42,0426,0240, Ea

/ Perfect Charging / Perfect Welding / Solar Energy
Operating Instructions
Robacta Reamer X-Line J EN-US Spare parts list
Robacta Reamer X-Line J Alu Welding torch cleaning
42,0426,0240,EA 002-11122018
2
Dear reader,
EN-US
Introduction Thank you for the trust you have placed in our company and congratulations on buying this
high-quality Fronius product. These instructions will help you familiarize yourself with the
product. Reading the instructions carefully will enable you to learn about the many different
features your Fronius product has to offer. This will allow you to make full use of its advan-
tages.
Please also note the safety rules to ensure greater safety when using the product. Careful
handling of the product will repay you with years of safe and reliable operation. These are
essential prerequisites for excellent results.
Explanation of
Safety Instruc- DANGER!
tions Indicates an immediate danger.
Death or serious injury may result if appropriate precautions are not taken.
WARNING!
Indicates a possibly dangerous situation.
Death or serious injury may result if appropriate precautions are not taken.
CAUTION!
Indicates a situation where damage or injury could occur.
Minor injury or damage to property may result if appropriate precautions are not taken.
NOTE!
Indicates the possibility of flawed results and damage to the equipment.
IMPORTANT!
Indicates tips for correct operation and other particularly useful information.
It does not indicate a potentially damaging or dangerous situation.
If you see any of the symbols depicted in the "Safety Rules," special care is required.
3
4
Contents
EN-US
Safety Instructions ..................................................................................................................................... 7
General ................................................................................................................................................. 7
Intended Use......................................................................................................................................... 7
Environmental Conditions ..................................................................................................................... 7
Obligations of the Operating Company................................................................................................. 8
Obligations of Personnel....................................................................................................................... 8
Particular Hazard Areas........................................................................................................................ 8
Personal Protection and Protection of Others....................................................................................... 9
EMC Device Classifications .................................................................................................................. 9
EMC Measures ..................................................................................................................................... 9
EMF measures...................................................................................................................................... 10
Safety Measures at the Setup Location and during Transport.............................................................. 10
Safety Measures in Normal Operation.................................................................................................. 10
Maintenance and repair ........................................................................................................................ 11
Safety Inspection .................................................................................................................................. 11
Disposal ................................................................................................................................................ 11
Safety Symbols ..................................................................................................................................... 11
Copyright............................................................................................................................................... 11
General 13
General ...................................................................................................................................................... 15
Principle ................................................................................................................................................ 15
Device Concept..................................................................................................................................... 15
Applications........................................................................................................................................... 15
Warning Notices on the Cleaning Device ............................................................................................. 16
Transport.................................................................................................................................................... 18
Transport Equipment ............................................................................................................................ 18
Transport instructions on the packaging ............................................................................................... 18
Scope of Supply......................................................................................................................................... 19
Scope of Supply.................................................................................................................................... 19
Operating controls, connections and mechanical components 21
Safety......................................................................................................................................................... 23
Safety.................................................................................................................................................... 23
Operating controls, connections and mechanical components.................................................................. 24
Operating Controls, Connections, and Mechanical Components - Front of Device ............................. 24
Operating Controls, Connections, and Mechanical Components - Rear of Device ............................. 25
Operating Controls, Connections, and Mechanical Components - Side of Device .............................. 26
Connections for robot control................................................................................................................ 27
Installation and Startup 29
Safety......................................................................................................................................................... 31
Safety.................................................................................................................................................... 31
ensure that the cleaning device is depressurized ................................................................................. 32
Before installation ...................................................................................................................................... 33
Intended Use......................................................................................................................................... 33
Operating Personnel, Maintenance Personnel ..................................................................................... 33
Setup Regulations................................................................................................................................. 33
Specifications for the Compressed Air Supply...................................................................................... 33
Measures to ensure safe operation of the device when operating personnel are untrained ................ 33
Diagram of the programmable logic control (PLC)..................................................................................... 34
Diagram of the programmable logic control (PLC)................................................................................ 34
Screwing the Cleaning Device to the Solid Surface................................................................................... 35
Screwing the cleaning device and work stand to the surface ............................................................... 35
Welding Torch Cleaning Position ............................................................................................................... 37
Welding Torch Cleaning Position.......................................................................................................... 37
Adjusting the Gas Nozzle Clamping Device .............................................................................................. 38
5
Adjusting the gas nozzle clamping device ............................................................................................ 38
Fitting the Cleaning Cutter ......................................................................................................................... 39
Fitting the cleaning cutter...................................................................................................................... 39
Adjusting the Position of the Cleaning Motor ............................................................................................. 40
Adjusting the position of the cleaning motor ......................................................................................... 40
Setting up the Compressed Air Supply ...................................................................................................... 41
Setting up the cleaning device compressed air supply, compressed air relief valve function............... 41
Starting Up the Parting Agent Atomizer ..................................................................................................... 42
Filling the parting agent container (1 liter) and connecting it to the cleaning device............................. 42
Connecting the parting agent container (10 liter) to the cleaning device .............................................. 43
Setting the injection quantity of the parting agent atomizer .................................................................. 44
Starting up the fill-level control sensor ....................................................................................................... 45
General ................................................................................................................................................. 45
Operating controls and displays on the sensor..................................................................................... 45
Performing empty adjustment ............................................................................................................... 45
Performing a full adjustment ................................................................................................................. 46
Unlocking/locking the fill-level control sensor ....................................................................................... 46
Manually Checking the Cleaning Device Functions ................................................................................... 47
General ................................................................................................................................................. 47
Manually checking the cleaning device functions ................................................................................. 47
Start up the Cleaning Device ..................................................................................................................... 49
Requirements for Start-up Operation.................................................................................................... 49
Start-up Operation ................................................................................................................................ 49
Cleaning Program Sequence..................................................................................................................... 50
Safety.................................................................................................................................................... 50
Cleaning Program Sequence................................................................................................................ 51
Cleaning Device Signal Sequences........................................................................................................... 55
Cleaning device signal sequences........................................................................................................ 55
Wire Cutter Signal Sequence..................................................................................................................... 56
Wire cutter signal sequence.................................................................................................................. 56
Service, maintenance and disposal 57
Safety......................................................................................................................................................... 59
Safety.................................................................................................................................................... 59
Service, maintenance and disposal ........................................................................................................... 61
General ................................................................................................................................................. 61
Before every start-up ............................................................................................................................ 61
Daily ...................................................................................................................................................... 61
Weekly .................................................................................................................................................. 61
Every six months................................................................................................................................... 61
Whenever required ............................................................................................................................... 61
Disposal ................................................................................................................................................ 61
Troubleshooting 63
Safety......................................................................................................................................................... 65
Safety.................................................................................................................................................... 65
Troubleshooting ......................................................................................................................................... 67
Errors in the Program Sequence .......................................................................................................... 67
Technical Data 69
Technical Data ........................................................................................................................................... 71

Robacta Reamer X-Line J, Robacta Reamer X-Line J Alu ................................................................... 71
Appendix 73
Spare parts list: Robacta Reamer X-Line J, Robacta Reamer X-Line J Alu .............................................. 74
Circuit diagrams: Circuit Diagram for Robacta Reamer X-Line J, Robacta Reamer X-Line J Alu ............. 76
Pneumatic Plan for Robacta Reamer X-Line J, Robacta Reamer X-Line J Alu......................................... 77
Declaration of conformity ........................................................................................................................... 78
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Safety Instructions
EN-US
General The device has been manufactured using state-of-the-art technology and according to rec-
ognized safety standards. If used incorrectly or misused, however, it can cause
- injury or death to the operator or a third party,
- damage to the device and other material assets belonging to the operating company,
- 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 instruc-
tions in full and follow them carefully.
The Operating Instructions must always be at hand wherever the device is being used. In
addition to the Operating Instructions, all applicable local rules and regulations regarding
accident prevention and environmental protection must also be followed.
All safety and danger notices on the device must

- must be kept in a legible state
- not be damaged/marked
- not be removed
- not be covered, pasted, or painted over
For the location of the safety and danger notices on the device, refer to the section headed
"General" in the Operating Instructions for the device.
Before switching on the device, remove any faults that could compromise safety.
Your personal safety is at stake!
Intended Use The device is to be used exclusively for its intended purpose.
The device is intended exclusively for the mechanical cleaning of Fronius robot welding
torches in automatic mode.
Utilization for any other purpose, or in any other manner, shall be deemed to be "not in ac-
cordance with the intended purpose." The manufacturer is not responsible for any damage
resulting from improper use.
Proper use also means

- Reading these Operating Instructions in their entirety
- Following all instructions and safety rules in these Operating Instructions
- Carrying out all the specified inspection and servicing work
The device is designed for operation in industry and business. The manufacturer shall not
be liable for any damage resulting from use in a living area.
The manufacturer shall also not be liable for faulty or incorrect work results.
Environmental Operation or storage of the device outside the stipulated area will be deemed as not in ac-
Conditions cordance with the intended purpose. The manufacturer is not responsible for any damage
resulting from improper use.
Temperature range of the ambient air:

- During 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)
7
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 The operating company must only allow persons to work with the device if they
Operating Com- - Are familiar with the basic occupational safety and accident prevention regulations
pany and are trained in handling the device
- Have read and understood these Operating Instructions, especially the section "Safe-
ty Rules," and have confirmed this with their signature
- Are trained according to the requirements for the work results
The safety-conscious work of the personnel must be checked regularly.
Obligations of All persons who are assigned to work with the device must do the following before begin-
Personnel ning the work:
- Follow the basic regulations for occupational safety and accident prevention
- Read these Operating Instructions, especially the section "Safety Rules," and confirm
that they have understood and will follow them by signing
Before leaving the workplace, ensure that no personal injury or property damage can occur
in one's absence.
Particular Hazard Do not linger in the operating area of the robot.

Areas
Always integrate the device into a higher-level safety system in a secured area.
If this area has to be accessed for preparatory or maintenance work, ensure that
- the entire system is shut down for the duration of access to this area
- and remains shut down to prevent unintended operation, e.g., as a result of a control
error.
If untrained operating 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.
In addition to these Operating Instructions, the safety rules of the robot manufacturer must
be followed.
The human body, and, in particular, hands, face and hair, plus items of clothing and all
tools, must be kept away from moving components, such as:
- the rotating cleaning cutter
- the cleaning motor that moves up and down
- the gas nozzle clamping device that moves in and out
- Wire cutter
Do not touch the cleaning cutter immediately after operation - burning hazard. Follow the
special safety regulations for handling the cleaning cutter in the Operating Instructions.
Protect hands, face and eyes from flying parts (chips, etc.) and compressed air/parting
agent mixture discharged from the parting-agent injection nozzle.
Covers must only be opened/removed during maintenance, installation and repair work.
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During operation:
- ensure that all covers are closed, and all side parts have been mounted properly
EN-US
- keep all covers closed
Personal Protec- You are exposed to numerous hazards while handling the device. In addition to these Op-
tion and Protec- erating Instructions, the safety rules of the manufacturer of the entire welding system must
tion of Others be followed.
Keep persons, especially children, away during the operation of the devices and during the
welding process. However, if persons are in the vicinity:
- instruct them about all hazards (crush hazard posed by moving mechanical parts, in-
jury hazard from the cleaning cutter, flying chips or similar, discharged compressed
air/parting agent mixture, injury hazard due to flying sparks, blinding hazard due to
arcs, welding fume hazardous to health, noise exposure, possible hazard due to
mains current or welding current, etc.)
- Provide suitable protective equipment, or
- construct suitable protective walls and curtains.
EMC Device Clas- Devices in emission class A:

sifications - Are only designed for use in industrial settings
- Can cause line-bound and radiated interference in other areas
Devices in emission class B:

- Satisfy the emissions criteria for residential and industrial areas. This is also true for
residential areas in which the energy is supplied from the public low-voltage grid.
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 sen-
sitive equipment at the same location, or if the site where the device is installed is close to
either radio or television receivers).
If this is the case, then the operating company is obliged to take appropriate action to rectify
the situation.
Check and evaluate possible problems and the interference immunity of equipment in the
vicinity according to national and international regulations:
- Safety devices
- Grid power lines, signal lines, and data transfer lines
- EMC and telecommunications equipment
- Devices for measuring and calibrating
Supporting measures to avoid EMC problems:

1. Grid power supply
- If electromagnetic interference occurs despite a grid connection that complies
with regulations, take additional measures (e.g., use a suitable grid filter).
2. Control lines
- Keep them as short as possible
- Route them close together (also to avoid EMF problems)
- Route them far from other lines
3. Equipotential bonding
4. Shield, if necessary
- Shield other devices in the vicinity
- Shield the entire welding installation
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EMF measures Electromagnetic fields 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 im-
mediate 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 welding cables and hosepacks over one's shoulder or wrap them around
one's body or body parts
Safety Measures A toppling device can be deadly! Install the device horizontally on a flat, stable surface free
at the Setup Loca- of vibration, anchor it securely on the surface, and secure against toppling.
tion and during
Transport Special regulations apply in areas at risk of fire or explosion
- Follow the appropriate national and international regulations.
Use instructions and checks within the company to ensure that the vicinity of the workplace
is always clean and organized.
Take care to ensure that the applicable national and regional guidelines and accident pre-
vention regulations are observed when transporting the device, especially guidelines con-
cerning hazards during transport and shipment.
It is essential to conduct a visual inspection of the device to check for damage after it has
been transported but before it is commissioned. Have any damage repaired by trained ser-
vice technicians before commissioning the device.
Safety Measures Only operate the device when all safety devices are fully functional. If the safety devices
in Normal Opera- are not fully functional, there is a risk of
tion - injury or death to the operator or a third party,
- damage to the device and other material assets belonging to the operating company,
- inefficient operation of the device.
Safety devices that are not fully functional must be repaired before the device is started up.
Never bypass or disable safety devices.
Before starting up the device, ensure that no one can be put in danger.
The device must be examined at least once a week for externally detectable damage and
functionality of the safety devices.
- Only use appropriate original parting agents from the manufacturer.

- When handling parting agent, observe the information on the parting agent safety data
sheet. The parting agent safety data sheet can be obtained from your service center
or via the manufacturer's website.
- Do not mix parting agents from the manufacturer with other parting agents.
- If damage occurs due to the use of other parting agents, the manufacture is not liable
for this and all warranty claims are forfeited.
- Properly dispose of used parting agent according to national and international regula-
tions.
10
EN-US
Maintenance and It is impossible to guarantee that bought-in parts are designed and manufactured to meet
repair 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 manufac-
turer's consent.
- Components that are not in perfect condition must be replaced immediately.
- When ordering, please give the exact designation and part number as shown in the
spare parts list, as well as the serial number of your device.
The housing screws provide the ground conductor connection for earthing the housing
parts.
Only use original housing screws in the correct number and tightened to the specified
torque.
Safety Inspection The manufacturer recommends that a safety inspection of the device be performed at least
every 12 months.
A safety inspection by a certified electrician is recommended:

- after changes
- after alterations
- after repair, care, and maintenance
- at least every 12 months.
For the safety inspection, follow the appropriate national and international standards and
guidelines.
You can obtain more information about the safety inspection and calibration from your ser-
vice center. The service center will provide the necessary documents upon request.
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 returned to an approved recycling facility. Any device that you no longer require must
be returned to your dealer, or you must locate the approved collection and recycling facil-
ities in your area. Ignoring this European Directive may have potentially adverse affects on
the environment and your health!
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 standards
for Canada and the USA.
Copyright Copyright of these operating instructions remains with the manufacturer.
Text and illustrations are technically correct at the time of going to print. The right to make
modifications is reserved. The contents of the operating instructions shall not provide the
basis for any claims whatsoever on the part of the purchaser. If you have any suggestions
for improvement, or can point out any mistakes that you have found in the operating in-
structions, we will be most grateful for your comments.
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12
General
General
EN-US
Principle The cleaning device is intended to auto-
matically clean MIG/MAG welding torches.
The cleaning device can be used to reliably
clean the inside of gas nozzles and the face
of the gas nozzles in a range of welding
torch geometries. This significantly increa-
ses the service life of wearing parts. At the
same time, the even application of parting
agent prevents the build-up of new dirt.
Device Concept The gas nozzle clamping device on the front of the cleaning device holds the gas nozzle
in place during 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 applications
and can be used for a range of materials.
Main applications:
- Automotive and supply industry
- Equipment engineering
- Chemical plant construction
- Mechanical engineering, rail vehicle construction
- Construction machinery and special-purpose vehicle construction
15
Warning Notices
The cleaning device has warning notices and a rating plate fitted. These warning notices
on the Cleaning
and the rating plate must not be removed or painted over.
Device
Type
Art.No.
www.fronius.com
Chargen No.
U1 24 V I1
pmax 6 bar (87psi.)
Warning notices on the cleaning device
WARNING! Danger of serious injuries due to:

- moving mechanical parts
- compressed air/parting agent mixture discharged from the parting-
agent injection nozzle
- flying debris (chips, etc.)
During maintenance and service, keep the device de-energized and depres-
surized.
Do not use the functions described here until you have fully read and under-
stood the following documents:
- These Operating Instructions
- All Operating Instructions for system components, especially the safety
rules
For indoor use only
16
Wear eye protection
EN-US
Warning before the device switches on automatically
17
Transport
Transport Equip- Transport the device using the following transport equipment:
ment - on a pallet using a forklift
- on a pallet using a lift truck
- manually
WARNING!
Falling or toppling devices can be deadly.
► When transporting the device by forklift or lift truck, secure the device from falling
► Do not turn, brake, or accelerate in a sudden, jerking manner
Transport in-
structions on the CAUTION!
packaging Improper transport can result in damage.
Follow the transport instructions on the device packaging.
18
Scope of Supply
EN-US
Scope of Supply
(2)
(3)
(1)
(4)
(5)
(6)
NOTE!
The “Robacta Reamer” parting agent (item number 42,0411,8042) and the cleaning
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
19
20
Operating controls, connections and
mechanical components
Safety
EN-US
Safety Please follow the safety rules below when using all the functions described in the "Operat-
ing Controls, Connections, and Mechanical Components" chapter.
WARNING!
Operating the device incorrectly can cause serious injury and damage.
The functions described may only be used by trained personnel. 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
23
Operating controls, connections and mechanical
components
Operating Con-
trols, Connec-
tions, and (1)
Mechanical Com-
ponents - Front of
Device (2)
(6)
(3)
(4)
(5)
(7)
(8)
Front of device
No. Function
(1) Gas nozzle clamping device

holds the gas nozzle in place during the cleaning process
(2) Parting agent 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 the cleaning cutter into the gas nozzle during the clean-
ing process
24
EN-US
Operating Con-
trols, Connec-
tions, and
Mechanical Com-
ponents - Rear of
Device
(4)
(1)
(5)
(2)
(3) (6)
Rear of device
No. Function
(1) Parting agent adjusting controller

to set the parting agent injection quantity
(2) Connection 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 33
(4) Parting agent collecting container

to collect excess parting agent after the injection process
(5) Parting agent container
(6) Fill-level control sensor
25
Operating Con-
trols, Connec-
tions, and
Mechanical Com-
ponents - Side of
Device
(1)
(3)
(2)
Side of device
No. Function
(1) “Spray in parting agent” screw

to manually check the injection device (compressed air or compressed air/parting
agent mixture is sprayed out of the parting-agent 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)
26
EN-US
Connections for
robot control No. Function
(1) Bus system connection
(1) (3)
(2) (4)
Connections for robot control
27
28
Installation and Startup
Safety
EN-US
Safety Please follow the safety rules below during all the tasks described in the "Installation and
Commissioning" chapter.
WARNING!
Incorrect operation and incorrectly performed work can cause serious injury and
damage to property.
All work listed in these Operating Instructions may only be performed by trained specialist
personnel. All functions described in these Operating Instructions may only be used by
trained specialist personnel. All work and functions specified must only be performed and
used once the following documents have been read and understood in full:
WARNING!
Machines that start automatically can cause serious injury and damage.
In addition to these Operating Instructions, the safety regulations of the robot manufacturer
and welding system manufacturer must be followed. For your personal safety, make sure
that all protective measures have been taken in the robot's operating area and remain in
effect while you are in this area.
WARNING!
Danger of serious injuries due to:
► moving mechanical parts

► flying debris (chips, etc.)
► compressed air/parting agent mixture discharged from the parting-agent injection noz-
zle
► Before starting work on the cleaning device or the associated system components:
► 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
► make sure that the cleaning device is depressurized - the necessary steps are provid-
ed in the “Ensure that the cleaning device is depressurized” section below
WARNING!
If the cleaning device is being supplied with voltage and/or compressed air, the fol-
lowing could cause serious injury:
► the rotating cleaning cutter

► the cleaning motor that moves up and down
► the gas nozzle clamping device that moves in and out
► activated wire cutter
zle
31
If work is required on the cleaning device while the cleaning device is being supplied with
voltage and/or compressed air:
► keep your body, especially hands, face and hair, as well as objects and all items of
clothing away from the cleaning cutter, cleaning motor, lifting device, gas nozzle
clamping device, wire cutter, and parting-agent injection nozzle
► wear hearing protection
► wear protective goggles with side protection
ensure that the To ensure that the cleaning device is depressurized, try to briefly activate the cleaning de-
cleaning device is vice without the compressed air supply. To do this, proceed as follows:
depressurized Take protective measures:
1
- the cleaning cutter, lifting device, gas nozzle clamping device, wire cutter and
parting-agent injection nozzle could be activated. therefore, keep your body, es-
pecially hands, face 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 “Cleaning motor 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 de-
vice is depressurized
- If the cleaning device reacts to the rotation of the screw, the cleaning device is still
connected to the compressed air supply.
In this case, make sure that the cleaning device is disconnected from the com-
pressed air supply before starting any work and then ensure that the cleaning de-
vice is depressurized.
32
Before installation
EN-US
Intended Use The cleaning device is used exclusively to mechanically clean Fronius robot welding torch-
es in automatic mode within the limits of technical data, especially to clean the gas nozzle
and gas nozzle internal space. Any other use does not constitute proper use. The manu-
facturer shall not be liable for any damage resulting from such improper use.
Proper use also means

- Reading these Operating Instructions in their entirety
- Following all instructions and safety rules in these Operating Instructions
- Carrying out all the specified inspection and servicing work
Operating Per-
sonnel, Mainte- NOTE!
nance Personnel In all situations, the device must only ever be operated by one person.
It must also be ensured that there are no other people in the device's operating area while
it is in operation.
NOTE!
In all situations, the device must only ever be maintained by one person.
It must also be ensured that there are no other people in the device's operating area while
work on it is ongoing.
Setup Regula- The cleaning device has been tested according to protection class IP 21. This means:
tions - Protection against solid foreign bodies larger than Ø 12.5 mm (0.49 in.)
- Protection against dripping water falling vertically
The device should not be set up and operated outdoors. The installed electrical compo-
nents should be protected against direct exposure to moisture.
Specifications for To ensure the proper functioning of the cleaning device, fulfill the following specifications
the Compressed for the compressed air supply:
Air Supply - Set up a compressed air supply using the pressure relief valve and compressed air
filter
- Guarantee the compressed air quality in accordance with ISO 8573-1:2001, class 7 4
3, instrument air
- Solid particle concentration  10 mg/m3
- Pressure concentration point vapor  + 3°C
- Oil concentration  1 mg/m3
Measures to en- If untrained operating personnel have access to the device, the compressed air supply to
sure safe opera- the device must be disconnected for the duration of this access in accordance with "Per-
tion of the device formance Level d" of ISO 13849-1.
when operating
personnel are un- We recommend FESTO's MS6-SV soft-start and quick exhaust valve for interrupting the
trained compressed air supply as required.
33
Diagram of the programmable logic control (PLC)
Diagram of the
Bus module link: XXXXXXXX++ST010+IR001.ZM001-KF70
programmable
logic control Placement: XXXXXXXX++ST010+IR001.ZM001+.&EFA/1.4
(PLC) Type: ProfiNet MVK-Metall DO8 /DI8 PushPull MVK-MPNIO D08 / DI8
PushPull
Address: Symbolname: Function text:

4/
I777 ++ST010+IR001.ZM001-VQ01-BG01:4 Gas nozzle free
2/
I778 ++ST010+IR001.ZM001-VQ01-BG02:4 Gas nozzle clamped
4/
I779 ++ST010+IR001.ZM001-VQ01-BG03:4 Cleaning motor rotated (pulse
signal)
2/
I780 ++ST010+IR001.ZM001-VQ01-BG04:4 Parting agent container full
4/
I781 ++ST010+IR001.ZM001-VQ01-BG05:4 Cleaning motor bottom
2/
I782 ++ST010+IR001.ZM001-VQ01-BG06:4 Cleaning motor top
4/
I783 ++ST010+IR001.ZM001-VQ01-BG07:4 Wire cutter open
2/
I784 ++ST010+IR001.ZM001-VQ01-BG08:4 Wire cutter closed
4/
Q777 ++ST010+IR001.ZM001-VQ01-KK01:x1 Clamp gas nozzle/cleaning
motor on
2/
Q778 ++ST010+IR001.ZM001-VQ01-KK02:x1 Cleaning motor up/down
4/
Q779 ++ST010+IR001.ZM001-VQ01-KK03:x2 Spray in parting agent
2/
Q780 - -
4/
Q781 ++ST010+IR001.ZM001-VQ01-KK04:x2 Cut the wire electrode
34
Screwing the Cleaning Device to the Solid Surface
EN-US
Screwing the
cleaning device NOTE!
and work stand to Depending on the surface (foundation), different mounting materials may be re-
the surface quired to assemble the work stand.
The mounting materials for the work stand are not part of the scope of supply for the 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 mounting material delivered with the cleaning device to screw the cleaning
device to the work stand.
1 2
3 4
3 4
5 6
35
5
36
Welding Torch Cleaning Position
EN-US
Welding Torch
Cleaning Position
37
Adjusting the Gas Nozzle Clamping Device
Adjusting the gas

nozzle clamping CAUTION!
device An incorrectly set gas nozzle clamping device may damage the cleaning device and
the welding torch.
► When using gas nozzles with an outside diameter of 25 mm (0.98 inches), the gas noz-
zle clamping device must not be adjusted - the gas nozzle clamping device has already
been set for the use of gas nozzles with an outside diameter of 25 mm (0.98 inches)
as part of the factory calibration.
► When using gas nozzles with an outside 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.
NOTE!
Set the clamping device so that no reac-
tion forces can be transmitted to the ro-
bot.
Only clamp gas nozzles on a cylindrical sur-
face.
(1)
(3)
(2) 1 Loosen the Allen screws on guide bolts
(1) and (2)
(4)
2 Move the welding torch to the cleaning
position
- centric to the cleaning motor
3 Use the adjusting screw (3) to position
the clamping device (4) so that the
clamping device is positioned against
the gas nozzle
4 Tighten the Allen screws on guide bolts (1) and (2)
NOTE!
Only clamp the gas nozzle in a central position over the cleaning motor.
38
Fitting the Cleaning Cutter
EN-US
Fitting the clean-
ing cutter CAUTION!
Burning hazard due to hot cleaning cutter as a result of operation.
Before handling the cleaning cutter, allow it to cool to room temperature (+25°C, +77°F).
NOTE!
Only use contact tips, gas nozzles and cleaning cutters provided by the manufactur-
er.
Correct operation is not ensured if products made by other manufacturers are used. The
manufacturer accepts no liability for damage caused if contact tips, gas nozzles or cleaning
cutters made by other manufacturers are used.
NOTE!
The cleaning cutter is not included in the scope of supply.
Find the right cleaning cutter in the manufacturer’s Spare Parts List.
1 Remove the protective cover from the cleaning device

6
3 Mount the protective cover on the cleaning device so that it is in its original position
once again
39
Adjusting the Position of the Cleaning Motor
Adjusting the po- Remove protective cover (1)

1
sition of the
cleaning motor 2 Remove the gas nozzle from the torch
body
3 Loosen the screw (2) on the lifting de-
vice
4 Make sure that the lifting device (3) is
(1) in the bottom lift position
5 Position the welding torch in the clea-
ning position (approx. 1 - 2 mm/0.039 -
(2) 0.079 in. over the protective cover,
(3) central to the cleaning motor)
(6) (5) (4)
6 Manually slide the lifting device (3) to the top lift position and hold it in this position
7 Manually slide the cleaning motor (4) with cleaning cutter into the cleaning position
- see detail (5) for welding torches with insulating sleeve
- see detail (6) for welding torches with spatter guard
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 mo-
tor into the top position
- The cleaning cutter must surround the contact tip without colliding with it.
If the cleaning cutter is in contact with welding torch parts, adjust the position of
the cleaning motor
10 Fit the gas nozzle onto the torch body
11 Perform a function test with the gas nozzle fitted: Manually slide the cleaning motor
into the top position
- The cleaning cutter must plunge into the gas nozzle without colliding with it.
If the cleaning cutter is in contact with welding torch parts, adjust the position of
the cleaning motor
12 Mount the protective cover on the cleaning device so that it is in its original position
40
Setting up the Compressed Air Supply
EN-US
Setting up the Set up the compressed air supply:
cleaning device Disconnect the compressed air supply to the cleaning device and ensure that this
1
compressed air compressed air supply remains disconnected while the tasks described below are be-
supply, com- ing carried out on the device
pressed air relief
valve function 2 Screw the supplied compressed air relief valve on to the compressed air connection
on the cleaning device
3 Connect the compressed air supply to the compressed air relief valve
NOTE!
You can interrupt and restore the compressed air supply to the cleaning device by
moving the compressed air relief valve back and forth.
The illustration to the left shows the com-

pressed air relief valve closed = compres-
sed air supply to the device interrupted
The illustration to the left shows the com-

pressed air relief valve open = device is
being supplied with compressed air
41
Starting Up the Parting Agent Atomizer
Filling the parting

agent container (1 NOTE!
liter) and con- Only use the “Robacta Reamer” parting agent (item number 42,0411,8042) provided
necting it to the by the manufacturer.
cleaning device Its composition is specifically tailored for use with the cleaning device. Correct operation is
not ensured when other products are used.
1 2
1 2
3 4
3 4
42
5
EN-US
Connecting the
parting agent NOTE!
container (10 li- Only use the “Robacta Reamer” parting agent (item number 42,0411,8042) provided
ter) to the clean- by the manufacturer.
ing device Its composition is specifically tailored for use with the cleaning device. Correct operation is
not ensured when other products are used.
1 2
1 2 *
1
4
* Option (longer parting agent hose)
43
1
Setting the injec-

tion quantity of NOTE!
the parting agent To correctly set the injection quantity, the welding torch must be in the cleaning po-
atomizer sition.
1 Connect the cleaning device’s compressed air supply

2 Connect the device to the robot control
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
2
Fine-tune the injection quantity on the parting agent

adjusting controller
44
Starting up the fill-level control sensor
EN-US
General The fill-level control sensor releases a signal as soon as the fill level in the parting agent
container falls below a defined level.
Operating con-
trols and displays No. Function
on the sensor
(1) ‘OUT OFF’ key
to program the sensor
(2) (2) ‘OUT ON’ key

(1)
to program the sensor
(3)
(3) LED
shows the operating mode of the
sensor
- LED on/flashing: Sensor active
- LED off/ not flashing: Sensor inac-
tive
Performing empty Drain the parting agent container until

1
adjustment the parting agent is at least 20 mm
(0.787 in.) below the sensor
2 Connect the sensor to the power sup-
ply
20 mm (0.79 in.)
3 Hold the ‘OUT OFF’ key for at least 2

seconds, maximum 6 seconds
- The LED on the sensor flashes
slowly
- after releasing the ‘OUT OFF’ key,
2-6s the LED turns off once again - the
sensor has detected a low fluid le-
vel
45
Performing a full Fill the parting agent container with
1
adjustment parting agent
2 Hold the ‘OUT OFF’ key for at least 6

seconds
- The LED on the sensor first flas-
hes slowly and then faster after 6
seconds
- after releasing the ‘OUT OFF’ key,
>6s the LED turns off once again - the
sensor has detected a high fluid
level
Unlocking/lock-
ing the fill-level
control sensor NOTE!
To prevent the unintentional adjustment
of the fill-level control sensor, it is pos-
10 s 10 s sible 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 the ‘OUT OFF’ and ‘OUT ON’ keys for at least 10 seconds
- The LED status briefly changes
- if the LED is illuminated during unlocking, the LED briefly turns off after un-
locking
- if the LED is not illuminated during unlocking, the LED is briefly illuminated
after unlocking
46
Manually Checking the Cleaning Device Functions
EN-US
General
NOTE!
The cleaning device’s functions must be manually checked before starting the au-
tomatic cleaning process.
NOTE!
To correctly check the functions, the welding torch must be in the cleaning position.
Manually check-
ing the cleaning NOTE!
device functions 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 cleaning device’s compressed air supply
Spray in parting agent function

Check the following while the function is executed:
- The correct insertion depth of the gas nozzle into the parting agent injection device.
The correct insertion depth must be individually set depending on the gas nozzle
After the function has been executed, check the following:
- Whether the gas nozzle is adequately wetted with parting agent
1 1
3 4
Spray in parting agent Deactivate the function
47
Clamp gas nozzle/cleaning motor on
- The function of the gas nozzle clamping device
- The function of the cleaning motor
1 1
5 6
Clamp gas nozzle/cleaning motor on Clamp gas nozzle/cleaning motor on
Cleaning motor up/down function

- The insertion depth of the cleaning cutter into the gas nozzle
1 1
7 8
Cleaning motor up/down Deactivate the function
48
Start up the Cleaning Device
EN-US
Requirements for The following requirements must be met in order to start up the cleaning device:
Start-up Opera- - Cleaning device work stand screwed tightly to the surface
tion - Cleaning device screwed tightly to the work stand
- Gas nozzle clamping device set - not when using a gas nozzle with an outside diam-
eter of 25 mm (0.98 inches). For more info, see the “Adjusting the Gas Nozzle Clamp-
ing 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 location
intended
Start-up Opera- An active signal from the robot control starts up the cleaning device.
tion
49
Cleaning Program Sequence
Safety
CAUTION!
Danger of damage to property.
Only start automatic mode once the cleaning device has been installed and commissioned
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.
Always wet the inside of the welding torch with the manufacturer’s parting agent before
starting an automatic mode.
50
EN-US
Cleaning Pro-
gram Sequence ,QLFLR
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LSP
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9HORFLGDGFPV
LSP
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51
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OLPSLH]D
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'HPDQGDGHVDOLGDVH³DOGHVDOLGD
6LQWREHUDGHJDV
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6LQWREHUDGHJDV
PRWRUGHOLPSLH]DHQODSDUWHLQIHULRU 'HPDQGD EDMD
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LQIHULRU
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OLPSLH]D
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WHQVRUGHODWREHUDGHJDV
9HORFLGDGFPV
LSP
(VWDEOHFHU
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PRWRUGHOLPSLH]DHQFHQGLGRರ
(VWDEOHFHU
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52
EN-US
(VWDEOHFHU
3XUJDGHJDVGHDLUHDSUHVLµQFRQ
DQWRUFKDGHVROGDGXUD
5HVWDEOHFHU
(QWUDGDಯPRWRUGHOLPSLH]DDELHUWRರ
WDQSURQWRFRPRODVH³DOಯPRWRUGH
OLPSLH]DDELHUWRರHVW«DOWD
5HVWDEOHFHU
(QWUDGDಯ7REHUDGHJDVGHODEULGD
PRWRUGHOLPSLH]DHQFHQGLGRSXUJD
GHJDVGHDLUHDSUHVLµQFRQDQWRUFKD
GHVROGDGXUDರWDQSURQWRFRPROD
VH³DOಯ0RWRUGHOLPSLH]DHQODSDUWH
LQIHULRUರHVW«DOWD
'HPDQGD EDMD
6LQWREHUDGHJDV
7REHUDGHJDVFRQWHQVRU
%DMDRDOWD
'HWHQHU
6DOLGDGHGHPDQGD DOWD
6LQWREHUDGHJDV
0RYHUDODSRVLFLµQ$
FHQWUDOPHQWHVREUHHO
GLVSRVLWLYRGHOLPSLH]D
9HORFLGDGFPV
LSP
0RYHUDODSRVLFLµQ(
FHQWUDOPHQWHVREUHHO
GLVSRVLWLYRGHLQ\HFFLµQGHOO¯TXLGR
DQWLSUR\HFFLRQHV
9HORFLGDGFPV
LSP
53
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SRVLFLµQGHLQ\HFFLµQ
DSUR[ದPPದLQGH
SURIXQGLGDGGHQWURGHOGLVSRVLWLYRGH
LQ\HFFLµQ9HORFLGDGFPV
LSP
(VWDEOHFHU
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(VSHUDUVHJXQGRV
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DQWLSUR\HFFLRQHVರ
0RYHUDODSRVLFLµQ(
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54
Cleaning Device Signal Sequences
EN-US
Cleaning device
signal sequences 24 VDC
(1)
0 VDC
(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
55
Wire Cutter Signal Sequence
Wire cutter signal

sequence (1) 24 VDC
0 VDC
(2)
(3)
(1) Cut the wire electrode
(2) Wire cutter open
(3) Wire cutter closed
56
Service, maintenance and disposal
Safety
EN-US
Safety Please follow the safety rules below during all the tasks described in the "Service, Mainte-
nance, and Disposal" chapter.
WARNING!
damage to property.
WARNING!
WARNING!

zle
WARNING!

zle
59
CAUTION!
1
60
Service, maintenance and disposal
EN-US
General The cleaning device does not usually require maintenance. To ensure the cleaning device
remains operational over time, there are a number of care and maintenance tasks that
need to be carried out, however:
Before every - Check the fill level in the parting agent container and top up the parting agent container
start-up if necessary
- Check the fill level in the parting agent collecting container and drain the parting agent
collecting container if necessary
- Check for wear of the cleaning cutter and replace the cleaning cutter if necessary
- Drain the cleaning device’s collecting container
- Drain the wire cutter’s collecting container, if in use
- In general, you should visually inspect the cleaning device and ensure that any dam-
age is repaired immediately (before commissioning)
Daily
NOTE!
Only use solvent-free cleaning products on the cleaning device.
- Remove parting agent deposits and dirt from device
Weekly
NOTE!
Only clean the parting agent container with cleaning products that are free of sol-
vents.
- Check the parting agent container and parting agent collecting container for contami-
nation and clean if necessary
- Blow out the intake filter in the parting agent container from the inside out with com-
pressed air using the intake hose (“Starting Up the Parting Agent Atomizer” chapter)
Every six months Open the device and check the pneumatic valves to ensure
- no leaks
- that all screws are screwed tightly in place
- that all screw joints are fixed firmly in place on the pneumatic valves
Whenever re- Open the device and

quired - blast the inside of the device clean with dry and reduced compressed air
- lightly oil the guides on the lifting device's lifting cylinder
Disposal Materials should be disposed of according to valid national and regional rules.
61
62
Troubleshooting
Safety
EN-US
Safety Please follow the safety rules below during all the tasks described in the "Troubleshooting"
chapter.
WARNING!
damage to property.
WARNING!
WARNING!

zle
WARNING!

zle
65
CAUTION!
1
66
Troubleshooting
EN-US
Errors in the Pro- Parting agent is not sprayed in
gram Sequence Parting agent container is full
Cause: Injection quantity too low

Remedy: Adjust the injection quantity (injection time or parting agent adjusting control-
ler)
Cause: Intake filter of the parting agent hose in the parting agent container is contam-
inated
Remedy: Clean the intake filter of the parting agent hose with compressed air (see
“Starting Up the Parting Agent Atomizer” chapter)
Cause: No signal from robot

Remedy: Check robot program
Cause: Parting-agent injection nozzle blocked

Remedy: Clean the parting-agent injection nozzle
Notify the service team (parting-agent injection nozzle needs replacing)
Cause: Vacuum pump defective

Remedy: Contact service team (vacuum pump needs replacing)
Cause: Solenoid valve has mechanical fault

Remedy: Contact service team (solenoid valve needs replacing)
Welding torch has been poorly cleaned or is damaged

Cause: Position of the cleaning motor incorrectly set
Remedy: Correctly set the position of the cleaning motor
Cause: Gas nozzle is clamped in incorrect position

Remedy: Adjust the gas nozzle clamping device
Cause: Cleaning cutter does not fit the welding torch geometry
Remedy: Fit a correct cleaning cutter
Cause: Cleaning cutter worn

Remedy: Replace cleaning cutter
67
Lifting device does not move up or down
Cause: Compressed air relief valve closed
Remedy: Open compressed air relief valve


Cause: Throttle valve cannot be adjusted or is faulty

Remedy: Contact service team (throttle valve needs replacing)
Cause: Seal on lifting cylinder is faulty

Remedy: Contact service team (lifting cylinder needs replacing)
Cleaning motor not working

Cause: Compressed air relief valve closed
Remedy: Open compressed air relief valve

Cause: Cleaning motor has mechanical fault

Remedy: Contact service team (cleaning motor needs replacing)

68
Technical Data
Technical Data
EN-US
Robacta Reamer
Supply voltage + 24 V DC
X-Line J, Robacta
Reamer X-Line J Nominal output 10.8 W
Alu Nominal pressure 6 bar
86.99 psi
Air consumption 420 l/min
443.81 qt./min
Standard I/O (X1) Input: + 24 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 1l
.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 10.5 kg
(not including parting agent and optional wire cut- 22.15 lb.
ter)
71
72
Appendix
Spare parts list: Robacta Reamer X-Line J, Robacta
Reamer X-Line J Alu
Robacta Reamer X-Line J 44,0450,1969

Robacta Reamer X-Line J Alu 44,0450,1996

HU $OX
OLW U
H
OLW 7&3

PP
PP

PP

PP

$OX

09.
09.

74
Wire Cutter Robacta Reamer X-Line J 44,0450,1029

75
Circuit diagrams: Circuit Diagram for Robacta
Reamer X-Line J, Robacta Reamer X-Line J Alu
-X1
Gasdüse spannen
13 -XS0
Motor dreht
1
14 NC
-Y1
WHITE 2
15 Q778
A1
A2
BLUE 3
16 0V
BLACK 4
Q777
5
PE
auf / ab
-Y2
Motor
A1
A2
-XS1
1
NC
2
Q780
BLUE 3
0V
4
Einsprühen
BLACK
Q779
-Y3
5
PE
A2
A1
-XS2
1
NC
2
-X2 Q782
BLUE 3
6 0V
Draht schneiden
BLACK 4
5 Q781
-Y4
5
PE
A2
A1
Spannzylinder GasdüseSpannzylinder Gasdüse
1 -XS4
BROWN 1
-X1 +24V US
WHITE 2
-B1
1 I778
frei
3 BLUE 3
2 0V
4 BLACK 4
3 I777
5
4 PE
5
1 6
gespannt
-B2
3
4
Motor dreht Impuls
1
+A1 Y-Verteiler
+A1-X1
BROWN
-B3
1
3 BLUE +A1-X3 -XS5
3 1
4 BLACK
1 +24V US
4 2
2 I780
3
3 0V
+A1-X2 4
4
Trennmittel Kontrolle
BROWN I779
1 1 5
BLUE
3 5 PE
BLACK
-B4
4
3
4
1 -XS6
BROWN 1
Motor unten
-X1 +24V US
WHITE 2
-B5
7 I782
3 BLUE 3
8 0V
4 BLACK 4
9 I781
5
10 PE
11
1 12
Motor oben
-B6
3
4
Drahtschneider offen
1 -XS7
BROWN 1
-X2 +24V US
WHITE 2
-B7
1 I782
3 BLUE 3
2 0V
4 BLACK 4
3 I781
5
4 PE
Draht geschnitten
1
-B8
3
4
76
23
03 20 35 61
26
03 - Spannzylinder
12 - Magnetventil -Y1 Spannen/Motor ein
34 13 - Magnetventil -Y2 Motor auf/ab
14 - Magnetventil -Y3 Einsprühen
32 15 - Magnetventil -Y4 Drahtabschneider
20 - Pneumatikmotor
23 - Aluminiumzylinder Einsprühen
37 36
26 - Einsprühdüse
33 30 - Kunststoffflasche ohne Verschraubung
31 - Kunststoffflasche mit Ferder in Rückschlagventil
31
30 32 - Venturidüse mit Rückschlagventil
33 - Rückschlagventil mit Feder
33
34 - Drosselventil
35 - Schiebeeinheit
36 - Drosselrückschlagventil
77
bacta Reamer X-Line J Alu
37 - Drosselrückschlagventil
-Y1 -Y2 -Y3 -Y4 44 - Luftanschluss
14 47
12 13 15 47 - Filter Ansaugung
61 - Schiebeeinheit
44
6bar/87psi
GASDÜSE SPANNEN MOTOR EINSPRÜHEN DRAHTABSCHNEIDER
MOTOR DREHT AUF / AB DA-10
Pneumatic Plan for Robacta Reamer X-Line J, Ro-
Declaration of conformity
EU-KONFORMITÄTSERKLÄRUNG 2017
EU-DECLARATION OF CONFORMITY 2017
DÉCLARATION UE DE CONFORMITÉ, 2017
Wels-Thalheim, 2017-06-07
Die Firma Manufacturer La compagnie
FRONIUS INTERNATIONAL GMBH

Froniusstraße 1, A-4643 Pettenbach
erklärt in alleiniger Verantwortung, Hereby certifies on its sole se déclare seule responsable du fait
dass folgendes Produkt: responsibility that the following que le produit suivant:
product:
Robacta Reamer X-Line J Robacta Reamer X-Line J Robacta Reamer X-Line J

(Alu) (Alu) (Alu)
Gasdüsenreinigungsgerät Gas nozzle cleaner Appareil de nettoyage de buses gaz
auf das sich diese Erklärung which is explicitly referred to by this qui est l’objet de la présente
bezieht, mit folgenden Richtlinien Declaration meet the following déclaration correspondent aux
bzw. Normen übereinstimmt: directives and standard(s): suivantes directives et normes:
Richtlinie 2014/30/EU Directive 2014/30/EU Directive 2014/30/UE

Elektromag. Verträglichkeit Electromag. compatibility Électromag. Compatibilité
Richtlinie 2006/42/EG Directive 2006/42/EC Directive 2006/42/CE

Maschinenrichtlinie Machinery Directive Directive aux machines
Europäische Normen inklusive European Standards including Normes européennes avec
zutreffende Änderungen relevant amendments amendements correspondants
EN ISO 12100:2010 EN ISO 12100:2010 EN ISO 12100:2010
EN 62311:2008 EN 62311:2008 EN 62311:2008
EN 61000-6-2:2005+AC:2005 EN 61000-6-2:2005+AC:2005 EN 61000-6-2:2005+AC:2005
EN 61000-6-4:2007+A1:2011 EN 61000-6-4:2007+A1:2011 EN 61000-6-4:2007+A1:2011
Die oben genannte Firma hält Documentation evidencing En tant que preuve de la satisfaction
Dokumentationen als Nachweis der conformity with the requirements of des demandes de sécurité la
Erfüllung der Sicherheitsziele und the Directives is kept available for documentation peut être consultée
die wesentlichen Schutzanforder- inspection at the above chez la compagnie susmentionnée.
ungen zur Einsicht bereit. Manufacturer.
Dokumentationsverantwortlicher: person responsible for documents: responsable documentation:

(technische Dokumentation) (technical documents) (technique documentation)
Ing. Josef Feichtinger Ing. Josef Feichtinger Ing. Josef Feichtinger

Günter Fronius Straße 1 Günter Fronius Straße 1 Günter Fronius Straße 1
A - 4600 Wels-Thalheim A - 4600 Wels-Thalheim A - 4600 Wels-Thalheim
2017 ppa. T. Herndler, MAS

Member of Board
Chief Production Officer
DE German Deutsch EN English English FR French Française
78
79
FRONIUS INTERNATIONAL GMBH
Froniusplatz 1, A-4600 Wels, Austria
Tel: +43 (0)7242 241-0, Fax: +43 (0)7242 241-3940
E-Mail: sales@fronius.com
www.fronius.com
www.fronius.com/addresses
Under http://www.fronius.com/addresses you will find all addresses
of our Sales & service partners and Locations

42,0426,0240, Ea

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/ Perfect Charging / Perfect Welding / Solar Energy

Operating controls, connections and mechanical components 21

Installation and Startup 29

Service, maintenance and disposal 57

Technical Data ........................................................................................................................................... 71

All safety and danger notices on the device must

Proper use also means

Temperature range of the ambient air:

Ambient air: free of dust, acids, corrosive gases or substances, etc.

Altitude above sea level: up to 2000 m (6500 ft.)

The safety-conscious work of the personnel must be checked regularly.

Particular Hazard Do not linger in the operating area of the robot.

EMC Device Clas- Devices in emission class A:

Devices in emission class B:

EMC device classification as per the rating plate or technical data.

Supporting measures to avoid EMC problems:

Never bypass or disable safety devices.

- Only use appropriate original parting agents from the manufacturer.

A safety inspection by a certified electrician is recommended:

Copyright Copyright of these operating instructions remains with the manufacturer.

Warning notices on the cleaning device

WARNING! Danger of serious injuries due to:

(1) Work stand

(1) Gas nozzle clamping device

(2) Parting agent injection device

(3) Parting-agent injection nozzle

(4) Cleaning cutter

(5) Protective cover

(6) Wire cutter

(7) Cleaning motor

(8) Lifting device

(1) Parting agent adjusting controller

(2) Connection area for robot control

(3) Compressed air connection

(4) Parting agent collecting container

(5) Parting agent container

(6) Fill-level control sensor

(1) “Spray in parting agent” screw

(2) “Lifting device up/down” screw

(3) “Clamp gas nozzle/cleaning motor on” screw

(1) Bus system connection

(2) Bus system connection

(3) Bus system connection

(4) Bus system connection

Connections for robot control

► moving mechanical parts

► the rotating cleaning cutter

Proper use also means

Address: Symbolname: Function text:

Adjusting the gas

4 Tighten the Allen screws on guide bolts (1) and (2)

1 Remove the protective cover from the cleaning device

Adjusting the po- Remove protective cover (1)

(6) (5) (4)

The illustration to the left shows the com-

The illustration to the left shows the com-

Filling the parting

* Option (longer parting agent hose)

Setting the injec-

1 Connect the cleaning device’s compressed air supply

Fine-tune the injection quantity on the parting agent

(2) (2) ‘OUT ON’ key

Performing empty Drain the parting agent container until

PP