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Fronius Robacta Reamer, Operating Instructions Manual, Page: 1 / 80

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Fronius prints on elemental chlorine free paper (ECF) sourced from certified sustainable forests (FSC).

/ Perfect Charging / 

Perfect Welding

 / Solar Energy

42,0426,0100,EN 016-08042019

Robacta Reamer brush head for 
aluminium applications

Operating Instructions
Spare parts list

Welding torch cleaning

EN

Summary of Contents for Robacta Reamer

Page 1: ...r ECF sourced from certified sustainable forests FSC Perfect Charging Perfect Welding Solar Energy 42 0426 0100 EN 016 08042019 Robacta Reamer brush head for aluminium applications Operating Instructi...

Page 2: ...2...

Page 3: ...essential prerequisites for excellent results Explanation of safety symbols DANGER Indicates immediate and real danger If it is not avoided death or serious injury will result WARNING Indicates a pote...

Page 4: ...4...

Page 5: ...ical components 21 Safety 23 Safety 23 Controls connections and mechanical components 24 Control elements connections and mechanical components 24 Harting Han6P connecting plug pin assignment X1 for r...

Page 6: ...stalling the electrically controlled wire cutter 43 Installing the compressed air supply 45 Establishing the compressed air supply for the cleaning device function of the compressed air relief valve 4...

Page 7: ...ad for aluminium applications 72 Circuit diagrams Robacta Reamer brush head for aluminium applications 74 Pneumatics diagram of Robacta Reamer brush head for aluminium applications 76 Circuit diagrams...

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Page 9: ...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...

Page 10: ...Checks must be carried out at regular intervals to ensure that operators are working in a safety conscious manner Before using the device all persons instructed to do so undertake to observe the basi...

Page 11: ...g sparks dazzling by arc in haling of harmful welding fumes noise possible danger from mains or welding current etc provide suitable protective equipment or erect suitable safety screens curtains Devi...

Page 12: ...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 aro...

Page 13: ...of properly in accordance with the relevant national and international regulations It is impossible to guarantee that bought in parts are designed and manufac tured to meet the demands made of them o...

Page 14: ...and electromagnetic compatibility directives e g relevant product standards of the EN 60 974 series Fronius International GmbH hereby declares that the device is compliant with Directive 2014 53 EU T...

Page 15: ...General...

Page 16: ......

Page 17: ...ead is equipped with different brush types giving optimal cleaning results All brushes can be replaced without the need for any tools Welding residues are blown away from the welding torch and brush h...

Page 18: ...wn 6 Harting Han6P connecting plug X1 without cable 7 Operating instructions 8 Fixings for assembling the cleaning device 4 screws 4 washers 4 lock washers 4 nuts Options The following options are ava...

Page 19: ...re during maintenance and servic ing Do not use the functions described here until you have thoroughly read and understood the following documents these operating instructions all the operating instru...

Page 20: ...ent that falls or topples over can cause serious or even fatal injury When transporting the device on a counterbalanced lift truck or lift truck secure it to prevent it from falling over Do not sudden...

Page 21: ...Controls connections and mechani cal components...

Page 22: ......

Page 23: ...ting the 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 t...

Page 24: ...ails on compressed air conditions see section Compressed air sup ply specifications on page 31 3 Cleaning screw for manually checking the following functions Cleaning motor ON OFF Supply of compressed...

Page 25: ...for connecting the cleaning device to the robot control is part of the scope of supply The cable harness must be adapted to the connection technology on the robot control Harting Han6P connecting plug...

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

Page 28: ......

Page 29: ...k ing area of the robot WARNING Risk of serious injury from mechanically powered components flying parts shavings etc compressed air escaping from the cleaning nozzles Before performing work on the cl...

Page 30: ...tion wear protective goggles with side protection Ensure that the cleaning device has been disconnected from the compressed air sup ply Briefly turn the Cleaning screw on the cleaning device 90 to the...

Page 31: ...serviced Setup regulations The cleaning device is tested to IP 21 meaning Protection against penetration by solid foreign bodies with diameters 12 5 mm 0 49 in protection against vertically falling dr...

Page 32: ...evice on the installation stand is as short as possible Screw the installation stand to the underlying surface foundation using the appropri ate fixings NOTE Screw on the cleaning device and the spatt...

Page 33: ...device and the spatter tray retainer on a level firm and vibration free surface foundation Position the cleaning device in such a way that the distance the robot has to travel to the cleaning positio...

Page 34: ...ising from the use of other manufacturers contact tips gas nozzles or brush heads The brush head has two different settings A and B to modify the distance between the diagonal brushes according to the...

Page 35: ...35 EN 1 2 3 Fitting the brush head Remove the protective covering from the cleaning device 4 Fit the protective covering to the cleaning device in its original position 1 2 3 1 1 2 3 2 3...

Page 36: ...trouble free operation of the device cannot be guaranteed The manufacturer accepts no liability for damage arising from the use of other manufacturers contact tips gas nozzles or brush heads The brus...

Page 37: ...37 EN 3 Fitting the brush head Remove the protective covering from the cleaning device 4 Fit the protective covering to the cleaning device in its original position 3 1 2 3...

Page 38: ...in beneath upper edge of clea ning device housing positioned cent rally with respect to the cleaning motor Cleaning posi tion of the weld ing torch Braze brush head End of gas nozzle is approx 90 mm 3...

Page 39: ...lly push the lifting device 1 into its highest lift position and hold in place Manually push the cleaning motor 3 and brush head 4 into the cleaning position see diagram 5 for welding torch with spatt...

Page 40: ...ng torch to the cleaning position Loosen screw 2 on the lifting device 1 Manually push the lifting device 1 into its highest lift position and hold in place Manually push the cleaning motor 3 and brus...

Page 41: ...han 15 with the gas nozzle the wire cutter is activated and the wire electrode is cut NOTE The wire electrode is cut while the torch neck is moving Maximum wire di ameter Wire electrodes with a diamet...

Page 42: ...42 2 NOTE Use the fixings supplied with the wire cutter for the assembly shown 3 Use a suitable adapter to connect the wire cutter compressed air hose to the cleaning device 1 1 2 2 3 2 1 3...

Page 43: ...re is an active signal from the robot control Maximum wire di ameter Wire electrodes with a diameter of up to 1 6 mm 0 063 in can be cut by the wire cutter Installing the electrically con trolled wire...

Page 44: ...44 NOTE The wire cutter must be controlled electrically by the robot control...

Page 45: ...mpressed air supply line 1 and ensure that it re mains depressurised for the duration of the work on the device Screw the supplied compressed air relief valve tightly to the compressed air connection...

Page 46: ...functions are being performed function of the cleaning motor cleaning motor OFF ON correct setting of the cleaning motor lifting device moves UP DOWN Standard brush head for more details see section...

Page 47: ...The cleaning device is screwed to the underlying surface Brush head is fitted Position of the cleaning motor has been set Compressed air supply has been established Functions have been checked manual...

Page 48: ...48 Cleaning program and signals Safety CAUTION Risk of damage Do not start in automated mode until the cleaning device has been properly installed and started up...

Page 49: ...ed High Wait 0 5 s Move to pos D Enter wire cutter Speed 60 cm min 23 62 ipm Start Stop program Cleaning motor not lowered Move to pos A approx 50 mm 1 97 in centrally above brush head Speed high spee...

Page 50: ...0 Reset Start cleaning signal Query Cleaning motor lowered High Stop program Cleaning motor not lowered Low Move to pos A approx 50 mm 1 97 in above Centre of brush head Speed high speed Wait 1 5 s En...

Page 51: ...51 EN Signal inputs and outputs Signal input start cleaning cleaning motor ON lifting device UP compressed air supply to cleaning nozzles ON Signal output cleaning motor down...

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Page 53: ...Care maintenance and disposal...

Page 54: ......

Page 55: ...work ing area of the robot WARNING Risk of serious injury from mechanically powered components flying parts shavings etc compressed air escaping from the cleaning nozzles Before performing work on the...

Page 56: ...tion wear protective goggles with side protection Ensure that the cleaning device has been disconnected from the compressed air sup ply Briefly turn the Cleaning screw on the cleaning device 90 to the...

Page 57: ...neral visual inspection of the cleaning device and wire cutter Daily Remove any dirt deposits from device Every 6 months Open the device and check the pneumatic valves for leaks the secure seating of...

Page 58: ...changing the brush note the setting of the brush head A or B and be sure to use this setting during assembly This will ensure that the correct clearance is maintained between the diagonal brushes af t...

Page 59: ...ng of the brush head A or B and be sure to use this setting during assembly This will ensure that the correct clearance is maintained between the diagonal brushes af ter the brush has been changed Rem...

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Page 61: ...Troubleshooting...

Page 62: ......

Page 63: ...area of the robot WARNING Risk of serious injury from mechanically powered components flying parts shavings etc compressed air escaping from the cleaning nozzles Before performing work on the cleanin...

Page 64: ...tion wear protective goggles with side protection Ensure that the cleaning device has been disconnected from the compressed air sup ply Briefly turn the Cleaning screw on the cleaning device 90 to the...

Page 65: ...Remedy Contact After Sales Service arrange for solenoid valve to be replaced Cause Choke valve not adjustable or faulty Remedy Contact After Sales Service arrange for choke valve to be replaced Cause...

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Page 67: ...Technical data...

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Page 69: ...umption 420 l min 443 81 qt min Max noise emission LWA 82 dB A Standard I O Input 24 V DC max 100 mA Output 24 V DC max 30 mA Cleaning time 3 0 5 0 s Total cycle time 4 0 7 5 s Degree of protection IP...

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Page 71: ...Appendix...

Page 72: ...72 Spare parts list Robacta Reamer brush head for al uminium applications...

Page 73: ...1451 42 0404 0332 42 0100 0522 42 0407 0080 42 0408 0109 42 0001 0041 42 0001 5601 42 0001 0039 42 0404 0408 42 0001 0040 44 0450 1453 44 0450 1452 42 0001 0261 B rstenkopf Alu Robacta Reamer B rsten...

Page 74: ...74 Circuit diagrams Robacta Reamer brush head for al uminium applications...

Page 75: ...75 Circuit diagrams Wire cutter Drahtelektrode abschneiden Cut wire Drahtabschneider offen Wire cutter open Drahtabschneider geschlossen Wire cutter closed...

Page 76: ...76 Pneumatics diagram of Robacta Reamer brush head for aluminium applications...

Page 77: ...Alu Gas 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 Dir...

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Page 80: ...NATIONAL GMBH Vorchdorfer Stra e 40 A 4643 Pettenbach Austria E Mail sales fronius com www fronius com Under www fronius com contact you will find the addresses of all Fronius Sales Service Partners a...

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