FRONIUS Robacta Reamer V Twin Bedienungsanleitung
/ Perfect Charging / Perfect Welding / Solar Energy
42,0426,0142,EN 020-12122018
Robacta Reamer V Twin Operating Instructions
Spare parts list
Welding torch cleaning
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Dear reader,
Introduction Thank you for the trust you have placed in our company and congratulations on buying this
high-quality Fronius product. These instructions will help you familiarise yourself with the
product. Reading the instructions carefully will enable you to learn about the many different
features it has to offer. This will allow you to make full use of its advantages.
Please also note the safety rules to ensure greater safety when using the product. Careful
handling of the product will repay you with years of safe and reliable operation. These are
essential prerequisites for excellent results.
Explanation of
safety symbols DANGER!
Indicates immediate and real danger.
If it is not avoided, death or serious injury will result.
WARNING!
Indicates a potentially dangerous situation.
Death or serious injury may result if appropriate precautions are not taken.
CAUTION!
Indicates a situation where damage or injury could occur.
If it is not avoided, minor injury and/or damage to property may result.
NOTE!
Indicates a risk of flawed results and possible damage to the equipment.
IMPORTANT!
Indicates tips for correct operation and other particularly useful information.
It does not indicate a potentially damaging or dangerous situation.
If you see any of the symbols depicted in the "Safety rules" chapter, special care is re-
quired.
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Contents
Safety rules ................................................................................................................................................ 9
General ................................................................................................................................................. 9
Proper use ............................................................................................................................................ 9
Environmental conditions...................................................................................................................... 9
Obligations of the operator.................................................................................................................... 10
Obligations of personnel ....................................................................................................................... 10
Specific hazards.................................................................................................................................... 10
Protecting yourself and others .............................................................................................................. 11
EMC Device Classifications .................................................................................................................. 11
EMC measures ..................................................................................................................................... 11
EMF measures...................................................................................................................................... 12
Safety measures at the installation location and during transport ........................................................ 12
Safety measures in normal operation ................................................................................................... 12
Commissioning, maintenance and repair.............................................................................................. 13
Safety inspection................................................................................................................................... 13
Disposal ................................................................................................................................................ 13
Safety symbols...................................................................................................................................... 13
Copyright............................................................................................................................................... 13
General 15
General ...................................................................................................................................................... 17
Principle ................................................................................................................................................ 17
Device concept ..................................................................................................................................... 17
Application areas .................................................................................................................................. 17
Scope of supply .................................................................................................................................... 18
Available options................................................................................................................................... 18
How the wire cutter works/Maximum wire diameter.............................................................................. 18
Warning notices on the device.............................................................................................................. 18
Transport.................................................................................................................................................... 21
Vehicles ................................................................................................................................................ 21
Transport notices on the packaging...................................................................................................... 21
Controls, connections and mechanical components 23
Safety......................................................................................................................................................... 25
Safety.................................................................................................................................................... 25
Robacta Reamer V Twin control elements, connections and mechanical components............................. 26
Controls, connections and mechanical components............................................................................. 26
Standard I/O connecting plug (X1) pin assignment for robot control ......................................................... 28
General ................................................................................................................................................. 28
Standard I/O (X1) connecting plug pin assignment .............................................................................. 28
Installation and commissioning 29
Safety......................................................................................................................................................... 31
Safety.................................................................................................................................................... 31
Ensuring that the cleaning device is depressurised.............................................................................. 32
Before commissioning................................................................................................................................ 33
Proper use ............................................................................................................................................ 33
Operators, maintenance personnel....................................................................................................... 33
Setup regulations .................................................................................................................................. 33
Compressed air supply specifications................................................................................................... 33
Measures for the safe operation of the device with untrained personnel.............................................. 33
Screwing the cleaning device to the underlying surface ............................................................................ 34
Screwing the cleaning device and installation stand to the underlying surface .................................... 34
Screwing the cleaning device to the underlying surface ....................................................................... 34
Fitting the cleaning cutter........................................................................................................................... 36
Fitting the cleaning cutter...................................................................................................................... 36
Torch cleaning position .............................................................................................................................. 37
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Welding torch cleaning position ............................................................................................................ 37
Adjusting the lifting device ......................................................................................................................... 38
Adjusting the lifting device .................................................................................................................... 38
Installing the compressed air supply.......................................................................................................... 40
Establishing the compressed air supply for the cleaning device, function of the compressed air relief
valve...................................................................................................................................................... 40
Starting up the parting agent nebuliser ...................................................................................................... 41
Fill parting agent container (1 litre) and connect to the cleaning device ............................................... 41
Connect the parting agent container (10 litres) to the cleaning device ................................................. 41
Adjusting the parting agent nebuliser spray amount.............................................................................42
Using the fill-level control sensor ............................................................................................................... 44
Optional fill-level control sensor ............................................................................................................ 44
Controls and indicators on the sensor .................................................................................................. 44
Installation adapter borehole dimensions ............................................................................................. 44
Fitting the fill-level control sensor.......................................................................................................... 45
Calibrating the empty state ................................................................................................................... 46
Calibrating the full state ........................................................................................................................ 46
Locking/unlocking the fill-level control sensor....................................................................................... 47
Electrical connection ............................................................................................................................. 47
Manually checking the cleaning device functions ...................................................................................... 48
General ................................................................................................................................................. 48
Checking functions manually ................................................................................................................ 48
Starting up the cleaning device.................................................................................................................. 50
Prerequisites for start-up....................................................................................................................... 50
Start-up ................................................................................................................................................. 50
Cleaning programme ................................................................................................................................. 51
Safety.................................................................................................................................................... 51
Cleaning program sequence................................................................................................................. 52
Signal waveform for cleaning..................................................................................................................... 57
Signal inputs ......................................................................................................................................... 57
Signal outputs ....................................................................................................................................... 57
Signals not defined using time .............................................................................................................. 58
Signal waveform: wire cutter (inputs and outputs) ................................................................................ 58
Care, maintenance and disposal 59
Safety......................................................................................................................................................... 61
Safety.................................................................................................................................................... 61
Ensuring that the cleaning device is depressurised.............................................................................. 62
Care, maintenance and disposal ............................................................................................................... 63
General ................................................................................................................................................. 63
Before each start-up ............................................................................................................................. 63
Daily ...................................................................................................................................................... 63
Weekly .................................................................................................................................................. 63
Every 6 months ..................................................................................................................................... 63
If necessary........................................................................................................................................... 63
Disposal ................................................................................................................................................ 63
Adjust the swivel mechanism stop angle ................................................................................................... 64
General ................................................................................................................................................. 64
Preparatory work................................................................................................................................... 64
Adjust the swivel mechanism stop angle .............................................................................................. 64
And finally... .......................................................................................................................................... 65
Troubleshooting 67
Safety......................................................................................................................................................... 69
Safety.................................................................................................................................................... 69
Ensuring that the cleaning device is depressurised.............................................................................. 70
Troubleshooting ......................................................................................................................................... 71
Errors in program sequence ................................................................................................................. 71
Technical data 73
Technical data............................................................................................................................................ 75
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Robacta Reamer V Twin....................................................................................................................... 75
Appendix 77
Spare parts list: Robacta Reamer V Twin.................................................................................................. 78
Circuit diagrams: Robacta Reamer V Twin................................................................................................ 79
Robacta Reamer V Twin pneumatic diagram ............................................................................................ 80
Declarations of Conformity......................................................................................................................... 81
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Safety rules
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 operating instruc-
tions 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 applica-
ble and local regulations regarding accident prevention and environmental protection.
All safety and danger notices on the device
- must be in a legible state,
- must not be damaged,
- must not be removed,
- must not be covered, pasted or painted over.
For the location of the safety and danger notices on the device, refer to the section headed
"General" in the operating instructions for the device.
Before commissioning the device, rectify any faults that could compromise safety.
This is for your personal safety!
Proper use The device is to be used exclusively for its intended purpose.
The device is intended solely for the mechanical cleaning of Fronius robot welding torches
in automatic mode.
Any use above and beyond this purpose is deemed improper. The manufacturer shall not
be held liable for any damage arising from such usage.
Proper use includes:
- carefully reading these operating instructions
- following all the instructions and safety rules in these operating instructions
- performing all stipulated inspection and maintenance work
The device is designed for use in industry and the workshop. The manufacturer accepts
no responsibility for any damage caused through use in a domestic setting.
The manufacturer likewise accepts no liability for inadequate or incorrect results.
Environmental
conditions
Operation or storage of the device outside the stipulated area will be deemed as not in ac-
cordance with the intended purpose. The manufacturer shall not be held liable for any dam-
age 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)
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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 section "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 prevention
- 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 secured area.
If this area has to be accessed when setup and maintenance work is carried out, make sure
that
- the entire system is switched off for the duration of the work in this area
- and that it is prevented from starting up accidentally, e.g. as the result of a control fault.
If untrained operators have access to the device, its compressed air supply must be dis-
connected 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 manufac-
turer must also be observed.
Keep your body, especially your hands, face, hair, clothing and all tools away from moving
parts, such as:
- rotating cleaning cutter
- upwards/downwards travelling cleaning motor
- extending/retracting gas nozzle clamping device
- wire cutter
Do not touch cleaning cutters immediately after use - risk of burns. Observe the special
safety rules in the Operating Instructions for handling cleaning cutters.
Protect hands, face and eyes against flying parts (shavings, etc.) and compressed air/part-
ing agent mixture escaping from the parting-agent injection nozzle.
Covers may only be opened/removed for the duration of any maintenance, installation or
repair work.
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