FRO­NIUS Robacta Reamer Alu Edition User manual

Fronius prints on elemental chlorine free paper (ECF) sourced from certified sustainable forests (FSC).
/ Perfect Charging / Perfect Welding / Solar Energy
42,0426,0146,EN 015-04042019
Robacta Reamer Alu Edition
Robacta Reamer Alu 3000upm
Robacta Reamer Twin
Operating Instructions
Spare parts list
Welding torch cleaning
EN

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EN
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
Illustration of the various device types .................................................................................................. 17
Scope of supply and options...................................................................................................................... 18
General ................................................................................................................................................. 18
Robacta Reamer Alu Edition scope of supply....................................................................................... 18
Robacta Reamer Alu Edition options .................................................................................................... 18
Robacta Reamer Alu 3000upm scope of supply................................................................................... 19
Robacta Reamer Alu 3000upm options ................................................................................................ 19
Robacta Reamer Twin scope of supply ................................................................................................ 19
Robacta Reamer Twin options.............................................................................................................. 20
Warning notices on the device................................................................................................................... 21
Warning notices on the cleaning device ............................................................................................... 21
Transport.................................................................................................................................................... 23
Vehicles ................................................................................................................................................ 23
Transport notices on the packaging...................................................................................................... 23
Controls, connections and mechanical components 25
Safety......................................................................................................................................................... 27
Safety.................................................................................................................................................... 27
Control elements, connections and mechanical components of the Robacta Reamer Alu Edition and Ro-
bacta Reamer Alu 3000upm ...................................................................................................................... 28
Control elements, connections and mechanical components............................................................... 28
Robacta Reamer Twin control elements, connections and mechanical components................................ 29
Control elements, connections and mechanical components .............................................................. 29
Harting Han6P connecting plug pin assignment (X1) for robot control ...................................................... 31
General ................................................................................................................................................. 31
Harting Han6P connecting plug pin assignment (X1) ........................................................................... 31
Installation and commissioning 33
Safety......................................................................................................................................................... 35
Safety.................................................................................................................................................... 35
Ensuring that the cleaning device is depressurised.............................................................................. 36
Before commissioning................................................................................................................................ 37
Proper use ............................................................................................................................................ 37

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Operators, maintenance personnel....................................................................................................... 37
Setup regulations .................................................................................................................................. 37
Compressed air supply specifications................................................................................................... 37
Measures for the safe operation of the device with untrained personnel.............................................. 37
Screwing the cleaning device to the underlying surface ............................................................................ 38
Screwing the cleaning device and installation stand to the underlying surface .................................... 38
Screwing the cleaning device to the underlying surface ....................................................................... 38
Torch cleaning position .............................................................................................................................. 40
Welding torch cleaning position - Robacta Reamer Alu Edition............................................................ 40
Welding torch cleaning position - Robacta Reamer Alu 3000upm........................................................ 40
Welding torch cleaning position - Robacta Reamer Twin ..................................................................... 40
Adjusting the gas nozzle clamping device on the Robacta Reamer Alu Edition and Robacta Reamer Alu
3000upm .................................................................................................................................................... 41
Adjusting the gas nozzle clamping device ............................................................................................ 41
Fitting the cleaning brush on the Robacta Reamer Alu Edition ................................................................. 42
Fitting the cleaning brush...................................................................................................................... 42
Fitting the cleaning cutter on the Robacta Reamer Alu 3000upm ............................................................. 43
Fitting the cleaning cutter...................................................................................................................... 43
Fitting the cleaning cutter on the Robacta Reamer Twin ........................................................................... 44
Fitting the cleaning cutter...................................................................................................................... 44
Adjusting the Robacta Reamer Alu Edition lifting device ........................................................................... 45
Adjusting the lifting device .................................................................................................................... 45
Adjusting the Robacta Reamer Alu 3000upm lifting device ....................................................................... 46
Adjusting the lifting device .................................................................................................................... 46
Adjusting the Robacta Reamer Twin lifting device..................................................................................... 47
Adjusting the lifting device .................................................................................................................... 47
Starting up the Robacta Reamer Twin parting agent nebuliser ................................................................. 48
Starting up the parting agent nebuliser ................................................................................................. 48
Correct adjustment of the parting agent spray nozzles on the Robacta Reamer Twin......................... 49
Installing mechanically-controlled wire cutter on the Robacta Reamer Alu Edition and Robacta Reamer
Alu 3000upm (optional).............................................................................................................................. 50
Installing the mechanically-controlled wire cutter.................................................................................. 50
Installing the electrically-controlled wire cutter on the Robacta Reamer Alu Edition and Robacta Reamer
Alu 3000upm (optional).............................................................................................................................. 54
Installing the electrically-controlled wire cutter...................................................................................... 54
Wire cutter function .................................................................................................................................... 56
Maximum wire diameter........................................................................................................................ 56
How the mechanically-controlled wire cutter works ..............................................................................56
How the electrically-controlled wire cutter works .................................................................................. 56
Installing the compressed air supply.......................................................................................................... 57
Establishing the compressed air supply for the cleaning device, function of the compressed air relief
valve...................................................................................................................................................... 57
Starting up the cleaning device.................................................................................................................. 58
Prerequisites for start-up....................................................................................................................... 58
Start-up ................................................................................................................................................. 58
Programme sequence and signal waveform on the Robacta Reamer Alu Edition and Robacta Reamer
Alu 3000upm.............................................................................................................................................. 59
Cleaning program sequence................................................................................................................. 59
Signal waveform ................................................................................................................................... 62
Robacta Reamer Twin programme sequence and signal waveform ......................................................... 63
Cleaning program sequence................................................................................................................. 63
Signal waveform ................................................................................................................................... 67
Care, maintenance and disposal 69
Safety......................................................................................................................................................... 71
Safety.................................................................................................................................................... 71
Ensuring that the cleaning device is depressurised.............................................................................. 72
Care, maintenance and disposal ............................................................................................................... 73
General ................................................................................................................................................. 73
Before each start-up ............................................................................................................................. 73
Daily ...................................................................................................................................................... 73
Weekly .................................................................................................................................................. 73
Every 6 months ..................................................................................................................................... 73

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If necessary........................................................................................................................................... 73
Disposal ................................................................................................................................................ 73
Troubleshooting 75
Safety......................................................................................................................................................... 77
Safety.................................................................................................................................................... 77
Ensuring that the cleaning device is depressurised.............................................................................. 78
Troubleshooting ......................................................................................................................................... 79
Errors in program sequence ................................................................................................................. 79
Technical data 81
Technical data............................................................................................................................................ 83
Robacta Reamer Alu Edition and Robacta Reamer Alu 3000upm ....................................................... 83
Robacta Reamer Twin .......................................................................................................................... 83
Appendix 85
Spare parts list: Robacta Reamer Alu Edition............................................................................................ 86
Spare parts list: Robacta Reamer Alu 3000upm........................................................................................ 87
Spare parts list: Robacta Reamer Twin ..................................................................................................... 88
Spare parts list: Robacta Reamer Twin ..................................................................................................... 89
Circuit diagrams: Robacta Reamer Alu Edition / Robacta Reamer Alu 3000upm ..................................... 90
Circuit diagrams: Robacta Reamer Twin ................................................................................................... 91
Robacta Reamer Twin pneumatic diagram................................................................................................ 92
Declarations of Conformity......................................................................................................................... 93

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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 manufactur-
er must also be observed.
Keep your body, especially your hands, face, hair, clothing and all tools away from moving
parts, such as:
- rotating cleaning cutter / rotating cleaning brushes
- lifting device moving up/down
- extending/retracting gas nozzle clamping device
- wire cutter
Do not touch cleaning cutter / cleaning brush immediately after use - risk of burns. Observe
the special safety rules in the operating instructions for handling the cleaning cutter / clean-
ing brush.
Protect hands, face and eyes against flying parts (shavings, etc.) and compressed air/part-
ing agent mixture escaping from the parting-agent injection nozzles.

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Covers may only be opened/removed for the duration of any maintenance, installation or
repair work.
During operation
- Ensure that all covers are closed and fitted properly
- Keep all covers closed
Protecting your-
self and others
When welding, you expose yourself to numerous dangers. In addition to these operating
instructions, the safety rules of the manufacturer of the entire welding system must also be
observed.
Keep all persons, especially children, out of the working area while any devices are in op-
eration or welding is in progress. If, however, there are people in the vicinity,
- make them aware of all the dangers and health risks (crushing from mechanically-
powered parts, injury from cleaning cutter / cleaning brush, flying shavings and similar
matter, escaping compressed air/parting agent mixture, flying sparks, dazzling by arc,
inhaling of harmful welding fumes, noise, possible danger from mains or welding cur-
rent, etc),
- provide suitable protective equipment or
- erect suitable safety screens/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 mains.
EMC device classification as per the rating plate or technical data.
EMC measures In certain cases, even though a device complies with the standard limit values for 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 operator is obliged to take appropriate action to rectify the situ-
ation.
Check for possible problems, and check and evaluate neighbouring devices' resistance 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, addition-
al 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

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EMF measures Electromagnetic fields may pose as yet unknown risks to health:
- effects on the health of others in the vicinity, e.g. wearers of pacemakers and hearing
aids
- wearers of pacemakers must seek advice from their doctor before approaching the de-
vice or any welding that is in progress
- for safety reasons, keep distances between the welding cables and the welder's head/
torso as large as possible
- do not carry welding cables and hosepacks over the shoulders or wind them around
any part of the body
Safety measures
at the installation
location and dur-
ing 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 ac-
cident prevention regulations. This applies especially to guidelines regarding the risks aris-
ing during transport.
After transporting the device, it must be visually inspected for damage before commission-
ing. Any damage must be repaired by trained service technicians before commissioning
the device.
Safety measures
in normal opera-
tion
Only operate the device if all safety devices are fully functional. If the safety devices are
not fully functional, there is a risk of
- injury or death to the operator or a third party,
- damage to the device and other material assets belonging to the operator,
- inefficient operation of the device.
Any safety devices that are not functioning properly must be repaired before switching on
the device.
Never bypass or disable safety devices.
Before switching on the device, ensure that no one is likely to be endangered.
Check the device at least once a week for obvious damage and proper functioning of safety
devices.
- Only use suitable original parting agent from the manufacturer.
- Observe the information on the parting agent safety data sheet when handling 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 accepts no
liability. In addition, no warranty claims will be entertained.
- Used parting agent must be disposed of properly in accordance with the relevant na-
tional and international regulations.

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EN
Commissioning,
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 is performed 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 standards and di-
rectives.
Further details on safety inspection and calibration can be obtained from your service cen-
tre. They will provide you on request with any documents you may require.
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
either be returned to your dealer or given to one of the approved collection and recycling
facilities in your area. Ignoring this European Directive may have potentially adverse af-
fects on the environment and your health!
Safety symbols Devices with the CE mark satisfy the essential requirements of the applicable directives
(e.g. low-voltage and electromagnetic compatibility directives, machinery directive).
Devices with the CSA test mark satisfy the requirements of the relevant standards in Can-
ada 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 ba-
sis 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 instructions, we will
be most grateful for your comments.

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General

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EN
General
Principle Robacta Reamer devices are welding torch cleaning devices that are used for automatic
cleaning of MIG/MAG welding torches. These devices can be relied upon to clean the in-
terior and front of gas nozzles on torches of many different shapes, thereby significantly
extending the service life of these wearing parts. With the Robacta Reamer Twin, an even
application of parting agent prevents re-accumulation of dirt.
Device concept A lifting cylinder for the lifting device, as well as all pneumatic components, form part of the
robust steel housing.
On the outside are the cleaning motor and the clamping device for the gas nozzle on the
welding torch.
The Robacta Reamer Twin is fitted with a wire cutter and parting agent nebuliser as stand-
ard.
During the cleaning process, both wire electrodes are shortened to a defined length for the
next welding process.
The wire cutter is an optional extra with the Robacta Reamer Alu Edition and Robacta
Reamer Alu 3000upm.
For professional installation, a stable fitting base is available for all devices.
Application areas Devices from the Robacta Reamer series are intended exclusively for use in robot and oth-
er automated applications.
The devices were designed for use in the automobile and component supply industry,
equipment construction, chemical plant construction and machine and rail vehicle manu-
facturing.
The Robacta Reamer Twin can be used for processing steel and aluminium materials.
The Robacta Reamer Alu Edition and the Robacta Reamer Alu 3000upm are intended ex-
clusively for aluminium applications.
Illustration of the
various device
types
Robacta Reamer Alu Edition, Robacta Reamer Alu 3000upm, Robacta Reamer Twin

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Scope of supply and options
General The cleaning devices can be used in conjunction with various options. This makes it pos-
sible to optimise various procedures in the welding process, as necessitated by the par-
ticular field of application.
Robacta Reamer
Alu Edition scope
of supply NOTE!
The cleaning brush and adapter for the
cleaning brush are not included in the
scope of supply.
(1) Robacta Reamer Alu Edition clea-
ning device
(2) Spatter tray retainer
(3) Spatter tray
(4) Tightening key for cleaning motor
(5) Compressed air relief valve
not shown:
(6) Harting Han6P connecting plug (X1) without cable
(7) Operating instructions
(8) Fixings for assembling the cleaning device:
- 4 screws
- 4 washers
- 4 lock washers
- 4 nuts
Robacta Reamer
Alu Edition op-
tions
- Fitting base
- Wire cutter
(1)
(2)
(3)
(4)
(5)

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EN
Robacta Reamer
Alu 3000upm
scope of supply NOTE!
The cleaning cutter and adapter for the
cleaning cutter are not included in the
scope of supply.
(1) Robacta Reamer Alu 3000upm cle-
aning device
(2) Spatter tray retainer
(3) Spatter tray
(4) Tightening key for cleaning motor
(5) Compressed air relief valve
not shown:
(6) Harting Han6P connecting plug (X1) without cable
(7) Operating instructions
(8) Fixings for assembling the cleaning device:
- 4 screws
- 4 washers
- 4 lock washers
- 4 nuts
Robacta Reamer
Alu 3000upm op-
tions
- Fitting base
- Wire cutter
Robacta Reamer
Twin scope of
supply NOTE!
The "Robacta Reamer" parting agent
(item number 42,0411,8042) and the cle-
aning cutter are not part of the scope of
supply.
(1) Robacta Reamer Twin cleaning de-
vice with wire cutter and parting
agent nebuliser
(2) Spatter tray retainer
(3) Spatter tray
(4) Tightening key for cleaning motor
(5) Compressed air relief valve
not shown:
(6) Harting Han6P connecting plug (X1) without cable
(7) Operating instructions
(1)
(2)
(3)
(4)
(5)
((11))
((22))
((33))
((44))
((55))

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(8) Filling funnel for parting agent
(9) Fixings for assembling the cleaning device:
- 4 screws
- 4 washers
- 4 lock washers
- 4 nuts
Robacta Reamer
Twin options
- Fitting base
- Cleaning cutter adjustment aid
- Parting agent - spray unit