Fronius Robacta Reamer V Twin Operating Instructions Manual Download Page 23

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Safety

Observe the following safety rules when using all functions described in the
"Controls, connections and mechanical components" section.

WARNING!

Danger from incorrect operation!

This can result in serious injury and damage to property.

▶

The functions described must only be used by trained and qualified person-
nel.

▶

Do not use the functions described here until you have fully read and under-
stood the following documents:
these Operating Instructions,
all the Operating Instructions for the system components, especially the
safety rules

Summary of Contents for Robacta Reamer V Twin

Page 1: ...Operating Instructions Robacta Reamer V Twin 42 0426 0142 EN 024 29082022 EN Operating instructions...

Page 2: ......

Page 3: ...ng 19 Controls connections and mechanical components 21 Safety 23 Safety 23 Robacta Reamer V Twin control elements connections and mechanical components 24 Control elements connections and mechanical...

Page 4: ...indicators on the sensor 47 Installation adapter borehole dimensions 47 Fitting the fill level control sensor 48 Calibrating the empty state 49 Calibrating the full state 49 Locking unlocking the fil...

Page 5: ...Troubleshooting 81 Errors in program sequence 81 Technical data 83 Technical data 85 Robacta Reamer V Twin 85 Appendix 87 Circuit diagram Robacta Reamer V Twin 89 Robacta Reamer V Twin pneumatic diagr...

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: ...4 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 and substances etc Can...

Page 8: ...on nozzle Covers may only be opened removed for the duration of any maintenance in stallation or repair work During operation Ensure that all covers are closed and fitted properly Keep all covers clos...

Page 9: ...ding installation EMF measures Electromagnetic fields may pose as yet unknown risks to health Effects on the health of persons in the vicinity e g those with pacemakers and hearing aids Individuals wi...

Page 10: ...nternational regulations Commissioning 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 sa...

Page 11: ...s Crush containers to reduce size Safety symbols Devices with the CE mark satisfy the essential requirements of the applicable directives e g low voltage and electromagnetic compatibility directives m...

Page 12: ...12...

Page 13: ...General 13...

Page 14: ...14...

Page 15: ...fixed in the middle of the cleaning motor The Robacta Reamer V Twin is fitted with a wire cutter as standard During the cleaning process the Robacta Reamer V Twin shortens both wire electrodes to a d...

Page 16: ...s 7 Fixings for assembling the cleaning device 4 screws 4 washers 4 lock washers 4 nuts Available op tions The following options are available for the cleaning device Installation stand Cleaning cutte...

Page 17: ...NING Risk of serious injury from mechanically powered parts compressed air parting agent mixture escaping from the part ing agent injection nozzle flying parts shavings etc Keep device free from curre...

Page 18: ...Wear eye protection Notice warning of automatic start up of the device 18...

Page 19: ...lling 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 direction...

Page 20: ...20...

Page 21: ...Controls connections and mechan ical components 21...

Page 22: ...22...

Page 23: ...ct operation This can result in serious injury and damage to property The functions described must only be used by trained and qualified person nel Do not use the functions described here until you ha...

Page 24: ...n thread identification G 3 Clamp gas nozzle Cleaning motor on screw For manually checking the gas nozzle clamping device and the cleaning motor gas nozzle clamping device extends retracts cleaning mo...

Page 25: ...h internal through hole for the parting agent injection nozzle 12 Gas nozzle clamping device Holds the gas nozzle in place during cleaning 13 Wire cutter 14 Side view 15 14 Compressed air and electric...

Page 26: ...7 Standard I O X1 connecting plug pin assign ment cable end view Input and output signals on the Robacta Reamer V Twin 1 Clamp gas nozzle Cleaning motor ON cleaning cutter turning input signal 24 V DC...

Page 27: ...Installation and commissioning 27...

Page 28: ...28...

Page 29: ...G Risk of machines starting automatically This can result in serious injury and damage to property In addition to these Operating Instructions also observe the safety rules is sued by the manufacturer...

Page 30: ...sed air sup ply to check whether the cleaning device is depressurised Proceed as follows 1 Take protective measures The cleaning cutter lifting device gas nozzle clamping device wire cutter and partin...

Page 31: ...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 devic...

Page 32: ...s 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 i...

Page 33: ...s 4 x 3 Position the cleaning device on the installation stand 4 Position the spatter tray on the cleaning device as shown 5 Securely screw the cleaning device and spatter tray to the installation sta...

Page 34: ...leaning device and spatter tray to the underlying surface foundation as shown us ing the fixings supplied For an underlying surface foundation thickness greater than 5 mm 0 197 in or an installation d...

Page 35: ...y 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 cleaning cutter...

Page 36: ...amage the coolant lines on the welding torch Ensure that the coolant lines on the gas nozzle cannot be damaged when the welding torch is moved into out of the gas nozzle clamping device NOTE The gas n...

Page 37: ...lant lines Tools required Torx screwdriver TX25 3 mm 5 mm Allen key Removing the existing clamp ing system 2 1 1 1 1 1 1 Undo the 5 Allen screws size 3 mm 2 Remove the housing cover 3 3 4 3 Undo the 2...

Page 38: ...untersunk screw size 5 mm 6 Remove the clamping device ele ment Fitting the Twin clamping system 1 1 Secure the clamping device ele ment with the M8 x 25 mm Allen countersunk screw size 5 mm 2 2 2 Ins...

Page 39: ...clamping device elements with two washers and two M6 x 25 mm Allen screws size 5 mm 5 5 5 5 Fit the clamping device elements with two M6 x 16 mm Allen screws size 5 mm 0 5 mm 6 Make sure that there i...

Page 40: ...8 7 8 8 8 8 7 Fit the housing cover 8 Secure the housing cover with five M4 x 8 mm Allen screws size 3 mm 40...

Page 41: ...id is not necessary when the gas nozzle is open as the welding torch is clamped above the gas nozzle The gas nozzle can be removed before hand The bracket must be back in the starting position When th...

Page 42: ...s highest lift position and hold in place 6 Push the cleaning motor 4 and cleaning cutter by hand into the cleaning position 5 NOTE The cleaning cutter must not touch any welding torch components 7 Fi...

Page 43: ...pressed 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 l...

Page 44: ...ng device NOTE Only use Robacta Reamer parting agent item number 42 0411 8042 supplied by the manufacturer The composition of the manufacturer s parting agent is designed specifically for the cleaning...

Page 45: ...nt item number 42 0411 8042 supplied by the manufacturer The composition of this parting agent is designed specifically for the cleaning device If other manufacturers products are used trouble free op...

Page 46: ...ng device to the robot control 3 Start the spraying process using the robot control and check that sufficient spray is being applied 4 If the spray amount is not sufficient increase it as required by...

Page 47: ...container falls below a specified level Controls and in dicators on the sensor 1 2 3 1 OUT OFF button for programming the sensor 2 OUT ON button for programming the sensor 3 LED indicates the sensor...

Page 48: ...ter press the sensor fully into the installation adapter the latch 3 on the installation adapter must snap back over the sensor sensor audibly engages 1 2 2 Use the fixings supplied with the sensor 1...

Page 49: ...econds The LED on the sensor flashes slowly After releasing the OUT OFF button the LED goes out the sensor has detected a low fluid level Calibrating the full state 1 Fill the parting agent container...

Page 50: ...p when locking it will go out briefly after locking if the LED does not light up when locking it will come on briefly after locking Unlocking the fill level control sensor 1 Simultaneously press the O...

Page 51: ...tion nozzle Wear ear protection Wear protective goggles with side protection Checking func tions manually NOTE When the slot for the Lifting device up down Spray in parting agent and Clamp gas nozzle...

Page 52: ...up down 5 1 Deactivating the function 6 The following must be checked when the function is being performed parting agent exit parting agent is sprayed in 0 1 2 1 Spraying in parting agent 7 1 Deactiva...

Page 53: ...s bolted to underlying surface Cleaning cutter is fitted Lifting device has been adjusted Parting agent nebuliser has been started up Compressed air supply has been established Functions have been che...

Page 54: ...cked before starting automatic operation Do not start in automated mode until the cleaning device has been properly installed and started up NOTE Not coating the interior of the welding torch may resu...

Page 55: ...you start to weld The cleaning program sequence is composed of the following sub processes 1 Wire cutter pos A 2 Parting agent level query option 3 Cleaning motor lowered query 4 Gas nozzle free quer...

Page 56: ...ignal to the power source Start wirefeeding Wait approx 0 5 sec Reset Signal to the power source Start wirefeeding Insert wire electrode into wire cut ter blade Speed 50 cm min 19 69 ipm Set External...

Page 57: ...program step 2 Parting agent level query option 2 Parting agent level query op tion Parting agent level OK query Low or High Parting agent level OK query High Parting agent level OK query Low Error me...

Page 58: ...y High Cleaning motor lowered query Low Set External signal Cleaning motor up Wait 0 5 seconds Reset External signal Cleaning motor up Cleaning motor lowered query Low or High Cleaning motor lowered q...

Page 59: ...as nozzle free query Low Set External signal Clamp gas nozzle cleaning motor on Wait 0 5 seconds Reset External signal Clamp gas nozzle cleaning motor on Gas nozzle free query Low or High Gas nozzle f...

Page 60: ...ipm Position the welding torch in the clamping device The gas nozzle must sit on the in side of the holder Set External signal Clamp gas nozzle cleaning motor on Wait 0 5 sec Gas nozzle clamped query...

Page 61: ...torch Set External signal Cleaning motor up start cleaning Wait 3 sec Cleaning motor raised query Low or High Cleaning motor raised query High Cleaning motor raised query Low Stop Error message Clean...

Page 62: ...motor lowered query Low Stop Error message Cleaning motor not fully lowered Reset External signal Swivel to the right Wait 0 5 sec Set External signal Swivel to the left Wait 0 5 sec Swivel mechanism...

Page 63: ...g motor raised query High Cleaning motor raised query Low Stop Error message Cleaning motor not fully raised Reset External signal Cleaning motor up Reset Signal to the power source Blow compressed ai...

Page 64: ...set External signal Swivel to the left Wait 0 5 sec Reset External signal Clamp gas nozzle cleaning motor on Wait 0 5 sec Gas nozzle free query Low or High Gas nozzle free query High Gas nozzle free q...

Page 65: ...2 0 s 0 7 s 0 7 s 0 5 s 1 2 3 4 5 2 Move swivel mechanism to the right 3 Move swivel mechanism to the left 4 Cleaning motor up 5 Spray parting agent Signal outputs Gas nozzle free Gas nozzle clamped...

Page 66: ...Signals not defined using time Parting agent level OK Signal waveform wire cutter in puts and out puts Cut wire electrode input signal 66...

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

Page 68: ...68...

Page 69: ...Risk of machines starting automatically This can result in serious injury and damage to property In addition to these Operating Instructions also observe the safety rules is sued by the manufacturer...

Page 70: ...ozzle If work has to be performed on the cleaning device while it is being supplied with voltage and or compressed air keep your body especially your hands face hair any objects and all clothing away...

Page 71: ...Only use solvent free cleaning products on the cleaning device 1 Remove parting agent deposits and dirt from device Weekly CAUTION Danger from cleaning agents containing solvents This can result in d...

Page 72: ...Disposal Dispose of in accordance with the applicable national and local regulations 72...

Page 73: ...of the following adjustment aids to the torch neck Robacta Twin 500 adjustment aid item no 42 0001 5559 Robacta Twin 900 adjustment aid item no 42 0001 5560 Preparatory work 1 Move the welding torch...

Page 74: ...otor to the side to be adjusted and move to the highest position 4 Adjust the respective banking screw so that the cleaning cutter cannot col lide with a contact tip or a gas nozzle 5 Return the clean...

Page 75: ...And finally 1 1 1 1 1 Screw on the cleaning device hous ing cover using the four original screws and washers 1 1 2 2 2 75 EN...

Page 76: ...76...

Page 77: ...Troubleshooting 77...

Page 78: ...78...

Page 79: ...machines starting automatically This can result in serious injury and damage to property In addition to these Operating Instructions also observe the safety rules is sued by the manufacturer of the r...

Page 80: ...ozzle If work has to be performed on the cleaning device while it is being supplied with voltage and or compressed air keep your body especially your hands face hair any objects and all clothing away...

Page 81: ...parting agent injection nozzle Contact After Sales Service arrange for parting agent injection nozzle to be replaced Vacuum pump faulty Contact After Sales Service arrange for vacuum pump to be re pl...

Page 82: ...valve Contact After Sales Service arrange for solenoid valve to be re placed Choke valve not adjustable or faulty Contact After Sales Service arrange for choke valve to be replaced Faulty sealing in l...

Page 83: ...Technical data 83...

Page 84: ...84...

Page 85: ...G Standard I O X1 Input 24 V DC max 300 mA Output 24 V DC max 30 mA Cleaning time 7 0 7 5 s Total cycle time 8 5 10 s Parting agent container capacity 1 l 0 26 gal US Protection class IP 21 Mark of co...

Page 86: ...86...

Page 87: ...Appendix 87...

Page 88: ...88...

Page 89: ...andCleaningmotoron Reinigungsmotorauf Cleaningmotorup Trennmitteleinspr hen Spraypartingagent Reinigungsmotorunten Cleaningmotorlowered Trennmittel StandI O PartingagentlevelOK Gasd segespannt Gasnozz...

Page 90: ...amping device cleaning motor solenoid valve 5 2 choke check valve solenoid valve 3 2 choke valve check valve wire cutter solenoid valve 3 2 swivel mechanism for cleaning motor solenoid valve 5 2 Magne...

Page 91: ...zzle 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 Directive Eur...

Page 92: ......

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