Fronius Robacta Reamer Alu 3000upm Operating Instructions Manual Download Page 51

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Installing mechanically-controlled wire cutter on

the Robacta Reamer Alu Edition and Robacta

Reamer Alu 3000upm (optional)

Installing the
mechanically-
controlled wire
cutter

NOTE!

Installation of the wire cutter is shown for the Robacta Reamer Alu Edition.

The wire cutter is installed in exactly the same way on the Robacta Reamer Alu
3000upm.

(1)

(2)

Position the mounting bracket (1)
on the wire cutter (2) as shown and
screw into place as described - us-
ing the fixings supplied

(3)

(4)

(3)

Undo 3 screws and washers (3)

Remove cleaning device housing
cover (4)

Summary of Contents for Robacta Reamer Alu 3000upm

Page 1: ...Operating Instructions Robacta Reamer Alu Edition Robacta Reamer Alu 3000upm Robacta Reamer Twin 42 0426 0146 EN 018 01062022 EN Operating Instructions...

Page 2: ......

Page 3: ...00upm scope of supply 18 Robacta Reamer Alu 3000upm options 18 Robacta Reamer Twin scope of supply 18 Robacta Reamer Twin options 19 Warning notices on the device 20 Warning notices on the cleaning de...

Page 4: ...e 48 Adjusting the lifting device 48 Starting up the Robacta Reamer Twin parting agent nebuliser 49 Starting up the parting agent nebuliser 49 Correct adjustment of the parting agent spray nozzles on...

Page 5: ...in program sequence 78 Technical data 81 Technical data 83 Robacta Reamer Alu Edition and Robacta Reamer Alu 3000upm 83 Robacta Reamer Twin 83 Appendix 85 Circuit diagram Robacta Reamer Robacta Reamer...

Page 6: ...ice 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 o...

Page 7: ...C to 40 C 32 F to 104 F during transport and storage 25 C to 55 C 13 F to 131 F Relative humidity up to 50 at 40 C 104 F up to 90 at 20 C 68 F Keep ambient air free from dust acids corrosive gases an...

Page 8: ...brush Protect hands face and eyes against flying parts shavings etc and compressed air parting agent mixture escaping from the parting agent injection nozzles Covers may only be opened removed for th...

Page 9: ...ssible 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 in...

Page 10: ...turer ac cepts no liability In addition no warranty claims will be entertained Used parting agent must be disposed of properly in accordance with the rel evant national and international regulations C...

Page 11: ...ls Separate collection according to material Check your local authority regulations Crush containers to reduce size Safety symbols Devices with the CE mark satisfy the essential requirements of the ap...

Page 12: ...12...

Page 13: ...General 13...

Page 14: ...14...

Page 15: ...is fitted with a wire cutter and parting agent nebuliser as standard During the cleaning process both wire electrodes are shortened to a defined length for the next welding process The wire cutter is...

Page 16: ...Illustration of the various device types Robacta Reamer Alu Edition Robacta Reamer Alu 3000upm Robacta Reamer Twin 16...

Page 17: ...5 NOTE The cleaning brush and adapter for the cleaning brush are not included in the scope of supply 1 Robacta Reamer Alu Edition cleaning device 2 Spatter tray retainer 3 Spatter tray 4 Tightening ke...

Page 18: ...ngs for assembling the cleaning device 4 screws 4 washers 4 lock washers 4 nuts Robacta Reamer Alu 3000upm options Fitting base Wire cutter Robacta Reamer Twin scope of supply 1 1 2 2 3 3 4 4 5 5 NOTE...

Page 19: ...unnel 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 spra...

Page 20: ...n as an example On the Robacta Reamer Alu Edition and Robacta Reamer Alu 3000upm the warning notices are in the same location Type Art No Chargen No U1 I1 Wels Austria p max 24 V 0 25 A 6 bar 87PSI Wa...

Page 21: ...ghly read and understood the following documents these operating instructions all the operating instructions for the system components es pecially the safety rules For indoor use only Wear eye protect...

Page 22: ...falling This can result in serious injury and damage to property Secure the device to prevent it from falling over when transporting on a fork lift truck or lift truck Avoid sudden changes in directio...

Page 23: ...Controls connections and mechan ical components 23...

Page 24: ...24...

Page 25: ...he equipment incorrectly can cause serious injury and damage The functions described must only be used by trained and qualified personnel Do not use the functions described here until you have thoroug...

Page 26: ...pply CAUTION Risk of damage to Harting Han6P connection X1 supply due to overcurrent Secure supply against overcurrent with a 500 mA slow blow fuse 3 Cleaning screw for manually checking the following...

Page 27: ...on X1 supply due to overcurrent Secure supply against overcurrent with a 500 mA slow blow fuse 4 Cleaning button for manually checking the following functions Cleaning motor ON OFF Compressed air and...

Page 28: ...9 9 1 11 1 9 Wire cutter valve lever activates the wire cutter 10 Wire cutter 11 Parting agent spray nozzles sprays the parting agent into the interior and onto the front of the gas nozzles using comp...

Page 29: ...cting plug X1 for connecting the cleaning device to the robot control is included in the scope of supply The cable harness must be adapted to the connection technology on the robot control Harting Han...

Page 30: ...30...

Page 31: ...Installation and commissioning 31...

Page 32: ...32...

Page 33: ...erious injury and damage In addition to these operating instructions the safety rules issued by the manu facturers of the robot and welding systems must also be observed For your per sonal safety ensu...

Page 34: ...Proceed as follows 1 Take protective measures The cleaning cutter cleaning brush lifting device gas nozzle clamping device wire cutter and parting agent injection nozzles could start up Therefore kee...

Page 35: ...ised If the wire cutter responds to the movement of the valve lever the cleaning device and therefore also the wire cutter is still connected to a compressed air supply If this is the case you must di...

Page 36: ...t only be serviced by 1 person at a time It is also necessary to ensure that no one else is within the working area of the device when the device is being serviced Setup regula tions The cleaning devi...

Page 37: ...to the device its compressed air supply must be disconnected for the duration of work in accordance with Performance Level d of the ISO 13849 1 standard To ensure that the compressed air supply is in...

Page 38: ...for selecting the right type of screws or bolts Always secure the cleaning device to the installation stand 1 Place the optionally available in stallation stand on a level firm and vibration free surf...

Page 39: ...plied with the cleaning device for fastening If the underlying surface thickness is greater than 5 mm 0 197 in do not use the fixings supplied for fastening In this situation the installer is re spons...

Page 40: ...Attach the spatter tray retainer as shown 3 40...

Page 41: ...n Welding torch cleaning position Robacta Ream er Alu 3000upm 2 2 8 8 0 0 m m m m 1 1 1 1 0 0 2 2 i i n n Welding torch cleaning position Robacta Ream er Twin 1 1 0 0 m m m m 0 0 3 3 9 9 i i n n NOTE...

Page 42: ...ot The gas nozzle must only be clamped onto the cylindrical surface 1 3 2 4 1 Loosen Allen screws on the guide bolts 1 and 2 2 Move the welding torch to the cleaning position centrally with respect to...

Page 43: ...hes If other manufacturers products are used trouble free operation of the device cannot be guaranteed The manufacturer accepts no liability for damage result ing from the use of other manufacturers c...

Page 44: ...If other manufacturers products are used trouble free operation of the device cannot be guaranteed The manufacturer accepts no liability for damage result ing from the use of other manufacturers cont...

Page 45: ...age to property and malfunctions Only use the device manufacturer s contact tips gas nozzles and cleaning cutters No liability is accepted for damage caused by the use of contact tips gas nozzles or c...

Page 46: ...into its highest position and hold in place 6 Manually push cleaning motor 4 and cleaning brush to the cleaning posi tion see diagram 5 correct adjustment see diagram 6 incorrect adjustment 7 Fix clea...

Page 47: ...g cutter must not touch any welding torch components 8 Fix cleaning motor 4 in this position in the lifting device 3 tighten screw 2 on the lifting device 9 Carry out function test on unfitted gas noz...

Page 48: ...he protective cover 1 2 Ensure that the lifting device is in its lowest lift position 3 Loosen the screw 2 on the lifting device 4 Move the welding torch to the cleaning position including fitted adju...

Page 49: ...ion the parting agent is sprayed through the blow out line directly into the welding torch interior 1 Open the sealing plug 1 2 Fill with Robacta Reamer parting agent using the filling funnel 2 3 Clos...

Page 50: ...Correct adjust ment of the part ing agent spray nozzles on the Robacta Reamer Twin NOTE Both spray jets of parting agent must meet in front of the gas nozzle so that they fully enter the nozzle 50...

Page 51: ...allation of the wire cutter is shown for the Robacta Reamer Alu Edition The wire cutter is installed in exactly the same way on the Robacta Reamer Alu 3000upm 1 2 1 2 1 2 1 Position the mounting brack...

Page 52: ...5 4 Remove screw 5 6 6 5 Undo screws and washers 6 Keep the screws and washers for future use 6 6 6 Screw the wire cutter to the clean ing device using the previously re moved screws and washers 6 52...

Page 53: ...7 7 Cut through the compressed air hose 7 in the interior of the clean ing device housing in the position shown 9 8 8 Detach compressed air connection 8 from compressed air connec tion 9 9 53 EN...

Page 54: ...sing as shown 11 Insert the compressed air hose 10 firmly into the compressed air distributor 11 12 Insert the two loose ends 12 and 13 of the previously cut com pressed air hose firmly into the compr...

Page 55: ...nstallation of the wire cutter is shown for the Robacta Reamer Alu Edition The wire cutter is installed in exactly the same way on the Robacta Reamer Alu 3000upm 1 2 1 2 1 2 1 Position the mounting br...

Page 56: ...ice using the previously re moved screws and washers 5 as shown 6 Fit the cleaning device housing cover 4 to the cleaning device in its original position NOTE The wire cutter must be supplied with com...

Page 57: ...ed wire cut ter works NOTE If you change over to a new welding torch the mechanically controlled wire cut ter must be reset 1 If a torch body pushes the valve lever 1 to the side by more than 15 with...

Page 58: ...mpressed air con nection on the cleaning device 3 Connect the compressed air supply line to the compressed air relief valve The compressed air supply to the cleaning device can be broken and re estab...

Page 59: ...Edition and Robacta Reamer Alu 3000upm gas nozzle clamping device is adjusted Cleaning cutter cleaning brush has been fitted Lifting device has been adjusted On the Robacta Reamer Twin Parting agent...

Page 60: ...NOTE Not coating the interior of the welding torch may result in permanent soiling of the torch when welding begins Always wet the interior of the welding torch with the manufacturer s parting agent b...

Page 61: ...or High Query Low Gas nozzle clamped Query High Gas nozzle free Stop Start from position B cleaning position Enter gas nozzle clamping device Speed 10 cm s 236 22 ipm Pos B Set Blow compressed air th...

Page 62: ...ery High Gas nozzle free Stop Start from position A approx 50 mm 1 97 in above centre of cleaning device Speed 10 cm s 236 22 ipm Pos A End Signal waveform LO HI LO HI 1 2 3 4 No Meaning 1 Input Begin...

Page 63: ...ch may result in permanent soiling of the torch when welding begins Always wet the interior of the welding torch with the manufacturer s parting agent before starting automatic operation Start Start f...

Page 64: ...Gas nozzle clamped Query High Gas nozzle free Reset Input Begin cleaning Query output Gas nozzle free output sig nal Low or High Query High Gas nozzle free Query Low Gas nozzle clamped Stop Start from...

Page 65: ...ide of the welding torch for approx 3 sec Cleaning motor moves to the starting position Gas nozzle clamping device opens for approx 0 5 sec to allow the cleaning motor to move to the first side of the...

Page 66: ...eaning device Speed 10 cm s 236 22 ipm Pos C End Signal waveform LO HI LO HI 1 2 3 4 5 No Meaning 1 Input Begin cleaning 2 Output Gas nozzle released 3 Gas nozzle released Cleaning page 1 4 Gas nozzle...

Page 67: ...Care maintenance and disposal 67...

Page 68: ...68...

Page 69: ...e serious injury and damage In addition to these operating instructions the safety rules issued by the manu facturers of the robot and welding systems must also be observed For your per sonal safety e...

Page 70: ...g that the cleaning device is depres surised Attempt to briefly activate the cleaning device without any compressed air sup ply to check whether the cleaning device is depressurised Proceed as follows...

Page 71: ...ve lever the cleaning device including the wire cutter is depressurised If the wire cutter responds to the movement of the valve lever the cleaning device and therefore also the wire cutter is still c...

Page 72: ...he cleaning device 1 Remove parting agent deposits and dirt from device Weekly NOTE Only use solvent free cleaning products on the parting agent container Only Robacta Reamer Twin Check parting agent...

Page 73: ...Troubleshooting 73...

Page 74: ...74...

Page 75: ...s injury and damage In addition to these operating instructions the safety rules issued by the manu facturers of the robot and welding systems must also be observed For your per sonal safety ensure th...

Page 76: ...g that the cleaning device is depres surised Attempt to briefly activate the cleaning device without any compressed air sup ply to check whether the cleaning device is depressurised Proceed as follows...

Page 77: ...ve lever the cleaning device including the wire cutter is depressurised If the wire cutter responds to the movement of the valve lever the cleaning device and therefore also the wire cutter is still c...

Page 78: ...just gas nozzle clamping device not on Robacta Reamer Twin Cleaning cutter cleaning brush not suited to welding torch shape Fit the correct cleaning cutter fit correct cleaning brush Cleaning cutter c...

Page 79: ...ir relief valve closed Open compressed air relief valve No signal from robot Check connection to robot control Mechanical fault on cleaning motor Contact After Sales Service replace cleaning motor Cau...

Page 80: ...80...

Page 81: ...Technical data 81...

Page 82: ...82...

Page 83: ...1 Mark of conformity CE CSA Max noise emission LWA 82 dB A Dimensions l x w x h 170 x 165 x 280 mm 6 69 x 6 50 x 11 02 in Weight without optional wire cutter 9 kg 19 84 lb Robacta Reamer Twin Supply v...

Page 84: ...Max noise emission LWA 82 dB A Dimensions l x w x h 325 x 220 x 350 mm 12 80 x 8 66 x 13 78 in Weight without parting agent and optional wire cut ter 17 kg 37 48 lb 84...

Page 85: ...Appendix 85...

Page 86: ...86...

Page 87: ...Circuit diagram Robacta Reamer Robacta Ream er Alu Edition Robacta Reamer Alu Edition 3000rpm 87 EN...

Page 88: ...le free motor left X2 1 2 3 4 5 6 7 8 9 10 BLUE BROWN BLACK 1S2 1 3 2 BLUE BROWN BLACK 2 3 1 3S1 2 1 K1 A2 A1 3 4 S1 1 2 2 1 1 2 4 3 2S2 2S1 motor right clamping device manual cleaning motor up motor...

Page 89: ...lap valve 3A2 pneumatic motor 3V2 signal interupter 2V1 solenoid valve 2A1 sliding unit 4V1 lever valve 3Z1 oiler 3A1 cylinder 32mm 1 3 1V3 1 2 1A1 2 1V2 1 3V1 1V1 5 4 2 3 5 1 4 2 3 5 3Z1 3X2 3A1 2A1...

Page 90: ...as nozzle cleaner which is explicitly referred to by this Declaration meet the following directives and standard s Directive 2014 30 EU Electromag compatibility Directive 2006 42 EC Machinery Directiv...

Page 91: ...hich is explicitly referred to by this Declaration meet the following directives and standard s Directive 2014 30 EU Electromag compatibility Directive 2006 42 EC Machinery Directive European Standard...

Page 92: ...Froniusstra e 1 4643 Pettenbach Austria contact fronius com www fronius com Under www fronius com contact you will find the adresses of all Fronius Sales Service Partners and locations spareparts fro...

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