FRO­NIUS Robacta Reamer V Twin User manual

Operating
Instructions
Robacta Reamer V Twin
42,0426,0142,EN 024-29082022
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
Copyright 11
General 13
General 15
Principle 15
Device concept 15
Application areas 15
Scope of supply 16
Available options 16
How the wire cutter works/Maximum wire diameter 16
Warning notices on the device 17
Transport 19
Transport devices 19
Transport notices on the packaging 19
Controls, connections and mechanical components 21
Safety 23
Safety 23
Robacta Reamer V Twin control elements, connections and mechanical components 24
Control elements, connections and mechanical components 24
Standard I/O connecting plug (X1) pin assignment for robot control 26
General 26
Standard I/O (X1) connecting plug pin assignment 26
Installation and commissioning 27
Safety 29
Safety 29
Ensuring that the cleaning device is depressurised 30
Before commissioning 31
Proper use 31
Operators, maintenance personnel 31
Setup regulations 31
Compressed air supply specifications 31
Measures for the safe operation of the device with untrained personnel 32
Screwing the cleaning device to the underlying surface 33
Screwing the cleaning device and installation stand to the underlying surface 33
Screwing the cleaning device to the underlying surface 33
Fitting the cleaning cutter 35
Fitting the cleaning cutter 35
Torch cleaning position 36
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Cleaning position of the welding torch with externally routed coolant lines 36
Cleaning position of the welding torch with internally routed coolant lines 36
Fitting the clamping system for welding torches with internally routed coolant lines 37
Tools required 37
Removing the existing clamping system 37
Fitting the Twin clamping system 38
Adjusting the lifting device 41
Adjusting the lifting device 41
Installing the compressed air supply 43
Establishing the compressed air supply for the cleaning device, function of the com-
pressed air relief valve
43
Starting up the parting agent nebuliser 44
Fill parting agent container (1 litre) and connect to the cleaning device 44
Connect the parting agent container (10 litres) to the cleaning device 45
Adjusting the parting agent nebuliser spray amount 46
Using the fill-level control sensor 47
Optional fill-level control sensor 47
Controls and indicators on the sensor 47
Installation adapter borehole dimensions 47
Fitting the fill-level control sensor 48
Calibrating the empty state 49
Calibrating the full state 49
Locking/unlocking the fill-level control sensor 50
Electrical connection 50
Manually checking the cleaning device functions 51
Safety 51
Checking functions manually 51
Starting up the cleaning device 53
Prerequisites for start-up 53
Start-up 53
Cleaning programme 54
Safety 54
Cleaning program sequence - overview 55
1. Wire cutter 56
2. "Parting agent level" query (option) 57
3. "Cleaning motor lowered" query 58
4. "Gas nozzle free" query 59
5. Cleaning 60
Signal waveform for cleaning 65
Signal inputs 65
Signal outputs 65
Signals not defined using time 66
Signal waveform: wire cutter (inputs and outputs) 66
Care, maintenance and disposal 67
Safety 69
Safety 69
Care, maintenance and disposal 71
General 71
Before each start-up 71
Daily 71
Weekly 71
Every 6 months 71
As necessary 71
Disposal 72
Adjust the swivel mechanism stop angle 73
General 73
Preparatory work 73
Adjust the swivel mechanism stop angle 74
And finally... 75
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Troubleshooting 77
Safety 79
Safety 79
Troubleshooting 81
Errors in program sequence 81
Technical data 83
Technical data 85
Robacta Reamer V Twin 85
Appendix 87
Circuit diagram Robacta Reamer V Twin 89
Robacta Reamer V Twin pneumatic diagram 90
Declaration of conformity 91
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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!
6

Proper use The device is to be used exclusively for its intended purpose.
The device is intended solely for the mechanical cleaning of Fronius robot 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.
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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
-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/parting agent mixture escaping from the parting-agent injection nozzle.
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
Anyone working with the device exposes themselves to numerous risks. In addi-
tion 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, flying shavings and similar
matter, escaping compressed air/parting agent mixture, flying sparks,
dazzling by arc, inhaling of harmful welding fumes, noise, possible danger
from mains or welding current, etc.)
-Provide suitable protective equipment
-Alternatively, erect suitable safety screens/curtains
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.
8

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.
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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.
Further details on safety inspection and calibration can be obtained from your
service centre. They will provide you on request with any documents you may re-
quire.
10

Disposal Waste electrical and electronic equipment must be collected separately and re-
cycled in an environmentally-friendly way, in accordance with the European Dir-
ective and national legislation. Used equipment must be returned to the distrib-
utor or disposed of via an approved local collection and disposal facility. Correct
disposal of used equipment promotes the sustainable recycling of material re-
sources. Failing to dispose of used equipment correctly can lead to adverse
health and/or environmental impacts.
Packaging materials
Separate collection according to material. Check your local authority regulations.
Crush containers to reduce size.
Safety symbols Devices with the CE mark satisfy the essential requirements of the applicable
directives (e.g. low-voltage and electromagnetic compatibility directives, ma-
chinery directive).
Devices with the CSA test mark satisfy the requirements of the relevant stand-
ards in Canada and the USA.
Copyright Copyright of these operating instructions remains with the manufacturer.
The text and illustrations are all technically correct at the time of printing. We
reserve the right to make changes. The contents of the operating instructions
shall not provide the basis for any claims whatsoever on the part of the pur-
chaser. If you have any suggestions for improvement, or can point out any mis-
takes that you have found in the instructions, we will be most grateful for your
comments.
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12

General
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14

General
Principle The Robacta Reamer V Twin is used for
the automatic cleaning of MIG/MAG
welding torches. The Robacta Reamer
V Twin allows you to clean the inside
and front of the gas nozzle on a wide
range of welding torch shapes. The res-
ult is a significant increase in the ser-
vice life of wearing parts. At the same
time, evenly applying parting agent
prevents the build-up of dirt.
Device concept The clamping device on the front of the Robacta Reamer V Twin holds the gas
nozzle in place during cleaning. A cleaning cutter is used to clean the nozzle.
After the cleaning process, a parting agent is applied to the inside and front of
the gas nozzle through the spray nozzle that is fixed in the middle of the cleaning
motor.
The Robacta Reamer V Twin is fitted with a wire cutter as standard. During the
cleaning process, the Robacta Reamer V Twin shortens both wire electrodes to a
defined length ready for the next welding process.
A robust fitting base is available for the installation of the Robacta Reamer V
Twin.
Application
areas
The cleaning device is exclusively intended for use in robot and other automated
applications, and can be used for a wide range of materials.
The main application areas are:
-Automotive and component supply industry
-Equipment construction
-Chemical plant construction
-Machine and tracked vehicle manufacturing
-Construction machinery and special vehicles
NOTE!
TWIN welding torches with a contact tip tilt angle of 4° cannot be cleaned with
the Robacta Reamer V Twin!
Alternatives:
▶Robacta Reamer Single/Twin
or
▶Robacta TC 2000 Twin
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Scope of supply
(1)
(2)
(3)
(4)
NOTE!
The "Robacta Reamer" parting agent
(item number 42,0411,8042) and the
cleaning cutter are not part of the
scope of supply.
(1) Robacta Reamer V Twin clean-
ing device with wire cutter
(2) Spatter tray
(3) Tightening key for cleaning mo-
tor
(4) Compressed air relief valve
not shown:
(5) Standard I/O connecting plug (X1) without cable
(6) Operating instructions
(7) Fixings for assembling the cleaning device:
-4 screws
-4 washers
-4 lock washers
-4 nuts
Available op-
tions
The following options are available for the cleaning device:
-Installation stand
-Cleaning cutter adjustment aid
-Level sensor
How the wire
cutter works/
Maximum wire
diameter
The wire cutter opens and closes when there is an active signal from the robot
control.
Two wire electrodes with a diameter of up to 1.6 mm (0.063 in.) can be cut at the
same time by the cleaning device wire cutter.
NOTE!
If you change over to a new welding torch, the wire cutter must be reset!
16

Warning notices
on the device
The Robacta Reamer V Twin is fitted with warning notices and a rating plate. The
warning notices and rating plate must not be removed or painted over.
Type
Art.No.
Chargen No.
U1
I1
Wels - Austria
p
max
24 V
6 bar (87psi.)
Warning notices affixed to the Robacta Reamer V Twin
WARNING! Risk of serious injury from:
-mechanically powered parts
-compressed air/parting agent mixture escaping from the part-
ing-agent injection nozzle
-flying parts (shavings, etc.)
Keep device free from current and pressure during maintenance
and servicing.
Do not use the functions described here until you have thoroughly
read and understood the following documents:
-these operating instructions
-all the operating instructions for the system components, es-
pecially the safety rules
For indoor use only
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EN

Wear eye protection
Notice warning of automatic start-up of the device
18

Transport
Transport
devices
The device is to be transported by the following devices:
-On pallets using a forklift truck
-On pallets using a lift truck
-Manual
WARNING!
Danger from machines and objects falling.
This can result in serious injury and damage to property.
▶Secure the device to prevent it from falling over when transporting on a fork-
lift truck or lift truck.
▶Avoid sudden changes in direction, braking or acceleration.
Transport no-
tices on the
packaging
CAUTION!
Danger due to improper transport.
This can result in damage to property.
▶Observe the transport notices on the device packaging.
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