FRO­NIUS Robacta Reamer V Comfort User manual

Operating
Instructions
Robacta Reamer V Comfort
42,0426,0385,EA 005-02082022
EN-US Operating instructions

Table of contents
Safety Instructions 5
General 5
Intended Use 5
Environmental Conditions 5
Obligations of the Operating Company 6
Obligations of Personnel 6
Particular Hazard Areas 6
Personal Protection and Protection of Others 7
EMC Device Classifications 7
EMC Measures 7
EMF measures 8
Safety Measures at the Setup Location and during Transport 8
Safety Measures in Normal Operation 8
Maintenance and repair 9
Safety Inspection 9
Disposal 9
Safety Symbols 10
Copyright 10
General 11
General 13
Device concept 13
Functionality of the cleaning device 13
Applications 13
Warning notices on the cleaning device 13
Transport 16
Transport equipment 16
Transport Instructions on the packaging 16
Scope of Supply and Options 17
Scope of supply 17
Available options 17
Operating controls, connections and mechanical components 19
Safety 21
Safety 21
Operating controls, connections and mechanical components 22
Operating controls, connections, and mechanical components 22
Harting Han12P (X1) connecting plug configuration for the robot control 26
General 26
Harting Han12P (X1) connecting plug configuration 26
Installation and Startup 27
Safety 29
Safety 29
Ensuring that the cleaning device is depressurized 30
Before installation 31
Intended Use 31
Operating personnel, maintenance personnel 31
Setup regulations 31
Specifications for the Compressed Air Supply 31
Measures to ensure safe operation of the device when operating personnel are untrained 32
Screwing the Cleaning Device to the Solid Surface 33
Screwing the cleaning device and work stand to the surface 33
Screw the cleaning device to the surface 34
Welding Torch Cleaning Position 36
Welding torch cleaning position 36
Adjusting the Gas Nozzle Clamping Device 37
Adjusting the gas nozzle clamping device 37
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EN-US

Fitting the Cleaning Cutter 38
Fitting the cleaning cutter 38
Adjusting the Position of the Cleaning Motor 39
Adjusting the position of the cleaning motor 39
Configuring the Injection Device 40
Configuring the injection device 40
Install electrically controlled wire cutter (option) 41
Functionality of the electrically controlled wire cutter 41
Maximum wire diameter 41
Installing the electrically controlled wire cutter 41
Setting up the Compressed Air Supply 43
Setting up the cleaning device compressed air supply, compressed air relief valve function 43
Starting Up the Parting Agent Atomizer 44
Filling the parting agent container (1 liter) and connecting it to the cleaning device 44
Connecting the parting agent container (10 liter) to the cleaning device 45
Manually Checking the Cleaning Device Functions 48
Safety 48
Manually checking the cleaning device functions 48
Start up the Cleaning Device 51
Requirements for starting up 51
Start-up Operation 51
Cleaning Program Sequence 52
Safety 52
Cleaning program sequence 53
Cleaning signal sequence 57
Defined signal input 57
Signal outputs defined in time 57
Signal input of the optional wire cutter 57
Signal input that cannot be defined in time 57
Signal inputs that cannot be defined in time 57
Service, maintenance and disposal 59
Safety 61
Safety 61
Ensuring that the cleaning device is depressurized 62
Service, maintenance and disposal 63
General 63
Before every start-up 63
Daily 63
Weekly 63
Every 6 months 63
Whenever required 63
Empty parting agent collecting container 64
Disposal 65
Troubleshooting 67
Safety 69
Safety 69
Ensuring that the cleaning device is depressurized 70
Troubleshooting 71
Errors in the Program Sequence 71
Technical data 73
Technical data 75
Robacta Reamer V Comfort 75
Appendix 77
Declaration of conformity 79
4

Safety Instructions
General The device has been manufactured using state-of-the-art technology and ac-
cording to recognized 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
instructions 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 reg-
ulations 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 sec-
tion 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 accordance with the intended purpose." The manufacturer is not respons-
ible 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 accordance with the intended purpose. The manufacturer is not respons-
ible for any damage resulting from improper use.
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EN-US

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)
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
Company
The operating company must only allow persons to work with the device if they
-Are familiar with the basic occupational safety and accident prevention regu-
lations and are trained in handling the device
-Have read and understood these Operating Instructions, especially the sec-
tion "Safety 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 be-
fore beginning 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 Haz-
ard 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 ac-
cordance with "Performance Level d" of ISO 13849-1.
In addition to these Operating Instructions, the safety rules of the robot manu-
facturer 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 Op-
erating Instructions.
6

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 re-
pair work.
During operation:
-ensure that all covers are closed, and all side parts have been mounted prop-
erly
-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 Operating 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, injury hazard from the cleaning cutter, flying chips or similar, dis-
charged 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
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 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
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 operating company is obliged to take appropriate ac-
tion to rectify the situation.
Check and evaluate possible problems and the interference immunity of equip-
ment 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
7
EN-US

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
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 immediate vicinity of the device and the welding process
-Keep distances between welding power-leads and the head/torso of the
welder as great as possible for safety reasons
-Do not carry welding power-leads and hosepacks over your shoulder or wrap
them around your body or body parts
Safety Measures
at the Setup
Location 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 acci-
dent prevention regulations are observed when transporting the device, espe-
cially guidelines concerning 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 re-
paired by trained service technicians before commissioning the device.
Safety Measures
in Normal Oper-
ation
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.
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The device must be examined at least once a week for externally detectable dam-
age 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 internation-
al regulations.
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 be per-
formed 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 service center. The service center will provide the necessary docu-
ments upon request.
Disposal To comply with European directives and national law, waste electrical and elec-
tronic equipment must be collected separately and sent for environmentally-
friendly recycling. Used devices must be returned to a distributor or an approved
collection and recycling facility in your area. Proper disposal of used devices pro-
motes the sustainable recycling of material resources. Ignoring this may have po-
tentially adverse effects on the environment and your health.
Packaging materials
Materials collected separately. Check the regulations in your area. Reduce the
volume of cardboard.
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EN-US

Safety Symbols Devices with CE marking satisfy the essential requirements of the relevant dir-
ectives (e.g. the low-voltage, electromagnetic compatibility, and machinery dir-
ectives).
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 were accurate at the time of printing. Fronius reserves 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 suggestions for improvement, or can point out any mistakes that you
have found in the Operating Instructions, we will be most grateful for your com-
ments.
10

General
11

12

General
Device concept The cleaning device is intended to
automatically 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 increases the service
life of wearing parts. At the same time,
the even application of parting agent
prevents the build-up of new dirt.
Functionality of
the cleaning
device
-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 in-
to 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
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.
13
EN-US

Art.No.
Chargen No.
0.1A24V I1U1
pmax 6bar (87PSI)
Robacta Reamer V Comfort
42,0411,0333
Warning notices on the cleaning device
PLEASE NOTE! Risk of serious injury from mechanically moving
parts.
Keep the device de-energized and depressurized during main-
tenance and servicing.
Do not use the functions described here until you have fully
read and understood the following documents:
-These Operating Instructions
-All system component Operating Instructions, especially
the safety rules
For indoor use only
Dispose of old devices in accordance with safety rules and not in
normal domestic waste.
14

Wear eye protection
Warning before the device switches on automatically
15
EN-US

Transport
Transport equip-
ment
Transport the device using the following transport equipment:
-On a pallet using a counterbalanced lift truck
-On a pallet using a lift truck
-Manually
WARNING!
Danger from devices and objects falling.
This can result in severe personal injury and damage to property.
▶When transporting the device by counterbalanced lift truck or lift truck, se-
cure the device to prevent it from falling.
▶Do not turn, brake, or accelerate in a sudden, jerking manner.
Transport In-
structions on the
packaging
CAUTION!
Danger due to improper transport.
This can result in damage to property.
▶Follow the transport instructions on the device packaging.
16

Scope of Supply and Options
Scope of supply
(1)
(2)
(3)
(4)
(5)
(1) Robacta Reamer V Comfort cleaning device
(2) Compressed air relief valve
(3) Leather seal for the parting agent injection device
(4) Wrench for cleaning motor
(5) Collecting container together with suitable holder
Included in scope of supply, but not shown:
-Harting Han12P (X1) connecting plug without cable
-Operating Instructions
-Mounting material to assemble the cleaning device:
-4 screws
-4 washers
-4 lock washers
-4 nuts
The "Robacta Reamer" parting agent (item number 42,0411,8042) and the clean-
ing cutter are not included in the scope of supply.
Available op-
tions
The following options are available for the cleaning device:
-Work stand
-Wire cutter
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EN-US

18

Operating controls, connections
and mechanical components
19

20