FRO­NIUS Robacta Reamer X-Line J User manual

/ Perfect Charging / Perfect Welding / Solar Energy
42,0426,0240,EA 002-11122018
Robacta Reamer X-Line J
Robacta Reamer X-Line J Alu
Operating Instructions
Spare parts list
Welding torch cleaning
EN-US

2

3
EN-US
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 familiarize yourself with the
product. Reading the instructions carefully will enable you to learn about the many different
features your Fronius product has to offer. This will allow you to make full use of its advan-
tages.
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 Instruc-
tions
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.
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," special care is required.

4

5
EN-US
Contents
Safety Instructions ..................................................................................................................................... 7
General ................................................................................................................................................. 7
Intended Use......................................................................................................................................... 7
Environmental Conditions ..................................................................................................................... 7
Obligations of the Operating Company................................................................................................. 8
Obligations of Personnel....................................................................................................................... 8
Particular Hazard Areas........................................................................................................................ 8
Personal Protection and Protection of Others....................................................................................... 9
EMC Device Classifications .................................................................................................................. 9
EMC Measures ..................................................................................................................................... 9
EMF measures...................................................................................................................................... 10
Safety Measures at the Setup Location and during Transport.............................................................. 10
Safety Measures in Normal Operation.................................................................................................. 10
Maintenance and repair ........................................................................................................................ 11
Safety Inspection .................................................................................................................................. 11
Disposal ................................................................................................................................................ 11
Safety Symbols ..................................................................................................................................... 11
Copyright............................................................................................................................................... 11
General 13
General ...................................................................................................................................................... 15
Principle ................................................................................................................................................ 15
Device Concept..................................................................................................................................... 15
Applications........................................................................................................................................... 15
Warning Notices on the Cleaning Device ............................................................................................. 16
Transport.................................................................................................................................................... 18
Transport Equipment ............................................................................................................................ 18
Transport instructions on the packaging ............................................................................................... 18
Scope of Supply......................................................................................................................................... 19
Scope of Supply.................................................................................................................................... 19
Operating controls, connections and mechanical components 21
Safety......................................................................................................................................................... 23
Safety.................................................................................................................................................... 23
Operating controls, connections and mechanical components.................................................................. 24
Operating Controls, Connections, and Mechanical Components - Front of Device ............................. 24
Operating Controls, Connections, and Mechanical Components - Rear of Device ............................. 25
Operating Controls, Connections, and Mechanical Components - Side of Device .............................. 26
Connections for robot control................................................................................................................ 27
Installation and Startup 29
Safety......................................................................................................................................................... 31
Safety.................................................................................................................................................... 31
ensure that the cleaning device is depressurized ................................................................................. 32
Before installation ...................................................................................................................................... 33
Intended Use......................................................................................................................................... 33
Operating Personnel, Maintenance Personnel .....................................................................................33
Setup Regulations................................................................................................................................. 33
Specifications for the Compressed Air Supply...................................................................................... 33
Measures to ensure safe operation of the device when operating personnel are untrained ................ 33
Diagram of the programmable logic control (PLC)..................................................................................... 34
Diagram of the programmable logic control (PLC)................................................................................34
Screwing the Cleaning Device to the Solid Surface................................................................................... 35
Screwing the cleaning device and work stand to the surface ............................................................... 35
Welding Torch Cleaning Position............................................................................................................... 37
Welding Torch Cleaning Position.......................................................................................................... 37
Adjusting the Gas Nozzle Clamping Device .............................................................................................. 38

6
Adjusting the gas nozzle clamping device ............................................................................................ 38
Fitting the Cleaning Cutter ......................................................................................................................... 39
Fitting the cleaning cutter...................................................................................................................... 39
Adjusting the Position of the Cleaning Motor ............................................................................................. 40
Adjusting the position of the cleaning motor ......................................................................................... 40
Setting up the Compressed Air Supply ...................................................................................................... 41
Setting up the cleaning device compressed air supply, compressed air relief valve function............... 41
Starting Up the Parting Agent Atomizer ..................................................................................................... 42
Filling the parting agent container (1 liter) and connecting it to the cleaning device............................. 42
Connecting the parting agent container (10 liter) to the cleaning device .............................................. 43
Setting the injection quantity of the parting agent atomizer .................................................................. 44
Starting up the fill-level control sensor ....................................................................................................... 45
General ................................................................................................................................................. 45
Operating controls and displays on the sensor..................................................................................... 45
Performing empty adjustment ............................................................................................................... 45
Performing a full adjustment ................................................................................................................. 46
Unlocking/locking the fill-level control sensor ....................................................................................... 46
Manually Checking the Cleaning Device Functions................................................................................... 47
General ................................................................................................................................................. 47
Manually checking the cleaning device functions ................................................................................. 47
Start up the Cleaning Device ..................................................................................................................... 49
Requirements for Start-up Operation.................................................................................................... 49
Start-up Operation ................................................................................................................................ 49
Cleaning Program Sequence..................................................................................................................... 50
Safety.................................................................................................................................................... 50
Cleaning Program Sequence................................................................................................................ 51
Cleaning Device Signal Sequences........................................................................................................... 55
Cleaning device signal sequences........................................................................................................ 55
Wire Cutter Signal Sequence..................................................................................................................... 56
Wire cutter signal sequence.................................................................................................................. 56
Service, maintenance and disposal 57
Safety......................................................................................................................................................... 59
Safety.................................................................................................................................................... 59
ensure that the cleaning device is depressurized ................................................................................. 60
Service, maintenance and disposal ........................................................................................................... 61
General ................................................................................................................................................. 61
Before every start-up ............................................................................................................................ 61
Daily ...................................................................................................................................................... 61
Weekly .................................................................................................................................................. 61
Every six months................................................................................................................................... 61
Whenever required ............................................................................................................................... 61
Disposal ................................................................................................................................................ 61
Troubleshooting 63
Safety......................................................................................................................................................... 65
Safety.................................................................................................................................................... 65
ensure that the cleaning device is depressurized ................................................................................. 66
Troubleshooting ......................................................................................................................................... 67
Errors in the Program Sequence .......................................................................................................... 67
Technical Data 69
Technical Data ........................................................................................................................................... 71
Robacta Reamer X-Line J, Robacta Reamer X-Line J Alu ................................................................... 71
Appendix 73
Spare parts list: Robacta Reamer X-Line J, Robacta Reamer X-Line J Alu .............................................. 74
Circuit diagrams: Circuit Diagram for Robacta Reamer X-Line J, Robacta Reamer X-Line J Alu ............. 76
Pneumatic Plan for Robacta Reamer X-Line J, Robacta Reamer X-Line J Alu......................................... 77
Declaration of conformity ........................................................................................................................... 78

7
EN-US
Safety Instructions
General The device has been manufactured using state-of-the-art technology and according to rec-
ognized 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 instruc-
tions 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!
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 ac-
cordance 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
Operation or storage of the device outside the stipulated area will be deemed as not in ac-
cordance 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)

8
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 Com-
pany
The operating company must only allow persons to work with the device if they
- Are familiar with the basic occupational safety and accident prevention regulations
and are trained in handling the device
- Have read and understood these Operating Instructions, especially the section "Safe-
ty 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 before begin-
ning 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 Hazard
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 accordance with "Per-
formance 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.
Covers must only be opened/removed during maintenance, installation and repair work.

9
EN-US
During operation:
- ensure that all covers are closed, and all side parts have been mounted properly
- 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 Op-
erating 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, in-
jury 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 Clas-
sifications
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 emis-
sions, it may affect the application area for which it was designed (e.g., when there is sen-
sitive 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:
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

10
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 im-
mediate vicinity of the device and the welding process
- Keep distances between welding cables and the head/torso of the welder as large as
possible for safety reasons
- Do not carry welding cables and hosepacks over one's shoulder or wrap them around
one's body or body parts
Safety Measures
at the Setup Loca-
tion 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 pre-
vention regulations are observed when transporting the device, especially guidelines con-
cerning 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 repaired by trained ser-
vice technicians before commissioning the device.
Safety Measures
in Normal Opera-
tion
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 international regula-
tions.

11
EN-US
Maintenance and
repair
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 manufac-
turer'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.
Safety Inspection 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.
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 ser-
vice center. The service center will provide the necessary documents upon request.
Disposal Do not dispose of this device with normal domestic waste! To comply with the European
Directive on Waste Electrical and Electronic Equipment and its implementation as national
law, electrical equipment that has reached the end of its life must be collected separately
and returned to an approved recycling facility. Any device that you no longer require must
be returned to your dealer, or you must locate the approved collection and recycling facil-
ities in your area. Ignoring this European Directive may have potentially adverse affects on
the environment and your health!
Safety Symbols Devices with CE marking satisfy the essential requirements of the relevant directives (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 are technically correct at the time of going to print. The right to make
modifications is reserved. 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 in-
structions, we will be most grateful for your comments.

12

General

15
EN-US
General
Principle The cleaning device is intended to auto-
matically 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 increa-
ses the service life of wearing parts. At the
same time, the even application of parting
agent prevents the build-up of new dirt.
Device Concept 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 into the gas nozzle and onto the
face of the gas nozzle.
Applications The cleaning device is exclusively suited for operation in automation and robot 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

16
Warning Notices
on the Cleaning
Device
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.
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 depres-
surized.
Do not use the functions described here until you have fully read and under-
stood the following documents:
- These Operating Instructions
- All Operating Instructions for system components, especially the safety
rules
For indoor use only
Type
Art.No.
Chargen No.
U 1
I 1
p
max
24 V
6 bar (87psi.)
www.fronius.com

17
EN-US
Wear eye protection
Warning before the device switches on automatically

18
Transport
Transport Equip-
ment
Transport the device using the following transport equipment:
- on a pallet using a forklift
- on a pallet using a lift truck
- manually
WARNING!
Falling or toppling devices can be deadly.
► When transporting the device by forklift or lift truck, secure the device from falling
► Do not turn, brake, or accelerate in a sudden, jerking manner
Transport in-
structions on the
packaging
CAUTION!
Improper transport can result in damage.
Follow the transport instructions on the device packaging.

19
EN-US
Scope of Supply
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.
(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
(2)
(3)
(4)
(5)
(6)
(1)

20