Fronius Robacta Reamer X-Line J Operating Instruction [EN]

Operating
Instructions

Robacta Reamer X-Line J
Robacta Reamer X-Line J Alu

EN-US

Operating instructions

42,0426,0240,EA 009-27012023

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
Disposal 10
Safety Symbols 10
Copyright 10

General 11

General 13

Principle 13
Functionality of the cleaning device 13
Applications 13
Warning Notices on the Cleaning Device 13

Transport 16

Transport equipment 16
Transport Instructions on the packaging 16

Scope of Supply 17

Scope of Supply 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 - Front of Device 22
Operating Controls, Connections, and Mechanical Components - Rear of Device 23
Operating Controls, Connections, and Mechanical Components - Side of Device 24
Connections for robot control 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
Specifications for the compressed air supply 29
Measures to ensure safe operation of the device when operating personnel are untrained 30

Diagram of the programmable logic control (PLC) 31

Diagram of the programmable logic control (PLC) 31

Screwing the Cleaning Device to the Solid Surface 32

Screwing the cleaning device and work stand to the surface 32

Welding Torch Cleaning Position 34

Welding Torch Cleaning Position 34

Adjusting the Gas Nozzle Clamping Device 35

3

Adjusting the gas nozzle clamping device 35

Fitting the Cleaning Cutter 36

Fitting the cleaning cutter 36

Adjusting the Position of the Cleaning Motor 37

Adjusting the position of the cleaning motor 37

Setting up the Compressed Air Supply 38

Setting up the cleaning device compressed air supply, compressed air relief valve function 38

Starting Up the Parting Agent Atomizer 39

Filling the parting agent container (1 liter) and connecting it to the cleaning device 39
Connecting the parting agent container (10 liter) to the cleaning device 40
Setting the injection quantity of the parting agent atomizer 41

Starting up the fill-level control sensor 42

General 42
Operating controls and displays on the sensor 42
Performing empty adjustment 42
Performing a full adjustment 43
Unlocking/locking the fill-level control sensor 43

Manually Checking the Cleaning Device Functions 44

Safety 44
Manually checking the cleaning device functions 44

Start up the Cleaning Device 46

Requirements for Start-up Operation 46
Commissioning 46

Cleaning Program Sequence 47

Safety 47
Cleaning Program Sequence 48

Cleaning Device Signal Sequences 52

Cleaning device signal sequences 52

Wire Cutter Signal Sequence 53

Wire cutter signal sequence 53

Service, maintenance and disposal 55

Safety 57

Safety 57
Ensuring that the cleaning device is depressurized 58

Service, maintenance and disposal 59

General 59
Before every start-up 59
Daily 59
Weekly 59
Every 6 months 59
Whenever required: 59
Disposal 60

Troubleshooting 61

Safety 63

Safety 63
Ensuring that the cleaning device is depressurized 64

Troubleshooting 65

Errors in the Program Sequence 65

Technical data 67

Technical data 69

Robacta Reamer X-Line J, Robacta Reamer X-Line J Alu 69

Appendix 71

Circuit Diagram for Robacta Reamer X-Line J, Robacta Reamer X-Line J Alu 73
Pneumatic Plan for Robacta Reamer X-Line J, Robacta Reamer X-Line J Alu 74
Declaration of conformity 75

4

Safety Instructions

EN-US

Explanation of
Safety Instruc­tions

DANGER!

Indicates an immediate danger.

Death or serious injury may result if appropriate precautions are not taken.

▶

WARNING!

Indicates a possibly dangerous situation.

Death or serious injury may result if appropriate precautions are not taken.

▶

CAUTION!

Indicates a situation where damage or injury could occur.

Minor injury or damage to property may result if appropriate precautions are

▶

not taken.

NOTE!

Indicates the possibility of flawed results and damage to the equipment.

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

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

-

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

-

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

-

Following all instructions and safety rules in these Operating Instructions

-

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

-

the cleaning motor that moves up and down

-

the gas nozzle clamping device that moves in and out

-

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.

-

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.

-

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).

-

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 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.

Disposal Waste electrical and electronic equipment must be collected separately and re-

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 ob­serve this may lead to potential health/environmental impacts.

Packaging materials

Separate collection. Check your municipality’s regulations. Reduce the volume of
the box.

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

Principle 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

Applications The cleaning device is exclusively suited for operation in automation and robot

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-

-

to the gas nozzle and onto the face of the gas nozzle.

applications and can be used for a range of materials.

Main applications:

Automotive and supply industry

-

Equipment engineering

-

Chemical plant construction

-

Mechanical engineering, rail vehicle construction

-

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

Type

Art.No.

Chargen No.

U

1

I

1

p

max

24 V

6 bar (87psi.)

www.fronius.com

Warning notices on the cleaning device

WARNING! Danger of serious injuries due to:

moving mechanical parts

-

compressed air/parting agent mixture discharged from the

-

parting-agent injection nozzle
flying debris (chips, etc.)

-

During maintenance and service, keep the device de-energized and
depressurized.

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, especially

-

the safety rules

For indoor use only

Wear eye protection

14

Warning before the device switches on automatically

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

-

On a pallet using a lift truck

-

Manually

-

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

(2)

(3)

(4)

(5)

(6)

(1)

Scope of Supply

NOTE!

The “Robacta Reamer” parting agent (item number 42,0411,8042) and the
cleaning cutter are not included in the scope of supply.

EN-US

(1) Work stand
(2) Cleaning device
(3) Maintenance unit
(4) Wrench for cleaning motor
(5) Compressed air relief valve
(6) Collecting container

not shown:

(7) Operating Instructions
(8) Mounting material to assemble the cleaning device:

4 screws

-

4 washers

-

4 lock washers

-

4 nuts

-

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

(6)

(8)

(7)

(2)

(3)

(5)

(1)

(4)

components

Operating Con­trols, Connec­tions, and Mech­anical Compon­ents - Front of
Device

Front of device

(1) Gas nozzle clamping device

holds the gas nozzle in place during the cleaning process

(2) Parting agent injection device

includes the parting-agent injection nozzle;
ensures that the parting agent only reaches the inside/face of the gas
nozzle

(3) Parting-agent injection nozzle

sprays the parting agent into the gas nozzle and onto the face of the gas
nozzle

(4) Cleaning cutter

(5) Protective cover

(6) Wire cutter

(7) Cleaning motor

drives the cleaning cutter

(8) Lifting device

lifts the cleaning motor with the cleaning cutter into the gas nozzle during
the cleaning process

22

Operating Con-

(2)

(1)

(3)

(4)

(5)

(6)

trols, Connec­tions, and Mech­anical Compon­ents - Rear of
Device

EN-US

Rear of device

(1) Parting agent adjusting controller

to set the parting agent injection quantity

(2) Connection area for robot control

(3) Compressed air connection

to supply dry compressed air at 6 bar (86.99 psi) - for more information
on compressed air quality, see the “Specifications for the compressed air

supply” section on page 29

Thread identification compressed air connection: G ¼“

(4) Parting agent collecting container

to collect excess parting agent after the injection process

(5) Parting agent container

(6) Fill-level control sensor

23

Operating Con-

(1)

(2)

(3)

(3)

(4)

(2)

(1)

trols, Connec­tions, and Mech­anical Compon­ents - Side of
Device

Side of device

Connections for
robot control

(1) “Spray in parting agent” screw

to manually check the injection device (compressed air or compressed air/
parting agent mixture is sprayed out of the parting-agent injection nozzle)

(2) “Lifting device up/down” screw

to manually check the lifting device (lifting device moves up/down)

(3) “Clamp gas nozzle/cleaning motor on” screw

to manually check the gas nozzle clamping device and the cleaning motor
(gas nozzle clamping device moves out/in, cleaning motor out/in)

(1) Bus system connection

(2) Bus system connection

(3) Bus system connection

(4) Bus system connection

24

Connections for robot control

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

Briefly turn the "Lifting device up/down" screw on the cleaning device 90° to

3

the right and immediately back to the starting position

If the cleaning device does not react to the rotation of the screw, the

-

cleaning device is depressurized

If the cleaning device reacts to the rotation of the screw, the cleaning

-

device is still connected to the compressed air supply.
In this case, make sure that the cleaning device is disconnected from the
compressed air supply before starting any work and then 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.

▶

Specifications
for the com­pressed air sup­ply

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

3

3

29

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.

30

Diagram of the programmable logic control (PLC)

4/

2/

4/

2/

4/

2/

4/

2/

4/

2/

4/

2/

4/

EN-US

Diagram of the
programmable
logic control
(PLC)

Bus module link: XXXXXXXX++ST010+IR001.ZM001-KF70

Placement: XXXXXXXX++ST010+IR001.ZM001+.&EFA/1.4

Type: ProfiNet MVK-Metall DO8 /DI8 PushPull MVK-MPNIO

D08 / DI8 PushPull

Address: Symbolname: Function text:

I777

++ST010+IR001.ZM001-VQ01-

Gas nozzle free

BG01:4

I778

++ST010+IR001.ZM001-VQ01-

Gas nozzle clamped

BG02:4

I779

I780

I781

++ST010+IR001.ZM001-VQ01­BG03:4

++ST010+IR001.ZM001-VQ01­BG04:4

++ST010+IR001.ZM001-VQ01-

Cleaning motor rotated
(pulse signal)

Parting agent container
full

Cleaning motor bottom

BG05:4

I782

++ST010+IR001.ZM001-VQ01-

Cleaning motor top

BG06:4

I783

++ST010+IR001.ZM001-VQ01-

Wire cutter open

BG07:4

I784

Q777

Q778

Q779

Q780

Q781

++ST010+IR001.ZM001-VQ01­BG08:4

++ST010+IR001.ZM001-VQ01­KK01:x1

++ST010+IR001.ZM001-VQ01­KK02:x1

++ST010+IR001.ZM001-VQ01­KK03:x2

- -

++ST010+IR001.ZM001-VQ01­KK04:x2

Wire cutter closed

Clamp gas nozzle/cleaning
motor on

Cleaning motor up/down

Spray in parting agent

Cut the wire electrode

31

Screwing the Cleaning Device to the Solid Sur­face

Screwing the
cleaning device
and work stand
to the surface

WARNING!

Danger from machines toppling over or falling.

This can result in serious personal injury and damage to property.

Depending on the surface (foundation), different mounting materials may be

▶

required to assemble the work stand.
The mounting materials for the work stand are not part of the scope of sup-

▶

ply for the work stand. The installer is responsible for selecting the proper
mounting materials.

Position the work stand on a level, solid and vibration-free surface (founda-

1

tion)

Position the work stand so that the robot’s approach route to the clean-

-

ing device on the work stand is as short as possible

Tightly screw the work stand to the surface (foundation) using the selected

2

mounting materials

WARNING!

Danger from machines toppling over or falling.

This can result in serious personal injury and damage to property.

Use the mounting material delivered with the cleaning device to screw the

▶

cleaning device to the work stand.

3 4

32

5

EN-US

33

Welding Torch Cleaning Position

Welding Torch
Cleaning Posi­tion

The welding torch (gas nozzle) must be centered over the cleaning motor / clean­ing cutter, with 1-2 mm (0.039 - 0.079 inches) distance to the protective cover.

34

Adjusting the Gas Nozzle Clamping Device

(1)

(3)

(2)
(4)

EN-US

Adjusting the
gas nozzle
clamping device

CAUTION!

An incorrectly set gas nozzle clamping device may damage the cleaning device
and the welding torch.

When using gas nozzles with an outside diameter of 25 mm (0.98 inches), the

▶

gas nozzle clamping device must not be adjusted - the gas nozzle clamping
device has already been set for the use of gas nozzles with an outside dia­meter of 25 mm (0.98 inches) as part of the factory calibration.
When using gas nozzles with an outside diameter larger/smaller than 25 mm

▶

(0.98 inches), the gas nozzle clamping device must be adjusted before it is
started for the first time and after every device replacement.

NOTE!

Set the clamping device so that no re­action forces can be transmitted to
the robot.

Only clamp gas nozzles on a cylindrical
surface.

Loosen the Allen screws on guide

1

bolts (1) and (2)

Move the welding torch to the

2

cleaning position

centric to the cleaning motor

-

Use the adjusting screw (3) to posi-

3

tion the clamping device (4) so that
the clamping device is positioned
against the gas nozzle

Tighten the Allen screws on guide bolts (1) and (2)

4

NOTE!

Only clamp the gas nozzle in a central position over the cleaning motor.

35

Fitting the Cleaning Cutter

Fitting the
cleaning cutter

CAUTION!

Danger due to hot cleaning cutter as a result of operation.

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 contact tips, gas nozzles and cleaning cutters provided by the man-

▶

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

The cleaning cutter is not included in the scope of supply. Find the right cleaning
cutter in the Spare Parts List for the welding torch used: https://spare-

parts.fronius.com/

Remove the protective cover from the cleaning device

1

2

36

Mount the protective cover on the cleaning device so that it is in its original

3

position once again

Adjusting the Position of the Cleaning Motor

(4)(6) (5)

(1)

(2)
(3)

EN-US

Adjusting the
position of the
cleaning motor

Remove protective cover (1)

1

Remove the gas nozzle from the

2

torch body

Loosen the screw (2) on the lifting

3

device

Make sure that the lifting device (3)

4

is in the bottom lift position

Position the welding torch in the

5

cleaning position (approx. 1 - 2
mm/0.039 - 0.079 in. over the pro­tective cover, central to the clean­ing motor)

Manually slide the lifting device (3) to the top lift position and hold it in this

6

position

Manually slide the cleaning motor (4) with cleaning cutter into the cleaning

7

position

see detail (5) for welding torches with insulating sleeve

-

see detail (6) for welding torches with spatter guard

-

NOTE!

The cleaning cutter must not come into contact with the welding torch parts.

Mount the cleaning motor (4) in this position in the lifting device (3) - tighten

8

the screw (2) on the lifting device

Perform a function test with the gas nozzle removed: Manually slide the

9

cleaning motor into the top position

The cleaning cutter must surround the contact tip without colliding with

-

it.
If the cleaning cutter is in contact with welding torch parts, adjust the
position of the cleaning motor

Fit the gas nozzle onto the torch body

10

Perform a function test with the gas nozzle fitted: Manually slide the cleaning

11

motor into the top position

The cleaning cutter must plunge into the gas nozzle without colliding

-

with it.
If the cleaning cutter is in contact with welding torch parts, adjust the
position of the cleaning motor

Mount the protective cover on the cleaning device so that it is in its original

12

position

37

Setting up the Compressed Air Supply

Setting up the
cleaning device
compressed air
supply, com­pressed air relief
valve function

Set up the compressed air supply:

Disconnect the compressed air supply to the cleaning device and ensure that

1

this compressed air supply remains disconnected while the tasks described
below are being carried out on the device

Screw the supplied compressed air relief valve on to the compressed air con-

2

nection on the cleaning device

Connect the compressed air supply to the compressed air relief valve

3

You can interrupt and restore the compressed air supply to the cleaning device
by moving the compressed air relief valve back and forth - see description below.

The following illustration shows the compressed air relief valve closed = com­pressed air supply to the device interrupted:

Compressed air relief valve closed

The following illustration shows the compressed air relief valve open = device is
being supplied with compressed air:

Compressed air relief valve open

38

Starting Up the Parting Agent Atomizer

EN-US

Filling the part­ing agent con­tainer (1 liter)
and connecting
it to the cleaning
device

NOTE!

Only use the “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.

1 2

3 4

39

5

1

*

2

3

4

Connecting the
parting agent
container (10
liter) to the
cleaning device

NOTE!

Only use the “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.

1

2

* Option (longer parting agent

hose)

40

3

EN-US

Setting the in­jection quantity
of the parting
agent atomizer

NOTE!

To correctly set the injection quantity, the welding torch must be in the cleaning
position.

Connect the cleaning device’s compressed air supply

1

Connect the device to the robot control

2

Activate the injection process using the robot control and check whether the

3

injection quantity is adequate

If the injection quantity is not adequate, adjust the injection quantity as re-

4

quired

use the robot control to adjust the injection time; an injection time of ~

-

0.7 seconds is recommended
or using the parting agent adjusting controller as illustrated below

-

5

Fine-tune the injection quantity on the parting agent adjusting controller

41

Starting up the fill-level control sensor

(1)

(2)

(3)

20 mm (0.79 in.)

2 - 6 s

General The fill-level control sensor releases a signal as soon as the fill level in the part-

ing agent container falls below a defined level.

Operating con­trols and dis­plays on the
sensor

Performing
empty adjust­ment

(1) ‘OUT OFF’ key

to program the sensor

(2) ‘OUT ON’ key

to program the sensor

(3) LED

shows the operating mode of
the sensor

LED on/flashing: Sensor

-

active
LED off/ not flashing:

-

Sensor inactive

Drain the parting agent container

1

until the parting agent is at least
20 mm (0.787 in.) below the sensor

Connect the sensor to the power

2

supply

42

Hold the ‘OUT OFF’ key for at least

3

2 seconds, maximum 6 seconds

The LED on the sensor flashes

-

slowly
after releasing the ‘OUT OFF’

-

key, the LED turns off once
again - the sensor has detected
a low fluid level

Performing a full

> 6 s

10 s

10 s

adjustment

Fill the parting agent container

1

with parting agent

Hold the ‘OUT OFF’ key for at least

2

6 seconds

The LED on the sensor first

-

flashes slowly and then faster
after 6 seconds
after releasing the ‘OUT OFF’

-

key, the LED turns off once
again - the sensor has detected
a high fluid level

EN-US

Unlocking/lock­ing the fill-level
control sensor

NOTE!

To prevent the unintentional adjust­ment of the fill-level control sensor, it
is possible to lock the sensor.

Locking the fill-level control sensor:

Simultaneously press the ‘OUT OFF’ and ‘OUT ON’ keys for at least 10

1

seconds

The LED status briefly changes

-

if the LED is illuminated during locking, the LED briefly turns off

-

after locking
if the LED is not illuminated during locking, the LED is briefly illumin-

-

ated after locking

Unlocking the fill-level control sensor:

Simultaneously press the ‘OUT OFF’ and ‘OUT ON’ keys for at least 10

1

seconds

The LED status briefly changes

-

if the LED is illuminated during unlocking, the LED briefly turns off

-

after unlocking
if the LED is not illuminated during unlocking, the LED is briefly illu-

-

minated after unlocking

43

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.

▶

NOTE!

The relevant function is deactivated when the slots of the “Lifting device up/
down”, “Clamp gas nozzle/cleaning motor on” and “Spray in parting agent”
screws are in a horizontal position.

Disconnect the connection between the cleaning device and the robot con-

1

trol

Connect the cleaning device’s compressed air supply

2

Spray in parting agent function

Check the following while the function is executed:

The correct insertion depth of the gas nozzle into the parting agent injection

-

device. The correct insertion depth must be individually set depending on the
gas nozzle

After the function has been executed, check the following:

Whether the gas nozzle is adequately wetted with parting agent

-

3

4

44

Spray in parting agent

Deactivate the function

Clamp gas nozzle/cleaning motor on

Check the following while the function is executed:

The function of the gas nozzle clamping device

-

The function of the cleaning motor

-

EN-US

5

Clamp gas nozzle/cleaning motor on

6

Clamp gas nozzle/cleaning motor on

Cleaning motor up/down function

Check the following while the function is executed:

The insertion depth of the cleaning cutter into the gas nozzle

-

7

8

Cleaning motor up/down

Deactivate the function

45

Start up the Cleaning Device

Requirements
for Start-up Op­eration

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 work stand screwed tightly to the surface

-

Cleaning device screwed tightly to the work stand

-

Gas nozzle clamping device set - not when using a gas nozzle with an outside

-

diameter of 25 mm (0.98 inches). For more info, see the “Adjusting the Gas
Nozzle Clamping Device” chapter
Cleaning cutter fitted

-

Position of the cleaning motor set

-

Parting agent atomizer started up

-

Compressed air supply set up

-

Functions manually checked

-

Cleaning device connected to the robot control

-

All covers installed and all safety devices in good order and installed in the

-

location intended

46

Cleaning Program Sequence

EN-US

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.

47

Cleaning Pro­gram Sequence

Start

Move to position C

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

- Speed: High speed mode

Move to position D

- Moving into wire cutter

- Speed: 10 cm/s
(236.22 ipm)

Set

- external signal “Cut the wire
electrode”

Wait 0.5 seconds

Move to position G

- approx. 50 mm (1.97 in) centrally
positioned above wire cutter

- Speed: 10 cm/s
(236.22 ipm)

Reset

- external signal “Cut the wire
elctrode”

48

Move to position A

- approx. 50 mm (1.97 in) centrally
positioned above cleaning device

- Speed: High speed mode

Output query (output signal Gas

nozzle free)

- Low or high

EN-US

Query = low

(Gas nozzle clamped)

Query = high

(Gas nozzle free)

Output query (output signal cleaning

motor botom)

- Low or high

Query = high

(cleaning motor at the bottom)

Move to position B (cleaning position)

- Moving into clamping device gas
nozzle

- Speed: 10 cm/s
(236.22 ipm)

Set

- Input “Clamp gas nozzle, cleaning
motor on”

Stop

Query = low

(cleaning motor not at bottom)

Stop

Set

- Input “Cleaning motor open”

49

Set

- Compressed air gas purging with
welding torch

Reset

- Input “cleaning motor open” (as soon
as the signall “cleaning motor open” is

high)

Reset

- Input “Clamp gas nozzle, cleaning

motor on, compressed air gas purging

with welding torch” (as soon as the

signal “Cleaning motor at bottom” is

high)

Output query (output signal Gas nozzle

free)

- Low or high

Query output = high

(Gas nozzle free)

Move to position A

- approx. 50 mm (1.97 in) centrally

positioned above cleaning device

- Speed: 10 cm/s
(236.22 ipm)

Move to position E

- approx. 50 mm (1.97 in) centrally
positioned above parting agent

injection device

- Speed: 10 cm/s
(236.22 ipm)

Query = low

(Gas nozzle clamped)

Stop

50

Move to position F
(injection position)

- approx. 10–35 mm (0.39–1.38 in)
deep into the injection device

- Speed: 10 cm/s
(236.22 ipm)

Set

- Input “Spray in parting agent”

Wait 0.7 seconds

Reset

- Input “Spray in parting agent”

Move to position E

- approx. 50 mm (1.97 in) centrally
positioned above parting agent

injection device

- Speed: 10 cm/s
(236.22 ipm)

EN-US

End

51

Cleaning Device Signal Sequences

24 VDC

0 VDC

(1)

(2)

(3)

(4)

(5)

(6)

(7)

(8)

(9)

Cleaning device
signal sequences

(1) Clamp gas nozzle, cleaning motor on

(2) Cleaning motor up/down

(3) Spray in parting agent

(4) Gas nozzle free

(5) Gas nozzle clamped

(6) Cleaning motor rotated (pulse signal)

(7) Parting agent container full

(8) Cleaning motor bottom

(9) Cleaning motor top

52

Wire Cutter Signal Sequence

24 VDC

0 VDC

(1)

(2)

(3)

EN-US

Wire cutter sig­nal sequence

(1) Cut the wire electrode

(2) Wire cutter open

(3) Wire cutter closed

53

54

Service, maintenance and disposal

55

56

Safety

Safety Follow the safety rules below when carrying out all the tasks described in the

"Service, maintenance, and disposal" 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.

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. For your personal
safety, make sure that all protective measures have been taken in the robot's
operating area and remain in effect while you are in this area.

EN-US

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 customer's compressed air and

▶

power supply 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 section En-

suring that the cleaning device is depressurized from page 58

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.

▶

57

CAUTION!

Danger due to hot cleaning cutter as a result of operation.

Serious burns may result.

Before handling the cleaning cutter, allow it to cool to room temperature

▶

(+25 °C, +77 °F).

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

Briefly turn the "Lifting device up/down" screw on the cleaning device 90° to

3

the right and immediately back to the starting position

If the cleaning device does not react to the rotation of the screw, the

-

cleaning device is depressurized

If the cleaning device reacts to the rotation of the screw, the cleaning

-

device is still connected to the compressed air supply.
In this case, make sure that the cleaning device is disconnected from the
compressed air supply before starting any work and then ensure that the
cleaning device is depressurized

58

Service, maintenance and disposal

General The cleaning device does not usually require maintenance. To ensure the cleaning

device remains operational over time, there are a number of care and mainten­ance tasks that need to be carried out, however:

EN-US

Before every
start-up

Daily

Check the fill level in the parting agent container and top up the parting

-

agent container if necessary
Check the fill level in the parting agent collecting container and drain the

-

parting agent collecting container if necessary
Check for wear of the cleaning cutter and replace the cleaning cutter if ne-

-

cessary
Drain the cleaning device's collecting container

-

Drain the wire cutter's collecting container, if present

-

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

Weekly

Every 6 months

Whenever re­quired:

NOTE!

Only clean the parting agent container with cleaning products that are free of
solvents.

Check the parting agent container and parting agent collecting container for

-

contamination and clean if necessary
Blow out the intake filter in the parting agent container from the inside out

-

with compressed air using the intake hose (“Starting Up the Parting Agent
Atomizer” chapter)

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

59

restore the operational state of the device.

3

Disposal Materials should be disposed of according to valid local and national regulations.

60

Troubleshooting

61

62

Safety

Safety Follow the safety rules below when carrying out all the tasks described in the

"Troubleshooting" 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.

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. For your personal
safety, make sure that all protective measures have been taken in the robot's
operating area and remain in effect while you are in this area.

EN-US

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 customer's compressed air and

▶

power supply 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 section En-

suring that the cleaning device is depressurized from page 64

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.

▶

63

CAUTION!

Danger due to hot cleaning cutter as a result of operation.

Serious burns may result.

Before handling the cleaning cutter, allow it to cool to room temperature

▶

(+25 °C, +77 °F).

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

Briefly turn the "Lifting device up/down" screw on the cleaning device 90° to

3

the right and immediately back to the starting position

If the cleaning device does not react to the rotation of the screw, the

-

cleaning device is depressurized

If the cleaning device reacts to the rotation of the screw, the cleaning

-

device is still connected to the compressed air supply.
In this case, make sure that the cleaning device is disconnected from the
compressed air supply before starting any work and then ensure that the
cleaning device is depressurized

64

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 39).

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 section Adjust-

ing the Position of the Cleaning Motor from page 37

Gas nozzle is clamped in incorrect position
Adjust the gas nozzle clamping device - see section Adjusting the

Gas Nozzle Clamping Device from page 35

Cleaning cutter does not fit the welding torch geometry
Fit a correct cleaning cutter

Cleaning cutter worn
Replace cleaning cutter

65

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).

66

Technical data

67

68

Technical data

EN-US

Robacta Reamer
X-Line J,
Robacta Reamer
X-Line J Alu

Supply voltage + 24 V DC

Nominal output 10.8 W

Nominal pressure 6 bar

86.99 psi

Air consumption 420 l/min

443.81 qt./min

Thread identification compressed air connec­tion

Standard I/O (X1) Input: + 24 V DC / max. 100

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 IP 21

Marks of conformity CE

Safety symbols S

G ¼“

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

.26 gal. (US)

"Performance Level" c

Maximum noise emission (LWA) 82 dB (A)

Dimensions L × W × H 255 x 245 x 390 mm

10.04 x 9.84 x 15.35 in.

Weight
(not including parting agent and optional wire
cutter)

10.5 kg

22.15 lb.

69

70

Appendix

71

72

Circuit Diagram for Robacta Reamer X-Line J,

NC

Q778

0V

Q777

BLUE

PE

-Y1

A1

A2

A2

A1

-Y2

Gasdüse spannen

Motor dreht

Motor

auf / ab

Spannzylinder Gasdüse

-XS0

3

4

5

2

1

-X1

13

14

15

16

6

-X2

5

-Y3

A2

A1

Einsprühen

1

2

5

4

3

-XS1

-XS2

3

4

5

2

1

A1

A2

-Y4

Draht schneiden

BLACK

BLUE

BLACK

WHITE

BLUE

BLACK

1

-X1

2

3

-B1

3

4

1

Spannzylinder Gasdüse

1

4

3

-B2

frei gespannt

Trennmittel KontrolleMotor dreht Impuls Motor unten Motor oben Draht geschnittenDrahtschneider offen

4

5

6

1

4

3

-B3 -B4

3

4

1

-XS4

3

4

5

2

1

BLUE

BLACK

BROWN

WHITE

NC

Q780

0V

Q779

PE

NC

Q782

0V

Q781

PE

+24V US

I778

0V

I777

PE

1

2

5

4

3

-XS5

PE

I779

0V

I780

+24V US

+A1-X1

1

4

3

1

+A1-X2

4

3

1

+A1-X3

2

3

4

5

+A1 Y-Verteiler

-X1

7

8

9

1

4

3

-B5 -B6

3

4

1

10

11

12

1

2

5

4

3

-XS6

PE

I781

0V

I782

+24V US

WHITE

BROWN

BLACK

BLUE

1

-X2

2

3

-B7

3

4

1

1

4

3

-B8

4

-XS7

3

4

5

2

1

BLUE

BLACK

BROWN

WHITE

+24V US

I782

0V

I781

PE

BLUE

BLACK

BROWN

BLUE

BLACK

BROWN

Robacta Reamer X-Line J Alu

EN-US

73

Pneumatic Plan for Robacta Reamer X-Line J,

6bar/87psi

-Y2

44

13

37 36

35

12

03

20

14

23

26

32

33

34

33

31

30

47

03 - Spannzylinder

20 - Pneumatikmotor

44 - Luftanschluss

13 - Magnetventil -Y2 Motor auf/ab

14 - Magnetventil -Y3 Einsprühen

36 - Drosselrückschlagventil

37 - Drosselrückschlagventil

47 - Filter Ansaugung

30 - Kunststoffflasche ohne Verschraubung

35 - Schiebeeinheit

33 - Rückschlagventil mit Feder

32 - Venturidüse mit Rückschlagventil

34 - Drosselventil

26 - Einsprühdüse

GASDÜSE SPANNEN

MOTOR DREHT

MOTOR

AUF / AB

-Y1 -Y4

15

61

DA-10

DRAHTABSCHNEIDER

EINSPRÜHEN

12 - Magnetventil -Y1 Spannen/Motor ein

61 - Schiebeeinheit

15 - Magnetventil -Y4 Drahtabschneider

23 - Aluminiumzylinder Einsprühen

31 - Kunststoffflasche mit Ferder in Rückschlagventil

-Y3

Robacta Reamer X-Line J Alu

74

Declaration of conformity

DE German Deutsch EN English English FR French Française

EU-KONFORMITÄTSERKLÄRUNG 2017
EU-DECLARATION OF CONFORMITY 2017
DÉCLARATION UE DE CONFORMITÉ, 2017

Wels-Thalheim, 2017-06-07

eingapmoc aLrerutcafunaMamriF eiD

FRONIUS INTERNATIONAL GMBH

Froniusstraße 1, A-4643 Pettenbach

erklärt in alleiniger Verantwortung,
dass folgendes Produkt:

Robacta Reamer X-Line J
(Alu)

Gasdüsenreinigungsgerät

auf das sich diese Erklärung
bezieht, mit folgenden Richtlinien
bzw. Normen übereinstimmt:

Richtlinie 2014/30/EU
Elektromag. Verträglichkeit

Richtlinie 2006/42/EG
Maschinenrichtlinie

Europäische Normen inklusive
zutreffende Änderungen
EN ISO 12100:2010
EN 62311:2008
EN 61000-6-2:2005+AC:2005
EN 61000-6-4:2007+A1:2011

Die oben genannte Firma hält
Dokumentationen als Nachweis der
Erfüllung der Sicherheitsziele und
die wesentlichen Schutzanforder­ungen zur Einsicht bereit.

Dokumentationsverantwortlicher:
(technische Dokumentation)

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

Hereby certifies on its sole
responsibility that the following
product:

Robacta Reamer X-Line J
(Alu)

Gas nozzle cleaner

which is explicitly referred to by this
Declaration meet the following
directives and standard(s):

Directive 2014/30/EU
Electromag. compatibility

Directive 2006/42/EC
Machinery Directive

European Standards including
relevant amendments
EN ISO 12100:2010
EN 62311:2008
EN 61000-6-2:2005+AC:2005
EN 61000-6-4:2007+A1:2011

Documentation evidencing
conformity with the requirements of
the Directives is kept available for
inspection at the above
Manufacturer.

person responsible for documents:
(technical documents)

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

se déclare seule responsable du fait
que le produit suivant:

Robacta Reamer X-Line J
(Alu)

Appareil de nettoyage de buses gaz

qui est l’objet de la présente
déclaration correspondent aux
suivantes directives et normes:

Directive 2014/30/UE
Électromag. Compatibilité

Directive 2006/42/CE
Directive aux machines

Normes européennes avec
amendements correspondants
EN ISO 12100:2010
EN 62311:2008
EN 61000-6-2:2005+AC:2005
EN 61000-6-4:2007+A1:2011

En tant que preuve de la satisfaction
des demandes de sécurité la
documentation peut être consultée
chez la compagnie susmentionnée.

responsable documentation:
(technique documentation)

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

2017 ppa. T. Herndler, MAS

Member of Board
Chief Production Officer

EN-US

75