FRONIUS Robacta Reamer Alu Edition User manual

Operating

Instructions

Robacta Reamer Alu Edition

Robacta Reamer Alu 3000upm

Robacta Reamer Twin

42,0426,0146,EN 018-01062022

EN Operating Instructions

Contents

Safety rules 6

Explanation of safety notices 6

General 6

Proper use 7

Environmental conditions 7

Obligations of the operator 7

Obligations of personnel 7

Specific hazards 7

Protecting yourself and others 8

EMC Device Classifications 8

EMC measures 9

EMF measures 9

Safety measures at the installation location and during transport 9

Safety measures in normal operation 10

Commissioning, maintenance and repair 10

Safety inspection 10

Disposal 11

Safety symbols 11

General 13

General 15

Principle 15

Device concept 15

Application areas 15

Illustration of the various device types 16

Scope of supply and options 17

General 17

Robacta Reamer Alu Edition scope of supply 17

Robacta Reamer Alu Edition options 17

Robacta Reamer Alu 3000upm scope of supply 18

Robacta Reamer Alu 3000upm options 18

Robacta Reamer Twin scope of supply 18

Robacta Reamer Twin options 19

Warning notices on the device 20

Warning notices on the cleaning device 20

Transport 22

Transport devices 22

Transport notices on the packaging 22

Controls, connections and mechanical components 23

Safety 25

Control elements, connections and mechanical components of the Robacta Reamer Alu Edi-

tion and Robacta Reamer Alu 3000upm

Control elements, connections and mechanical components 26

Robacta Reamer Twin control elements, connections and mechanical components 27

Control elements, connections and mechanical components 27

Harting Han6P connecting plug pin assignment (X1) for robot control 29

General 29

Harting Han6P connecting plug pin assignment (X1) 29

Installation and commissioning 31

Safety 33

Ensuring that the cleaning device is depressurised 34

Before commissioning 36

Proper use 36

Operators, maintenance personnel 36

Setup regulations 36

Compressed air supply specifications 36

Measures for the safe operation of the device with untrained personnel 37

Screwing the cleaning device to the underlying surface 38

Screwing the cleaning device and installation stand to the underlying surface 38

Screwing the cleaning device to the underlying surface 39

Torch cleaning position 41

Welding torch cleaning position - Robacta Reamer Alu Edition 41

Welding torch cleaning position - Robacta Reamer Alu 3000upm 41

Welding torch cleaning position - Robacta Reamer Twin 41

Adjusting the gas nozzle clamping device on the Robacta Reamer Alu Edition and Robacta

Reamer Alu 3000upm

Adjusting the gas nozzle clamping device 42

Fitting the cleaning brush on the Robacta Reamer Alu Edition 43

Fitting the cleaning brush 43

Fitting the cleaning cutter on the Robacta Reamer Alu 3000upm 44

Fitting the cleaning cutter 44

Fitting the cleaning cutter on the Robacta Reamer Twin 45

Fitting the cleaning cutter 45

Adjusting the Robacta Reamer Alu Edition lifting device 46

Adjusting the lifting device 46

Adjusting the Robacta Reamer Alu 3000upm lifting device 47

Adjusting the lifting device 47

Adjusting the Robacta Reamer Twin lifting device 48

Adjusting the lifting device 48

Starting up the Robacta Reamer Twin parting agent nebuliser 49

Starting up the parting agent nebuliser 49

Correct adjustment of the parting agent spray nozzles on the Robacta Reamer Twin 50

Installing mechanically-controlled wire cutter on the Robacta Reamer Alu Edition and

Robacta Reamer Alu 3000upm (optional)

Installing the mechanically-controlled wire cutter 51

Installing the electrically-controlled wire cutter on the Robacta Reamer Alu Edition and

Robacta Reamer Alu 3000upm (optional)

Installing the electrically-controlled wire cutter 55

Wire cutter function 57

Maximum wire diameter 57

How the mechanically controlled wire cutter works 57

How the electrically-controlled wire cutter works 57

Installing the compressed air supply 58

Establishing the compressed air supply for the cleaning device, function of the com-

pressed air relief valve

Starting up the cleaning device 59

Prerequisites for start-up 59

Start-up 59

Programme sequence and signal waveform on the Robacta Reamer Alu Edition and Robacta

Reamer Alu 3000upm

Cleaning programme sequence 60

Signal waveform 62

Robacta Reamer Twin programme sequence and signal waveform 63

Cleaning programme sequence 63

Signal waveform 66

Care, maintenance and disposal 67

Safety 69

Ensuring that the cleaning device is depressurised 70

Care, maintenance and disposal 72

General 72

Before each start-up 72

Daily 72

Weekly 72

Every 6 months 72

As necessary 72

Disposal 72

Troubleshooting 73

Safety 75

Ensuring that the cleaning device is depressurised 76

Troubleshooting 78

Errors in program sequence 78

Technical data 81

Technical data 83

Robacta Reamer Alu Edition and Robacta Reamer Alu 3000upm 83

Robacta Reamer Twin 83

Appendix 85

Circuit diagram Robacta Reamer, Robacta Reamer Alu Edition, Robacta Reamer Alu Edition

3000rpm

Circuit diagram Robacta Reamer Twin 88

Robacta Reamer Twin pneumatic diagram 89

Declarations of Conformity 90

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

-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 en-

vironmental 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 sec-

tion headed "General" in the operating instructions for the device.

Before commissioning the device, rectify any faults that could compromise

safety.

This is for your personal safety!

Proper use The device is to be used exclusively for its intended purpose.

The device is intended solely for the mechanical cleaning of Fronius robot weld-

ing 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 set-

ting.

The manufacturer likewise accepts no liability for inadequate or incorrect results.

Environmental

conditions

Operation or storage of the device outside the stipulated area will be deemed as

not in accordance with the intended purpose. The manufacturer shall not be held

liable for any damage arising from such usage.

Ambient temperature range:

-during operation: 0 °C to + 40 °C (32 °F to 104 °F)

-during transport and storage: -25 °C to +55 °C (-13 °F to 131 °F)

Relative humidity:

-up to 50 % at 40 °C (104 °F)

-up to 90 % at 20 °C (68 °F)

Keep ambient air free from dust, acids, corrosive gases and substances, etc.

Can be used at altitudes of up to 2000 m (6500 ft)

Obligations of

the operator

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.

Obligations of

personnel

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.

Specific hazards

Stay out of the working area of the robot.

The device must be incorporated into a higher-level safety system within a se-

cured 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 / rotating cleaning brushes

-lifting device moving up/down

-extending/retracting gas nozzle clamping device

-wire cutter

Do not touch cleaning cutter / cleaning brush immediately after use - risk of

burns. Observe the special safety rules in the operating instructions for handling

the cleaning cutter / cleaning brush.

Protect hands, face and eyes against ﬂying parts (shavings, etc.) and compressed

air/parting agent mixture escaping from the parting-agent injection nozzles.

Covers may only be opened/removed for the duration of any maintenance, in-

stallation or repair work.

During operation

-Ensure that all covers are closed and fitted properly

-Keep all covers closed

Protecting your-

self and others

When welding, you expose yourself to numerous dangers. In addition to these

operating instructions, the safety rules of the manufacturer of the entire welding

system must also be observed.

Keep all persons, especially children, out of the working area while any devices

are in operation or welding is in progress. If, however, there are people in the vi-

cinity,

-make them aware of all the dangers and health risks (crushing from mechan-

ically-powered parts, injury from cleaning cutter / cleaning brush, ﬂying

shavings and similar matter, escaping compressed air/parting agent mixture,

ﬂying sparks, dazzling by arc, inhaling of harmful welding fumes, noise, pos-

sible danger from mains or welding current, etc),

-provide suitable protective equipment or

-erect suitable safety screens/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 low-

voltage 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 recti-

fy the situation.

Check for possible problems, and check and evaluate neighbouring devices' res-

istance to interference according to national and international requirements:

-Safety devices

-Power, signal and data transfer lines

-IT and telecommunications devices

-Measuring and calibrating devices

Supporting measures for avoidance of EMC problems:

1.Mains supply

-If electromagnetic interference arises despite correct mains connection,

additional measures are necessary (e.g. use a suitable line filter).

2.Control lines

-must be kept as short as possible

-must run close together (to avoid EMF problems)

-must be kept well apart from other leads

3.Equipotential bonding

4.Shield, if necessary

-Shield off other nearby devices

-Shield off entire welding installation

EMF measures Electromagnetic fields may pose as yet unknown risks to health:

-Effects on the health of persons in the vicinity, e.g. those with pacemakers

and hearing aids

-Individuals with pacemakers must seek advice from their doctor before ap-

proaching the device or any welding that is in progress

-For safety reasons, maintain as large a distance as possible between the

welding power-leads and the head/torso of the welder

-Do not carry welding power-leads and hosepacks over the shoulders or wind

them around any part of the body

Safety measures

at the installa-

tion 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 regard-

ing 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 be-

fore commissioning the device.

Safety measures

in normal opera-

tion

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 function-

ing 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

It is impossible to guarantee that bought-in parts are designed and manufac-

tured to meet the demands made of them, or that they satisfy safety require-

ments.

-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 spe-

cified torque.

Safety inspec-

tion

The manufacturer recommends that a safety inspection of the device is per-

formed 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 stand-

ards and directives.

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