FRONIUS Robacta Reamer V Comfort User manual

Operating

Instructions

Robacta Reamer V Comfort

42,0426,0385,EA 005-02082022

EN-US Operating instructions

Table of contents

Safety Instructions 5

General 5

Intended Use 5

Environmental Conditions 5

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 7

EMF measures 8

Safety Measures at the Setup Location and during Transport 8

Safety Measures in Normal Operation 8

Maintenance and repair 9

Safety Inspection 9

Disposal 9

Safety Symbols 10

General 11

General 13

Device concept 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 and Options 17

Scope of supply 17

Available options 17

Operating controls, connections and mechanical components 19

Safety 21

Operating controls, connections and mechanical components 22

Operating controls, connections, and mechanical components 22

Harting Han12P (X1) connecting plug configuration for the robot control 26

General 26

Harting Han12P (X1) connecting plug configuration 26

Installation and Startup 27

Safety 29

Ensuring that the cleaning device is depressurized 30

Before installation 31

Intended Use 31

Operating personnel, maintenance personnel 31

Setup regulations 31

Specifications for the Compressed Air Supply 31

Measures to ensure safe operation of the device when operating personnel are untrained 32

Screwing the Cleaning Device to the Solid Surface 33

Screwing the cleaning device and work stand to the surface 33

Screw the cleaning device to the surface 34

Welding Torch Cleaning Position 36

Welding torch cleaning position 36

Adjusting the Gas Nozzle Clamping Device 37

Adjusting the gas nozzle clamping device 37

EN-US

Fitting the Cleaning Cutter 38

Fitting the cleaning cutter 38

Adjusting the Position of the Cleaning Motor 39

Adjusting the position of the cleaning motor 39

Configuring the Injection Device 40

Configuring the injection device 40

Install electrically controlled wire cutter (option) 41

Functionality of the electrically controlled wire cutter 41

Maximum wire diameter 41

Installing the electrically controlled wire cutter 41

Setting up the Compressed Air Supply 43

Setting up the cleaning device compressed air supply, compressed air relief valve function 43

Starting Up the Parting Agent Atomizer 44

Filling the parting agent container (1 liter) and connecting it to the cleaning device 44

Connecting the parting agent container (10 liter) to the cleaning device 45

Manually Checking the Cleaning Device Functions 48

Safety 48

Manually checking the cleaning device functions 48

Start up the Cleaning Device 51

Requirements for starting up 51

Start-up Operation 51

Cleaning Program Sequence 52

Safety 52

Cleaning program sequence 53

Cleaning signal sequence 57

Defined signal input 57

Signal outputs defined in time 57

Signal input of the optional wire cutter 57

Signal input that cannot be defined in time 57

Signal inputs that cannot be defined in time 57

Service, maintenance and disposal 59

Safety 61

Ensuring that the cleaning device is depressurized 62

Service, maintenance and disposal 63

General 63

Before every start-up 63

Daily 63

Weekly 63

Every 6 months 63

Whenever required 63

Empty parting agent collecting container 64

Disposal 65

Troubleshooting 67

Safety 69

Ensuring that the cleaning device is depressurized 70

Troubleshooting 71

Errors in the Program Sequence 71

Technical data 73

Technical data 75

Robacta Reamer V Comfort 75

Appendix 77

Declaration of conformity 79

Safety Instructions

General The device has been manufactured using state-of-the-art technology and ac-

cording to recognized safety standards. If used incorrectly or misused, however,

it can cause

-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 reg-

ulations 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 sec-

tion 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!

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 respons-

ible 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

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 respons-

ible for any damage resulting from improper use.

EN-US

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.)

Obligations of

the Operating

Company

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

All persons who are assigned to work with the device must do the following be-

fore 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.

Particular Haz-

ard Areas

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 ac-

cordance with "Performance Level d" of ISO 13849-1.

In addition to these Operating Instructions, the safety rules of the robot manu-

facturer 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 Op-

erating Instructions.

Protect hands, face and eyes from ﬂying parts (chips, etc.) and compressed air/

parting agent mixture discharged from the parting-agent injection nozzle.

Covers must only be opened/removed during maintenance, installation and re-

pair work.

During operation:

-ensure that all covers are closed, and all side parts have been mounted prop-

erly

-keep all covers closed

Personal Protec-

tion and Protec-

tion of Others

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, dis-

charged 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 low-

voltage grid.

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 ac-

tion to rectify the situation.

Check and evaluate possible problems and the interference immunity of equip-

ment 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

EN-US

Supporting measures to avoid EMC problems:

1.Grid power supply

-If electromagnetic interference occurs despite a grid connection that

complies with regulations, take additional measures (e.g., use a suitable

grid filter).

2.Control lines

-Keep them as short as possible

-Route them close together (also to avoid EMF problems)

-Route them far from other lines

3.Equipotential bonding

4.Shield, if necessary

-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 acci-

dent prevention regulations are observed when transporting the device, espe-

cially guidelines concerning hazards during transport and shipment.

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 re-

paired by trained service technicians before commissioning the device.

Safety Measures

in Normal Oper-

ation

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 dam-

age 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

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 be per-

formed 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.

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 docu-

ments upon request.

Disposal To comply with European directives and national law, waste electrical and elec-

tronic equipment must be collected separately and sent for environmentally-

friendly recycling. Used devices must be returned to a distributor or an approved

collection and recycling facility in your area. Proper disposal of used devices pro-

motes the sustainable recycling of material resources. Ignoring this may have po-

tentially adverse effects on the environment and your health.

Packaging materials

Materials collected separately. Check the regulations in your area. Reduce the

volume of cardboard.

EN-US

Safety Symbols Devices with CE marking satisfy the essential requirements of the relevant dir-

ectives (e.g. the low-voltage, electromagnetic compatibility, and machinery dir-

ectives).

Devices marked with the CSA test mark satisfy the requirements of the relevant

standards for Canada and the USA.

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 com-

ments.

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