Fronius Robacta Reamer V 70 Han12P, Operating Instructions Manual

Page 1: ...tal chlorine free paper ECF sourced from certified sustainable forests FSC Perfect Charging Perfect Welding Solar Energy Robacta Reamer V 70 Han12P EN Operating instructions Welding torch cleaning 42 0426 0220 EN 008 21092020 ...

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Page 3: ...cal components 19 Safety 21 Safety 21 Controls connections and mechanical components 22 Control elements connections and mechanical components 22 Harting Han12P connecting plug X1 pin assignment for robot control 24 General 24 Harting Han12P connecting plug X1 pin assignment 24 Installation and commissioning 25 Safety 27 Safety 27 Ensuring that the cleaning device is depressurised 28 Before commis...

Page 4: ...e parting agent nebuliser spray amount 43 Manually checking the cleaning device functions 44 Safety 44 Manually checking the cleaning device functions 44 Starting up the cleaning device 46 Prerequisites for start up 46 Start up 46 Cleaning programme 47 Safety 47 Cleaning program sequence 48 Signal waveform for cleaning 52 Signal inputs 52 Signal outputs 52 Signal waveform optional wire cutter inpu...

Page 5: ...r to the section headed General in the operating instructions for the device Before commissioning the device rectify any faults that could compromise safety This is for your personal safety Proper use The device is to be used exclusively for its intended purpose The device is intended solely for the mechanical cleaning of Fronius robot welding torches in automatic mode Any use above and beyond thi...

Page 6: ...c hazards Stay out of the working area of the robot The device must be incorporated into a higher level safety system within a secured area If this area has to be accessed when setup and maintenance work is carried out make sure that the entire system is switched off for the duration of the work in this area and that it is prevented from starting up accidentally e g as the result of a control faul...

Page 7: ...and industrial areas This is also true for residential areas in which the energy is supplied from the public low voltage mains 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 emis sions it may affect the application area for which it was designed e g when there is sensitive equipment ...

Page 8: ... be visually inspected for damage before commis sioning Any damage must be repaired by trained service technicians before commis sioning the device Safety measures in normal opera tion Only operate the device if 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 ma...

Page 9: ...libration can be obtained from your service centre They will provide you on request with any documents you may require Disposal Do not dispose of this device with normal domestic waste To comply with the European Directive on Waste Electrical and Electronic Equipment and its implementation as national law electrical equipment that has reached the end of its life must be collected separately and re...

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Page 11: ...General 11 ...

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Page 13: ... is used to clean the nozzle After the cleaning process a parting agent is applied to the inside and front of the gas nozzle through the parting agent injection nozzle Application areas The cleaning device is exclusively intended for use in robot and other automated applica tions and can be used for a wide range of materials The main application areas are Automotive and component supply industry E...

Page 14: ...ing agent mixture escaping from the parting agent injection nozzle Flying parts shavings etc Keep the device free from current and pressure during maintenance and servicing Do not use the functions described here until you have fully read and understood the fol lowing documents These Operating Instructions All the Operating Instructions for the system components especially the safety rules 14 ...

Page 15: ...For indoor use only Wear eye protection Warning of automatic start up of the device 15 EN ...

Page 16: ...s falling This can result in serious injury and damage to property Secure the device to prevent it from falling over when transporting on a forklift truck or lift truck Avoid sudden changes in direction braking or acceleration Transport notices on the packaging CAUTION Danger due to improper transport This can result in damage to property Observe the transport notices on the device packaging 16 ...

Page 17: ...ncluded in scope of supply but not shown Harting Han12P connecting plug X1 without cable Operating instructions Fixings for assembling the cleaning device 4 screws 4 washers 4 lock washers 4 nuts The Robacta Reamer parting agent item number 42 0411 8042 and the cleaning cut ter are not included in the scope of supply Available options The following options are available for the cleaning device Ins...

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Page 19: ...Controls connections and mechan ical components 19 ...

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Page 21: ...incorrect operation and incorrectly performed work This can result in serious 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 ...

Page 22: ...om overcurrent Damage to the Harting Han12P X1 connection supply may result Secure supply against overcurrent with a 500 mA slow blow fuse 4 Parting agent spatter tray 5 Parting agent container 6 Gas nozzle clamping device holds the gas nozzle in place during cleaning 7 Parting agent spray device Includes the parting agent injection nozzle Ensures that the parting agent is only applied to the insi...

Page 23: ...ray in parting agent screw For manually checking the spray device compressed air or compressed air part ing agent mixture is sprayed out of the parting agent injection nozzle 13 Compressed air connection for the wire cutter option 14 Electrical connection for the wire cutter option 15 Cleaning motor Drives the cleaning cutter 16 Lifting device Lifts the cleaning motor and the cleaning cutter when ...

Page 24: ...necting the cleaning device to the robot control is included in the scope of supply The cable harness must be adapted to the con nection technology on the robot control Harting Han12P connecting plug X1 pin assign ment Harting Han12P connecting plug X1 pin assignment cable end view Input and output signals 1 Start cleaning input signal clamp gas nozzle cleaning motor on cleaning motor off 2 Spray ...

Page 25: ...Installation and commissioning 25 ...

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Page 27: ...and damage to property Before carrying out any work disconnect the customer s compressed air and power supplies from the cleaning device and the connected system components and ensure that they remain disconnected until work is complete Before carrying out any work make sure that the cleaning device is depressurised for the necessary steps see the following section Ensuring that the cleaning devic...

Page 28: ...ts referred to above Wear ear protection Wear protective goggles with side protection 2 Ensure that the cleaning device has been disconnected from the compressed air supply 3 Briefly turn the Start cleaning screw on the cleaning device 90 to the right then turn it straight back to its original position If the cleaning device does not respond to the turning of the screw the cleaning device is depre...

Page 29: ...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 regulations The cleaning device is tested to protection class IP 20 meaning Protection against penetration by solid foreign bodies with diameters 12 5 mm 0 49 in No protection against the ingress of water The device must not be se...

Page 30: ...ss to the device its compressed air supply must be dis connected 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 interrupted as required MS6 SV pressure build up and pressure relief valves from FESTO are recommended 30 ...

Page 31: ...and is as short as possible 2 Secure the installation stand to the underlying surface Screw on the cleaning device and the spatter tray retainer using the fixings sup plied with the cleaning device 3 Screwing the cleaning device to the underlying surface WARNING Danger from machines falling or toppling over This can result in serious injury and damage to property Always secure the cleaning device ...

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Page 33: ...ning position Welding torch cleaning position The welding torch gas nozzle must be located centrally above the cleaning motor cleaning cutter at a distance of 1 2 mm 0 039 0 079 inch to the protective cover 33 EN ...

Page 34: ...ansferred to the robot The gas nozzle must only be clamped onto the cylindrical surface Only clamp the gas nozzle centrally above the cleaning motor 1 3 2 4 1 Loosen the Allen screws on the guide bolts 1 and 2 2 Move the welding torch to the cleaning position centrally with respect to the clean ing motor 3 Using the adjusting screw 3 position the clamping device 4 so that the clamping device is to...

Page 35: ...ge 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 cleaning cutters from third party manufacturers The cleaning cutter is not part of the scope of supply Consult the manufacturer s spare parts list for the appropriate cleaning cutter 1 Remove the protec...

Page 36: ...g torch with insulating sleeve See diagram 6 for welding torch with spatter guard 8 Fix the cleaning motor 4 in this position in the lifting device 3 tighten the screw 2 on the lifting device 9 Complete a function test without the gas nozzle fitted move the cleaning motor manually to the uppermost position The cleaning cutter must close around the contact tip without touching it If the cleaning cu...

Page 37: ... the spray device Configuring the spray device If the opening on the standard leather seal is too large for the gas nozzle used fit the second leather seal included in the scope of supply as shown below 1 2 37 EN ...

Page 38: ...ally controlled wire cutter opens and closes when there is an active signal from the robot control Maximum wire diameter 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 cutter 1 2 3 Use the adapter previously removed from the wire cutter 38 ...

Page 39: ...4 Use the fixings supplied with the wire cut ter Ensure that the recesses in the spacers face the cleaning device 5 The wire cutter is controlled electrically by the robot control 39 EN ...

Page 40: ...compressed air connection 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 established by moving the compressed air relief valve forwards and backwards see description below The diagram below shows the compressed air relief valve in the closed position no compressed air supply to...

Page 41: ...t to the cleaning device Only use Robacta Reamer parting agent item number 42 0411 8042 supplied by the manufacturer The composition of this parting agent is designed specifically for the clean ing device If other manufacturers products are used trouble free operation cannot be guaranteed 1 2 3 4 41 EN ...

Page 42: ...eamer parting agent item number 42 0411 8042 supplied by the manufacturer The composition of this parting agent is designed specifically for the clean ing device If other manufacturers products are used trouble free operation cannot be guaranteed 1 2 3 4 1 Option long parting agent hose 2 3 42 ...

Page 43: ...robot control 4 Start the spraying process using the robot control and check that sufficient spray is being applied 5 If the spray amount is not sufficient increase it as required by adjusting the spray time using the robot control a spray time of 0 7 seconds is recommended or by using the parting agent adjuster see figure below Finely adjusting the spray amount on parting agent adjuster 6 43 EN ...

Page 44: ...e cleaning position 2 Disconnect the cleaning device from the robot control 3 Establish a compressed air supply to the cleaning device Start cleaning function The following must be checked when the function is being performed Function of the gas nozzle clamping device clamping device piston extends The insertion depth of the cleaning cutter in the gas nozzle lifting device moves the cleaning motor...

Page 45: ...Spraying in parting agent 6 Deactivating the function 7 45 EN ...

Page 46: ...amping device is adjusted Cleaning cutter is fitted Position of the cleaning motor has been set If present the wire cutter has been installed Parting agent nebuliser has been started up Compressed air supply has been established Functions have been checked manually Cleaning device is connected to the robot control All coverings are fitted and all safety devices are intact and in their proper place...

Page 47: ... 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 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 47 EN ...

Page 48: ... high speed Start Start from position D Enter wire cutter Speed 10 cm s 236 22 ipm Wire cutter option Set External signal Cut wire electrode Wait 0 5 sec Reset External signal Cut wire electrode Start from position G approx 50 mm 1 97 in centrally above the wire cutter Speed 10 cm s 236 22 ipm 48 ...

Page 49: ...as nozzle free Query Low Gas nozzle clamped Stop Query output cleaning motor UP output signal Low or High Query High Cleaning motor raised Query Low Cleaning motor not raised Stop Start from position B cleaning position Enter gas nozzle clamping device Speed 10 cm s 236 22 ipm Set Input Begin cleaning Set Blow compressed air through welding torch Wait 5 sec 49 EN ...

Page 50: ...prox 50 mm 1 97 in centrally above the cleaning device Speed 10 cm s 236 22 ipm Query output High Gas nozzle free Reset Input Begin cleaning Reset Blow compressed air through welding torch Wait 1 5 sec Start from position E approx 50 mm 1 97 in centrally above parting agent spray device Speed 10 cm s 236 22 ipm 50 ...

Page 51: ... 39 1 38 in Deep in the spray device Speed 10 cm s 236 22 ipm Set Input Spray in parting agent Reset Input Spray in parting agent Wait 0 7 sec Start from position E approx 50 mm 1 97 in centrally above parting agent spray device Speed 10 cm s 236 22 ipm 51 EN ...

Page 52: ...or cleaning Signal inputs Start cleaning signal Spray in parting agent signal Signal outputs Gas nozzle free signal Cleaning motor up signal Signal waveform optional wire cut ter input Cut wire electrode input signal 52 ...

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

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Page 55: ...y and damage to property Before carrying out any work disconnect the customer s compressed air and power supplies from the cleaning device and the connected system components and ensure that they remain disconnected until work is complete Before carrying out any work make sure that the cleaning device is depressurised for the necessary steps see the following section Ensuring that the cleaning dev...

Page 56: ...p your body especially your hands face and hair any objects and all cloth ing away from the components referred to above Wear ear protection Wear protective goggles with side protection 2 Ensure that the cleaning device has been disconnected from the compressed air supply 3 Briefly turn the Start cleaning screw on the cleaning device 90 to the right then turn it straight back to its original posit...

Page 57: ...ty 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 damage to property Only use solvent free cleaning products on the parting agent container 1 Check the parting agent container for soiling and clean if necessary 2 Blow through suction filter in parti...

Page 58: ...Disposal Dispose of in accordance with applicable national and local regulations 58 ...

Page 59: ...Troubleshooting 59 ...

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Page 61: ...amage to property Before carrying out any work disconnect the customer s compressed air and power supplies from the cleaning device and the connected system components and ensure that they remain disconnected until work is complete Before carrying out any work make sure that the cleaning device is depressurised for the necessary steps see the following section Ensuring that the cleaning device is ...

Page 62: ...p your body especially your hands face and hair any objects and all cloth ing away from the components referred to above Wear ear protection Wear protective goggles with side protection 2 Ensure that the cleaning device has been disconnected from the compressed air supply 3 Briefly turn the Start cleaning screw on the cleaning device 90 to the right then turn it straight back to its original posit...

Page 63: ...laced Vacuum pump faulty Contact After Sales Service arrange for vacuum pump to be replaced Mechanical fault on solenoid valve Contact After Sales Service arrange for solenoid valve to be replaced Cause Remedy Cause Remedy Cause Remedy Cause Remedy Cause Remedy Cause Remedy Welding torch is poorly cleaned or damaged Position of the cleaning motor has been set incorrectly Set the position of the cl...

Page 64: ...sealing in lifting cylinder Contact After Sales Service arrange for lifting cylinder to be replaced Cause Remedy Cause Remedy Cause Remedy Cause Remedy Cause Remedy Cleaning motor does not work No compressed air supply Establish a compressed air supply No signal from robot Check robot program Mechanical fault on cleaning motor Contact After Sales Service arrange for cleaning motor to be replaced M...

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

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Page 67: ...ax 100 mA Output 24 V DC max 30 mA Cleaning time 4 5 6 5 s Total cycle time 5 0 9 0 s Parting agent container capacity 1 l 0 26 gal US Degree of protection IP 21 Mark of conformity CE Safety symbols S Performance Level c Max noise emission LWA 82 dB A Dimensions l x w x h 255 x 245 x 390 mm 10 04 x 9 84 x 15 35 in Weight without parting agent and optional wire cutter 10 5 kg 23 15 lb 67 EN ...

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Page 69: ...Appendix 69 ...

Page 70: ...hen GND Volt 24V Dauer frei frei frei frei frei Drahtabschneiden Gasdüse frei X1 3 4 5 6 7 8 9 10 11 12 2 1 X2 1 2 3 1 4 1 5 6 12 4 2 3 2 3 3 3 4 3 5 Y1 A2 A1 A1 A2 Y2 X3 4 3 2 1 blown white blue black B1 3 2 1 1 2 3 B2 Start Reinigung Sprühen Antihaftmittel Gasdüse frei Drahtabschneider Motor oben 70 ...

Page 71: ...s 17 Magnetventil Y1 Motor auf ab 20 Magnetventil Y2 Einsprühen 21 Stösselventil Y3 22 Drosselrückschlagventil 23 Drosselrückschlagventil 42 Rückschlagventil ohne Feder 43 Filter Ansaugung 30 Kunststoffflasche für Antihaftmittel 31 Kunststoffflasche für Antihaftmittel 15 Schiebeeinheit 41 Rückschlagventil mit Feder 25 Venturidüse mit Rückschlagventil 24 Drosselventil 27 Einsprühdüse 40 Aluminiumzy...

Page 72: ...s 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 Directive European Standards including relevant amendments EN ISO 12100 2010 EN 61000 6 2 2005 AC 2005 EN 61000 6 4 2007 A1 2011 Documentation evidencing conformity with the requirements of the Directives is k...

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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 ...