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Robacta Reamer X-Line J
Robacta Reamer X-Line J Alu

EN-US

Operating instructions

Welding torch cleaning

42,0426,0240,EA 005-17022021

Summary of Contents for Robacta Reamer X-Line J

Page 1: ...ree paper ECF sourced from certified sustainable forests FSC Perfect Charging Perfect Welding Solar Energy Robacta Reamer X Line J Robacta Reamer X Line J Alu EN US Operating instructions Welding torch cleaning 42 0426 0240 EA 005 17022021 ...

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Page 3: ... 19 Safety 21 Safety 21 Operating controls connections and mechanical components 22 Operating Controls Connections and Mechanical Components Front of Device 22 Operating Controls Connections and Mechanical Components Rear of Device 23 Operating Controls Connections and Mechanical Components Side of Device 24 Connections for robot control 24 Installation and Startup 25 Safety 27 Safety 27 Ensuring ...

Page 4: ...evice Functions 43 Safety 43 Manually checking the cleaning device functions 43 Start up the Cleaning Device 45 Requirements for Start up Operation 45 Start up Operation 45 Cleaning Program Sequence 46 Safety 46 Cleaning Program Sequence 47 Cleaning Device Signal Sequences 51 Cleaning device signal sequences 51 Wire Cutter Signal Sequence 52 Wire cutter signal sequence 52 Service maintenance and d...

Page 5: ...he operating com pany 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...

Page 6: ...uring 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 Com pany The operating company must only allow persons to work with the device if they Are familiar...

Page 7: ...ened removed during maintenance installation and repair work During operation ensure that all covers are closed and all side parts have been mounted properly 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 ...

Page 8: ...lds 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 cables and the head torso of the welder as large as possible for safety reasons Do not carry ...

Page 9: ...rting agent according to national and international regu lations 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 fa...

Page 10: ...alth Safety Symbols Devices with CE marking satisfy the essential requirements of the relevant directives e g the low voltage electromagnetic compatibility and machinery directives Devices marked with the CSA test mark satisfy the requirements of the relevant stand ards for Canada and the USA Copyright Copyright of these Operating Instructions remains with the manufacturer Text and illustrations w...

Page 11: ...General 11 ...

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Page 13: ...the cleaning process A cleaning cutter is used for cleaning After cleaning the parting agent injection nozzle parting agent is sprayed into the gas nozzle and onto the face of the gas nozzle Applications The cleaning device is exclusively suited for operation in automation and robot applica tions and can be used for a range of materials Main applications Automotive and supply industry Equipment en...

Page 14: ...re discharged from the parting agent injection nozzle flying debris chips etc During maintenance and service keep the device de energized and depressurized Do not use the functions described here until you have fully read and understood the following documents These Operating Instructions All Operating Instructions for system components especially the safety rules For indoor use only Wear eye prot...

Page 15: ...Warning before the device switches on automatically 15 EN US ...

Page 16: ...ing This can result in severe personal injury and damage to property When transporting the device by counterbalanced lift truck or lift truck secure the device to prevent it from falling Do not turn brake or accelerate in a sudden jerking manner Transport Instructions on the packaging CAUTION Danger due to improper transport This can result in damage to property Follow the transport instructions o...

Page 17: ...aning cutter are not included in the scope of supply 1 Work stand 2 Cleaning device 3 Maintenance unit 4 Wrench for cleaning motor 5 Compressed air relief valve 6 Collecting container not shown 7 Operating Instructions 8 Mounting material to assemble the cleaning device 4 screws 4 washers 4 lock washers 4 nuts 17 EN US ...

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Page 19: ...Operating controls connections and mechanical components 19 ...

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Page 21: ...correct operation and work that is not carried out properly This can result in severe personal injury and damage to property All the work and functions described in this document must only be carried out by trained and qualified personnel Read and understand this document Read and understand all the Operating Instructions for the system components especially the safety rules 21 EN US ...

Page 22: ...nt injection device includes the parting agent injection nozzle ensures that the parting agent only reaches the inside face of the gas nozzle 3 Parting agent injection nozzle sprays the parting agent into the gas nozzle and onto the face of the gas nozzle 4 Cleaning cutter 5 Protective cover 6 Wire cutter 7 Cleaning motor drives the cleaning cutter 8 Lifting device lifts the cleaning motor with th...

Page 23: ...onnection area for robot control 3 Compressed air connection to supply dry compressed air at 6 bar 86 99 psi for more information on com pressed air quality see the Specifications for the Compressed Air Supply section on page 29 4 Parting agent collecting container to collect excess parting agent after the injection process 5 Parting agent container 6 Fill level control sensor 23 EN US ...

Page 24: ... injection nozzle 2 Lifting device up down screw to manually check the lifting device lifting device moves up down 3 Clamp gas nozzle cleaning motor on screw to manually check the gas nozzle clamping device and the cleaning motor gas nozzle clamping device moves out in cleaning motor out in Connections for robot control 3 4 2 1 Connections for robot control 1 Bus system connection 2 Bus system con...

Page 25: ...Installation and Startup 25 ...

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Page 27: ...damage to property Before carrying out any work disconnect the customer s compressed air and power supply from the cleaning device and the associated system components and make sure that the compressed air and power supply remain disconnected until all work has been completed Before carrying out any work ensure that the cleaning device is depressurized the necessary steps for this can be found in ...

Page 28: ...rts Wear hearing protection Wear protective goggles with side protection 2 Ensure that the cleaning device is disconnected from the compressed air supply 3 Briefly turn the Lifting device up down screw on the cleaning device 90 to the right and immediately back to the starting position If the cleaning device does not react to the rotation of the screw the cleaning device is depressurized If the cl...

Page 29: ...device must only ever be maintained by one person In addition make sure that there are no other people in the device s operating area while work on it is ongoing Setup regulations The cleaning device has been tested according to protection class IP 20 This means Protection against solid foreign bodies larger than Ø 12 5 mm 0 49 in No protection against penetrating water The device should not be se...

Page 30: ...ting personnel have access to the device the compressed air supply to the device must be disconnected for the duration of this access in accordance with Per formance Level d of ISO 13849 1 We recommend FESTO s MS6 SV soft start and quick exhaust valve for interrupting the compressed air supply as required 30 ...

Page 31: ...ZM001 VQ01 BG03 4 Cleaning motor rotated pulse signal I780 2 ST010 IR001 ZM001 VQ01 BG04 4 Parting agent container full I781 4 ST010 IR001 ZM001 VQ01 BG05 4 Cleaning motor bottom I782 2 ST010 IR001 ZM001 VQ01 BG06 4 Cleaning motor top I783 4 ST010 IR001 ZM001 VQ01 BG07 4 Wire cutter open I784 2 ST010 IR001 ZM001 VQ01 BG08 4 Wire cutter closed Q777 4 ST010 IR001 ZM001 VQ01 KK01 x1 Clamp gas nozzle ...

Page 32: ...e work stand The installer is responsible for selecting the proper mounting materials 1 Position the work stand on a level solid and vibration free surface foundation Position the work stand so that the robot s approach route to the cleaning device on the work stand is as short as possible 2 Tightly screw the work stand to the surface foundation using the selected mounting materials NOTE Use the m...

Page 33: ...ch Cleaning Position Welding Torch Cleaning Position The welding torch gas nozzle must be centered over the cleaning motor cleaning cut ter with 1 2 mm 0 039 0 079 inches distance to the protective cover 33 EN US ...

Page 34: ...tside diameter larger smaller than 25 mm 0 98 inches the gas nozzle clamping device must be adjusted before it is started for the first time and after every device replacement 1 3 2 4 NOTE Set the clamping device so that no reaction forces can be transmitted to the robot Only clamp gas nozzles on a cylindrical surface 1 Loosen the Allen screws on guide bolts 1 and 2 2 Move the welding torch to the...

Page 35: ...ty 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 cutters from third party manufacturers The cleaning cutter is not part of the scope of supply Find the right cleaning cutter in the manufacturer s Spare Parts List 1 Remove the protective cover from the cl...

Page 36: ... NOTE The cleaning cutter must not come into contact with the welding torch parts 8 Mount the cleaning motor 4 in this position in the lifting device 3 tighten the screw 2 on the lifting device 9 Perform a function test with the gas nozzle removed Manually slide the cleaning motor into the top position The cleaning cutter must surround the contact tip without colliding with it If the cleaning cutt...

Page 37: ...ve on to the compressed air connection on the cleaning device 3 Connect the compressed air supply to the compressed air relief valve You can interrupt and restore the compressed air supply to the cleaning device by mov ing the compressed air relief valve back and forth see description below The following illustration shows the compressed air relief valve closed compressed air supply to the device ...

Page 38: ...d con necting it to the cleaning device NOTE Only use the Robacta Reamer parting agent item number 42 0411 8042 provided by the manufacturer Its composition is specifically tailored for use with the cleaning device Correct operation is not ensured when other products are used 1 2 3 4 38 ...

Page 39: ...ly use the Robacta Reamer parting agent item number 42 0411 8042 provided by the manufacturer Its composition is specifically tailored for use with the cleaning device Correct operation is not ensured when other products are used 1 1 2 3 4 2 Option longer parting agent hose 39 EN US ...

Page 40: ...ontrol 3 Activate the injection process using the robot control and check whether the injection quantity is adequate 4 If the injection quantity is not adequate adjust the injection quantity as required use the robot control to adjust the injection time an injection time of 0 7 seconds is recommended or using the parting agent adjusting controller as illustrated below Fine tune the injection quant...

Page 41: ...shows the operating mode of the sensor LED on flashing Sensor act ive LED off not flashing Sensor inactive Performing empty adjust ment 20 mm 0 79 in 1 Drain the parting agent container until the parting agent is at least 20 mm 0 787 in below the sensor 2 Connect the sensor to the power sup ply 2 6 s 3 Hold the OUT OFF key for at least 2 seconds maximum 6 seconds The LED on the sensor flashes slow...

Page 42: ...le to lock the sensor Locking the fill level control sensor 1 Simultaneously press the OUT OFF and OUT ON keys for at least 10 seconds The LED status briefly changes if the LED is illuminated during locking the LED briefly turns off after locking if the LED is not illuminated during locking the LED is briefly illuminated after locking Unlocking the fill level control sensor 1 Simultaneously press ...

Page 43: ...zzle Wear hearing protection Wear protective goggles with side protection Manually check ing the cleaning device functions NOTE The relevant function is deactivated when the slots of the Lifting device up down Clamp gas nozzle cleaning motor on and Spray in parting agent screws are in a horizontal position 1 Disconnect the connection between the cleaning device and the robot control 2 Connect the ...

Page 44: ...mping device The function of the cleaning motor Clamp gas nozzle cleaning motor on 5 Clamp gas nozzle cleaning motor on 6 Cleaning motor up down function Check the following while the function is executed The insertion depth of the cleaning cutter into the gas nozzle Cleaning motor up down 7 Deactivate the function 8 44 ...

Page 45: ...le with an outside dia meter of 25 mm 0 98 inches For more info see the Adjusting the Gas Nozzle Clamping Device chapter Cleaning cutter fitted Position of the cleaning motor set Parting agent atomizer started up Compressed air supply set up Functions manually checked Cleaning device connected to the robot control All covers installed and all safety devices in good order and installed in the locat...

Page 46: ...ting automatic operation Only start automatic mode once the cleaning device has been installed and commis sioned properly NOTE If wetting agent has not been applied to the inside of the welding torch this may lead to the permanent contamination of the welding torch when welding begins Always wet the inside of the welding torch with the manufacturer s parting agent before starting an automatic mode...

Page 47: ...la posición D Moviéndose hacia el cortador de hilo Velocidad 10 cm s 236 22 ipm Establecer señal externa Cortar el electrodo de soldadura Esperar 0 5 segundos Restablecer señal externa Cortar el electrodo de soldadura Mover a la posición G aprox 50 mm 1 97 in posicionada centralmente sobre el cortador de hilo Velocidad 10 cm s 236 22 ipm 47 EN US ...

Page 48: ...sor Detener Demanda de salida señal de salida motor de limpieza en la parte inferior Baja o alta Demanda alta motor de limpieza en la parte inferior Demanda baja motor de limpieza no en la parte inferior Detener Mover a la posición B posición de limpieza Moviéndose hacia el dispositivo tensor de la tobera de gas Velocidad 10 cm s 236 22 ipm Establecer Entrada Tobera de gas de la brida motor de lim...

Page 49: ... 1 97 in posicionada centralmente sobre el dispositivo de inyección del líquido antiproyecciones Velocidad 10 cm s 236 22 ipm Restablecer Entrada motor de limpieza abierto tan pronto como la señal motor de limpieza abierto esté alta Establecer Purga de gas de aire a presión con antorcha de soldadura Restablecer Entrada Tobera de gas de la brida motor de limpieza encendido purga de gas de aire a pr...

Page 50: ...ón Velocidad 10 cm s 236 22 ipm Establecer Entrada Rociar con líquido antiproyecciones Restablecer Entrada Rociar con líquido antiproyecciones Esperar 0 7 segundos Mover a la posición E aprox 50 mm 1 97 in posicionada centralmente sobre el dispositivo de inyección del líquido antiproyecciones Velocidad 10 cm s 236 22 ipm 50 ...

Page 51: ... 0 VDC 1 2 3 4 5 6 7 8 9 1 Clamp gas nozzle cleaning motor on 2 Cleaning motor up down 3 Spray in parting agent 4 Gas nozzle free 5 Gas nozzle clamped 6 Cleaning motor rotated pulse signal 7 Parting agent container full 8 Cleaning motor bottom 9 Cleaning motor top 51 EN US ...

Page 52: ...Wire Cutter Signal Sequence Wire cutter signal sequence 24 VDC 0 VDC 1 2 3 1 Cut the wire electrode 2 Wire cutter open 3 Wire cutter closed 52 ...

Page 53: ...Service maintenance and disposal 53 ...

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Page 55: ...age to property Before carrying out any work disconnect the customer s compressed air and power supply from the cleaning device and the associated system components and make sure that the compressed air and power supply remain disconnected until all work has been completed Before carrying out any work ensure that the cleaning device is depressurized the necessary steps for this can be found in the...

Page 56: ...ce and hair as well as objects and all items of clothing away from the aforementioned parts Wear hearing protection Wear protective goggles with side protection 2 Ensure that the cleaning device is disconnected from the compressed air supply 3 Briefly turn the Lifting device up down screw on the cleaning device 90 to the right and immediately back to the starting position If the cleaning device do...

Page 57: ...er due to cleaning agents containing solvents This can result in damage to property Only clean the cleaning device with cleaning products that are free of solvents 1 Remove deposited parting agent and contamination from the device Weekly NOTE Only clean the parting agent container with cleaning products that are free of solvents Check the parting agent container and parting agent collecting contai...

Page 58: ...Disposal Materials should be disposed of according to valid national and regional rules 58 ...

Page 59: ...Troubleshooting 59 ...

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Page 61: ...roperty Before carrying out any work disconnect the customer s compressed air and power supply from the cleaning device and the associated system components and make sure that the compressed air and power supply remain disconnected until all work has been completed Before carrying out any work ensure that the cleaning device is depressurized the necessary steps for this can be found in the followi...

Page 62: ...ce and hair as well as objects and all items of clothing away from the aforementioned parts Wear hearing protection Wear protective goggles with side protection 2 Ensure that the cleaning device is disconnected from the compressed air supply 3 Briefly turn the Lifting device up down screw on the cleaning device 90 to the right and immediately back to the starting position If the cleaning device do...

Page 63: ...tify the service team parting agent injection nozzle needs replacing Vacuum pump defective Contact service team vacuum pump needs replacing Solenoid valve has mechanical fault Contact service team solenoid valve needs replacing Cause Remedy Cause Remedy Cause Remedy Cause Remedy Cause Remedy Cause Remedy Welding torch has been poorly cleaned or is damaged Position of the cleaning motor incorrectly...

Page 64: ...eplacing Seal on lifting cylinder is faulty Contact service team lifting cylinder needs replacing Cause Remedy Cause Remedy Cause Remedy Cause Remedy Cause Remedy Cleaning motor not working Compressed air supply missing Set up the compressed air supply No signal from robot Check robot program Cleaning motor has mechanical fault Contact service team cleaning motor needs replacing Solenoid valve has...

Page 65: ...Technical data 65 ...

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Page 67: ...V DC max 100 mA Output 24 V DC max 30 mA Cleaning time 4 5 6 5 s Overall cycle time 5 0 9 0 s Capacity of the parting agent container 1 l 26 gal US Protection class IP 21 Marks of conformity CE Safety symbols S Performance Level c Maximum noise emission LWA 82 dB A Dimensions L W H 255 x 245 x 390 mm 10 04 x 9 84 x 15 35 in Weight not including parting agent and optional wire cutter 10 5 kg 22 15 ...

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Page 69: ...Appendix 69 ...

Page 70: ...Gasdüse 1 4 3 B2 frei gespannt Trennmittel Kontrolle Motor dreht Impuls Motor unten Motor oben Draht geschnitten Drahtschneider offen 4 5 6 1 4 3 B3 B4 3 4 1 XS4 3 4 5 2 1 BLUE BLACK BROWN WHITE NC Q780 0V Q779 PE NC Q782 0V Q781 PE 24V US I778 0V I777 PE 1 2 5 4 3 XS5 PE I779 0V I780 24V US A1 X1 1 4 3 1 A1 X2 4 3 1 A1 X3 2 3 4 5 A1 Y Verteiler X1 7 8 9 1 4 3 B5 B6 3 4 1 10 11 12 1 2 5 4 3 XS6 PE...

Page 71: ...ntil 37 Drosselrückschlagventil 47 Filter Ansaugung 30 Kunststoffflasche ohne Verschraubung 35 Schiebeeinheit 33 Rückschlagventil mit Feder 32 Venturidüse mit Rückschlagventil 34 Drosselventil 26 Einsprühdüse GASDÜSE SPANNEN MOTOR DREHT MOTOR AUF AB Y1 Y4 15 61 DA 10 DRAHTABSCHNEIDER EINSPRÜHEN 12 Magnetventil Y1 Spannen Motor ein 61 Schiebeeinheit 15 Magnetventil Y4 Drahtabschneider 23 Aluminiumz...

Page 72: ...zle 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 European Standards including relevant amendments EN ISO 12100 2010 EN 62311 2008 EN 61000 6 2 2005 AC 2005 EN 61000 6 4 2007 A1 2011 Documentation evidencing conformity with the requirements of the Direct...

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Page 76: ...S INTERNATIONAL GMBH Froniusstraße 1 A 4643 Pettenbach AUSTRIA contact fronius com www fronius com Under www fronius com contact you will find the addresses of all Fronius Sales Service Partners and locations ...

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