FRO­NIUS Robacta Reamer V 70 Han12P User manual

Fronius prints on elemental chlorine free paper (ECF) sourced from certified sustainable forests (FSC).
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Robacta Reamer V 70 Han12P
EN
Operating instructions
Welding torch cleaning
42,0426,0220,EN 008-21092020

Contents
Safety rules 5
General 5
Proper use 5
Environmental conditions 5
Obligations of the operator 6
Obligations of personnel 6
Specific hazards 6
Protecting yourself and others 7
EMC Device Classifications 7
EMC measures 7
EMF measures 8
Safety measures at the installation location and during transport 8
Safety measures in normal operation 8
Commissioning, maintenance and repair 9
Safety inspection 9
Disposal 9
Safety symbols 9
Copyright 9
General 11
General 13
Principle 13
Device concept 13
Application areas 13
Warning notices on the cleaning device 13
Transport 16
Transport devices 16
Transport notices on the packaging 16
Scope of supply and options 17
Scope of supply 17
Available options 17
Controls, connections and mechanical components 19
Safety 21
Safety 21
Controls, connections and mechanical components 22
Control elements, connections and mechanical components 22
Harting Han12P connecting plug (X1) pin assignment for robot control 24
General 24
Harting Han12P connecting plug (X1) pin assignment 24
Installation and commissioning 25
Safety 27
Safety 27
Ensuring that the cleaning device is depressurised 28
Before commissioning 29
Proper use 29
Operators, maintenance personnel 29
Setup regulations 29
Compressed air supply specifications 29
Measures for the safe operation of the device with untrained personnel 30
Screwing the cleaning device to the underlying surface 31
Screwing the cleaning device and installation stand to the underlying surface 31
Screwing the cleaning device to the underlying surface 31
Torch cleaning position 33
Welding torch cleaning position 33
Adjust gas nozzle clamping device 34
Adjusting the gas nozzle clamping device 34
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Fitting the cleaning cutter 35
Fitting the cleaning cutter 35
Adjusting the position of the cleaning motor 36
Adjusting the position of the cleaning motor 36
Configuring the spray device 37
Configuring the spray device 37
Installing the electrically controlled wire cutter (optional) 38
How the electrically-controlled wire cutter works 38
Maximum wire diameter 38
Installing the electrically controlled wire cutter 38
To establish the compressed air supply: 40
Establishing the compressed air supply for the cleaning device, function of the compressed air
relief valve
40
Starting up the parting agent nebuliser 41
Filling the parting agent container (1 litre) and connecting it to the cleaning device 41
Connecting the parting agent container (10 litres) to the cleaning device 42
Adjusting the parting agent nebuliser spray amount 43
Manually checking the cleaning device functions 44
Safety 44
Manually checking the cleaning device functions 44
Starting up the cleaning device 46
Prerequisites for start-up 46
Start-up 46
Cleaning programme 47
Safety 47
Cleaning program sequence 48
Signal waveform for cleaning 52
Signal inputs 52
Signal outputs 52
Signal waveform optional wire cutter (input) 52
Care, maintenance and disposal 53
Safety 55
Safety 55
Ensuring that the cleaning device is depressurised 56
Care, maintenance and disposal 57
General 57
Before each start-up 57
Daily 57
Weekly 57
Every 6 months 57
As necessary 57
Disposal 58
Troubleshooting 59
Safety 61
Safety 61
Ensuring that the cleaning device is depressurised 62
Troubleshooting 63
Errors in program sequence 63
Technical data 65
Technical data 67
Robacta Reamer V 70 Han12P 67
Appendix 69
Robacta Reamer V 70 Han12P Circuit Diagram 70
Robacta Reamer V 70 Han12P pneumatic diagram 71
Declaration of conformity 72
4

Safety rules
General The device is manufactured using state-of-the-art technology and according to recog-
nised 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 com-
pany,
- 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
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 applic-
able 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
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)
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Relative humidity:
- up to 50 % at 40 °C (104 °F)
- up to 90 % at 20 °C (68 °F)
Keep ambient air free from dust, acids, corrosive gases and substances, etc.
Can be used at altitudes of up to 2000 m (6500 ft)
Obligations of the
operator
The operator must only allow persons to work with the device who:
- are familiar with the fundamental instructions regarding safety at work and accident
prevention and have been instructed in how to use the device
- have read and understood these operating instructions, especially the section
"safety rules", and have confirmed as much with their signatures
- are trained to produce the required results.
Checks must be carried out at regular intervals to ensure that operators are working in a
safety-conscious manner.
Obligations of
personnel
Before using the device, all persons instructed to do so undertake:
- to observe the basic instructions regarding safety at work and accident prevention
- to read these operating instructions, especially the "Safety rules" section and sign to
confirm that they have understood them and will follow them.
Before leaving the workplace, ensure that people or property cannot come to any harm
in your absence.
Specific hazards Stay out of the working area of the robot.
The device must be incorporated into a higher-level safety system within a secured area.
If this area has to be accessed when setup and maintenance work is carried out, make
sure that
- the entire system is switched off for the duration of the work in this area
- and that it is prevented from starting up accidentally, e.g. as the result of a control
fault.
If untrained operators have access to the device, its compressed air supply must be dis-
connected for the duration of work in accordance with "Performance Level d" of the ISO
13849-1 standard.
In addition to these Operating Instructions, the safety rules issued by the robot manufac-
turer must also be observed.
Keep your body, especially your hands, face, hair, clothing and all tools away from mov-
ing 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, installation or
repair work.
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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 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
operation 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, flying shavings and similar matter, escap-
ing 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 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
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 rectify the
situation.
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, addi-
tional 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 hear-
ing aids
- wearers of pacemakers must seek advice from their doctor before approaching the
device 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
accident prevention regulations. This applies especially to guidelines regarding the risks
arising during transport.
After transporting the device, it must be visually inspected for damage before commis-
sioning. Any damage must be repaired by trained service technicians before commis-
sioning 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 part-
ing 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
national and international regulations.
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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 manu-
facturer'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
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 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 poten-
tially adverse affects 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
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 purchaser. If you have any sugges-
tions for improvement, or can point out any mistakes that you have found in the instruc-
tions, we will be most grateful for your comments.
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