after any conversions
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after repair, care and maintenance has been carried out
-
at least every twelve months.
-
10
For safety inspections, follow the appropriate national and international stand­ards and directives.
Further details on safety inspection and calibration can be obtained from your service centre. They will provide you on request with any documents you may re­quire.
Disposal Waste electrical and electronic equipment must be collected separately and re-
cycled in an environmentally responsible manner in accordance with the EU Dir­ective and national law. Used equipment must be returned to the distributor or through a local, authorised collection and disposal system. Proper disposal of the old device promotes sustainable recycling of material resources. Ignoring this may lead to potential health/environmental impacts.
Packaging materials
Collected separately. Check your municipality’s regulations. Reduce the volume of the box.
Safety symbols Devices with the CE mark satisfy the essential requirements of the applicable
directives (e.g. low-voltage and electromagnetic compatibility directives, ma­chinery directive).
Devices with the CSA test mark satisfy the requirements of the relevant stand­ards in Canada and the USA.
Copyright Copyright of these operating instructions remains with the manufacturer.
The text and illustrations are all technically correct at the time of printing. We reserve the right to make changes. The contents of the operating instructions shall not provide the basis for any claims whatsoever on the part of the pur­chaser. If you have any suggestions for improvement, or can point out any mis­takes that you have found in the instructions, we will be most grateful for your comments.
EN
11
12
General
13
14
General
Principle The Robacta Reamer V Twin is used for
the automatic cleaning of MIG/MAG welding torches. The Robacta Reamer V Twin allows you to 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.
Device concept The clamping device on the front of the Robacta Reamer V Twin 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 spray nozzle that is fixed in the middle of the cleaning motor.
EN
Application areas
The Robacta Reamer V Twin is fitted with a wire cutter as standard. During the cleaning process, the Robacta Reamer V Twin shortens both wire electrodes to a defined length ready for the next welding process.
A robust fitting base is available for the installation of the Robacta Reamer V Twin.
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
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Equipment construction
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Chemical plant construction
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Machine and tracked vehicle manufacturing
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Construction machinery and special vehicles
-
NOTE!
TWIN welding torches with a contact tip tilt angle of 4° cannot be cleaned with the Robacta Reamer V Twin!
Alternatives:
Robacta Reamer Single/Twin
▶
or Robacta TC 2000 Twin
▶
15
Scope of supply
(1)
(2)
(3)
(4)
NOTE!
The "Robacta Reamer" parting agent (item number 42,0411,8042) and the cleaning cutter are not part of the scope of supply.
(1) Robacta Reamer V Twin clean-
ing device with wire cutter (2) Spatter tray (3) Tightening key for cleaning mo-
tor (4) Compressed air relief valve
not shown:
(5) Standard I/O connecting plug (X1) without cable (6) Operating instructions (7) Fixings for assembling the cleaning device:
4 screws
-
4 washers
-
4 lock washers
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4 nuts
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Available op­tions
How the wire cutter works/ Maximum wire diameter
The following options are available for the cleaning device:
Installation stand
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Cleaning cutter adjustment aid
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Level sensor
-
The wire cutter opens and closes when there is an active signal from the robot control.
Two wire electrodes with a diameter of up to 1.6 mm (0.063 in.) can be cut at the same time by the cleaning device wire cutter.
NOTE!
If you change over to a new welding torch, the wire cutter must be reset!
16
Warning notices
Type
Art.No.
Chargen No.
U1
I1
Wels - Austria
p
max
24 V
6 bar (87psi.)
on the device
The Robacta Reamer V Twin is fitted with warning notices and a rating plate. The warning notices and rating plate must not be removed or painted over.
EN
Warning notices affixed to the Robacta Reamer V Twin
WARNING! Risk of serious injury from:
mechanically powered parts
-
compressed air/parting agent mixture escaping from the part-
-
ing-agent injection nozzle flying parts (shavings, etc.)
-
Keep device free from current and pressure during maintenance and servicing.
Do not use the functions described here until you have thoroughly read and understood the following documents:
these operating instructions
-
all the operating instructions for the system components, es-
-
pecially the safety rules
For indoor use only
17
Wear eye protection
Notice warning of automatic start-up of the device
18
Transport
EN
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.
▶
19
20
Controls, connections and mechan-
ical components
21
22
Safety
Safety Observe the following safety rules when using all functions described in the
"Controls, connections and mechanical components" section.
WARNING!
Danger from incorrect operation!
This can result in serious injury and damage to property.
The functions described must only be used by trained and qualified person-
▶
nel. Do not use the functions described here until you have fully read and under-
▶
stood the following documents: these Operating Instructions, all the Operating Instructions for the system components, especially the safety rules
EN
23
Robacta Reamer V Twin control elements, con-
(7)
(6)
(1)
(2)
(3)
(4)
(5)
(8)
(13)
(9)
(12)
(10)
(11)
nections and mechanical components
Control ele­ments, connec­tions and mech­anical compon­ents
Side view
(1) Standard I/O connection socket (X1)
For a + 24 V DC supply
CAUTION!
Danger from overcurrent.
Damage to the standard I/O (X1) connection supply may result.
Secure supply against overcurrent with a 500 mA slow-blow fuse.
▶
(2) Compressed air connection
For a compressed air supply at 6 bar (86.99 psi) Compressed air connection thread identification: G ¼"
(3) "Clamp gas nozzle/Cleaning motor on" screw
For manually checking the gas nozzle clamping device and the cleaning motor (gas nozzle clamping device extends/retracts, cleaning motor off/on)
(4) "Lifting device up/down" screw
For manually checking the lifting device (lifting device moves up/down)
(5) "Spray 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)
Front view
24
(6) Parting agent adjuster
For setting the amount of parting agent applied
(7) Parting agent container
(8) Lifting device
Lifts the cleaning motor and the cleaning cutter when cleaning the inside of the gas nozzle
(9) Cleaning motor with parting-agent injection nozzle
(14)
(15)
The cleaning motor drives the cleaning cutter
(10) Protective cover
(11) Cleaning cutter
With internal through hole for the parting-agent injection nozzle
(12) Gas nozzle clamping device
Holds the gas nozzle in place during cleaning
(13) Wire cutter
EN
Side view
(14) Compressed air and electrical connection for the wire cutter
(15) Parting-agent injection nozzle
Applies the parting agent to the inside and front of the gas nozzle
25
Standard I/O connecting plug (X1) pin assign-
1
2
11
10
9
8
7
6
5
4
3
12
13
14
15
16
17
ment for robot control
General
Standard I/O (X1) connecting plug pin assign­ment
CAUTION!
Danger from overcurrent.
Damage to the standard I/O (X1) connection supply may result.
Secure the power supply of the cleaning device against overcurrent with a
▶
500 mA slow-blow fuse.
NOTE!
To avoid malfunction, keep the cable length between the cleaning device and ro­bot control as short as possible.
The standard I/O (X1) connecting plug for connecting the cleaning device to the robot control is part of the scope of supply. The cable harness must be adapted to the connection technology on the robot control.
Input and output signals on the Robacta Reamer V Twin:
Clamp gas nozzle/Cleaning motor
1.
ON (cleaning cutter turning) input signal + 24 V DC GND general
2.
Cleaning motor UP input signal
3.
(cleaning cutter moves to cleaning position) + 24 V DC Spray parting agent input signal +
4.
24 V DC + 24 V DC (supply)
5.
Gas nozzle free output signal
6.
26
Standard I/O (X1) connecting plug pin assign­ment - cable-end view
Gas nozzle clamped output signal
7. Not assigned
8. Parting agent level OK output signal
9. Cleaning motor lowered output signal (cleaning cutter in start position)
10. Cleaning motor raised output signal (cleaning cutter in cleaning position)
11. Cut wire electrode input signal + 24 V DC
12. Swivel mechanism left output signal
13. Swivel mechanism right output signal
14. Move swivel mechanism to the left input signal
15. Move swivel mechanism to the right input signal
16. Not assigned
17.
Installation and commissioning
27
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