MWR Reamer 08/01/2010

MWR Reamer 08/01/2010 Operating Instructions and Spare Parts List Torch Nozzle Cleaning Device for Robotic Mig Welding System Registration Purchaser: Address; City State Zip Phone: Email: Contact: Purchased from: Midwest Robotics LLC. Address; 12224 Plymouth GoshenTrail City Plymouth State IN. Zip 46544 Phone: 574-276-5016 Email: kkeifer@mwrobotics.com Contact: Customer Service System Serial Number Date of Purchase / / PO No. Robot Mfgr. Robot Model Register ; Email the information above to kkeifer@mwrobotics.com or mail a copy to Midwest Robotics 1205 Industrial Dr. Mishawaka, IN 46544 2010 All Rights Reserved

Contents Page Safety Precautions... 1 Preparation / Mounting... 1 Electrical / Air Supply / Wire Cutter... 1 Operation / Maintenance... 2 Illustrations...... 3 Parts List... 4 Reamer Blade List... 5-8 Schematic... 9 Troubleshooting... 10 Wire Cutter (optional)... 11 Introduction: The product you have purchased has been carefully manufactured, assembled and factory performance tested.this manual contains operational instructions and parts lists for this product. While every precaution has been taken to assure the accuracy of this manual Midwest Robotics, and the manufacturer, assume no responsibility for errors or ommissions. Midwest Robotics assumes no liability for damages resulting from the use of the information contained herein and shall have no liability to the buyer / user for consequential damages or be liable to the buyer / user in any tort action for any neglect in the manufacture of the goods or for the ommission of any warning. The CE mark certifies that a product has met EU consumer safety, health or environmental requirements. Warranty: Warranty is extended to the original purchaser of the product from Midwest Robotics for a period of 15 months from the date of purchase upon the following conditions: Purchaser registers the product with Midwest Robotics by mail or email at kkeifer@mwrobotics.com and includes the following information: Purchaser s Name, Address & Phone Number; Date of Purchase, PO Number, Model & Serial Number, Distributor / Supplier s Name, Address, Phone Number; Purchaser warrants that installation includes the recommended FRL air supply system part #220.110, installation is performed by a qualified technician and that all installation recommendations listed in the owners manual are adhered to. Any Midwest Robotics product found to be defective because of material or workmanship under normal circumstances and intended use within the 15 month period will, at Midwest Robotics discretion, be repaired, replaced or issued credit for the purchase price of the product excluding taxes and delivery costs. Upon written notification from the original purchaser of a possible defect or failure Midwest Robotics will issue an RMA number and instructions for the merchandise return. Return freight, handling or other charges necessary to return any product are the responsibility of the purchaser. Upon verification of the claim appropriate adjustments will be made. For safety and performance reasons only genuine Midwest Robotics parts must be used or this warranty may become void.

MWR REAMER Electro-Pneumatic Torch Cleaning Station Product Description: MWR REAMER Torch Cleaning Station designed for automatic cleaning of the interior and face of the gas nozzles of Robotic MIG Welding Torches Model Dimensions Weight Ambient temperature Protection to DIN 40050 Air connection Internal dia. Nominal Air Pressure (Clean shop air) Operating Air Pressure Nominal flow Nominal stroke and rotation 5/2-way valves Rated voltage Power consumption Relative operating time Current consumption Inductive proximity switch, normaly-open contact, (pnp) Operating voltage Permitted residual ripple Continuos current MWR REAMER Electro-Pneumatic 13.8 x 8.1 x 7.8 (350 x 206 x 200 ) 20 lbs. (9 kg) +5 bis +50 IP 21 ¼ NPT minimal ø6 mm 100 psi.(7 bar) 90-120 psi 8 SCFM (18 Litre/sec.) 2 (90mm) 1500-2000 rpm 24 VDC 4,2 W 100% ED 105 ma 10-30 V DC Vss < 10% 1,5 W

Safety Precautions 1. 1. The torch cleaning unit is constructed to the latest state of the art and is safe to operate provided: It is correctly installed and maintained by qualified personnel and the safety specifications of the relevant city, state & country are observed. 2. Installation, commissioning and maintenance shall be performed only by authorised personnel and all safety precautions outlined in these Operating Instructions shall be observed. 3. This product shall be integrated into a higher safety system by plant engineering if the installation site is within a secured area which has to be entered for assembly or maintenance work. In this case it shall also be ensured that the complete cell is shut down and remains locked out against inadvertent operation, e.g. due to control malfunction. 4. The torch cleaning unit is to be used only for torch cleaning within the parameters of its technical specification. 5. The specified operating pressure shall not be exceeded. 6. When used independently, the torch cleaning unit only is operated with covers closed. 7. Keep hands clear of the area of the clamp and reamer operating space. 8. When making adjustment, shut off the air supply so that the equipment is unpressurised. 9. Additional fittings not offered as accessories may only be fitted with manufacturers approval. 10. If it is intended to use the torch cleaning unit in an environment with corrosive or aggressive vapours or liquids, approval of the manufacturer shall be obtained. 11. When shutting down a system, it shall be ensured that there is no handling equipment (e.g. robot) in the torch cleaning unit. Preparation Before starting installation work in the area of the robot ensure, for your personal safety, that all protective measures have been taken and will remain in place when personnel are in the area of the robot. Mounting Secure the torch cleaning unit to a vibration-free base, or to the optional mounting stand. The torch cleaning unit can be mounted, with certain limitations, in any position and direction, but a completely trouble-free operation can only be guaranteed when the system and air filter/regulator/oiler are installed in the vertical position. Electrical Socket 5 Pin Terminal 1 = Input signal from Robot, +24 vdc IF Terminal 2 is 0 vdc. Terminal 2 = Input signal from Robot, 0 vdc IF Terminal 1 is +24vdc. NOTE: Values for terminals 1 & 2 are reversible. Terminal 3 = Not Used, Open Terminal 4 = +24 vdc Output from cleaning station to Robot Terminal 5 = Ground Terminal 1 + 2 on cord set must be connected to the Robot Output cable. The duration of the signal determines the length of time the reaming motor is active. Terminal 3 is open and unused. Terminal 4 on the cordset must be connected to the Robot Input receiving a 24 vdc signal from the cleaning station. This signal indicates cleaning is complete. Terminal 5 is the Ground terminal.

Air Supply: 2. The cleaning station requires 90-120 PSI clean, lubricated, water free shop air @ 8 S.C.F.M. minimum. The system is equipped with a ¼ NPT female fitting for the air supply connection. For best performance the use of the Air Filter/Regulator/Lubricator, part number 202.110 is required. Wire Cutter (optional) When equipped with a wire cutter a 0.5 second signal from the robot is required to activate the cutter air solenoid as the wire passes through the cutter blades. Reamer Blade: Select the appropriate reamer blade for the application. The reamer blade ID. should be (1mm) larger than the contact tip OD. The reamer blade OD should be (1mm) smaller than the nozzle ID. Standard reamer blades have a 3/8-24 RH internal thread. The reamer blade should be hand tightened against the jam nut on the motor shaft then the jam nut should be secured against the reamer blade. Nozzle alignment: Correct alignment of the welding nozzle is critical for proper operation. The clamping V- Block must be adjusted to center the nozzle above the reamer blade when the clamp is closed. The V-Block may be adjusted by turning the set screw in or out as required. Side to side adjustment is normally not required as this is fixed at the factory. a. Reaming depth (reamer insertion into the nozzle) is controlled by the robot positioning. Adjustments may be made by the robot programmer with respect to the nozzle positioning by the robot. Additional depth adjustment may be made by adjusting the reamer motor up or down within the motor holding fixture. b. CAUTION! Avoid interference with the reamer blade, nozzle, contact tip, insulators or torch neck. Damage to the reamer blade, components or torch may occur Anti-Spatter Solution: Anti spatter solution is retained in the container mounted on the rear of the system. Container holds approximately 1 quart of liquid. Solvent base formulas are recommended. Operation: Cycle time for the reaming process is controlled by the robot. With the robot signal on the V-Block clamp secures the nozzle, the reamer starts upward travel and the blade begins rotation. The reamer travels upward to it maximum stop and remains there as long as the signal is applied. When the signal is turned off the reamer begins downward travel with the blade continuing to rotate and the nozzle clamp still closed. Upon reaching the bottom of its stroke the reamer blade will stop rotating and the nozzle clamp will open. When the V-Block nozzle clamp is open the robot receives a 24vdc signal telling it that it may remove the torch from the cleaning station. Anti-Spatter Spray is automatically dispensed as the reaming action is completed. The sprayer may be manually operated by pressing the test button on the side of the unit. Feed Rate up and down may be controlled by adjusting the flow control fittings located inside the unit. The top fitting controls the (up) rate the lower fitting controls the (down) rate. Maintenance - Weekly or as required (1) Empty & wipe clean the catch pan if supplied (2) Check anti-spatter fluid level, drain & clean tank and refill as required (3) Check hoses & fittings for leaks (4) Check air pressure & oiler if supplied (5) Check reamer blade / nozzle alignment (6) Check reamer blade for damage / wear (7) Check that mounting bolts are secure (8) Check electrical cable for cuts or damage (9) Check electrical connections (10) Operate cleaning station manualy (Robot shut down and Locked Out) to confirm proper operation.

Torch Cleaning Station Type MWR REAMER 3. 6 1. 7 12 2 14 16 21 17 10 15 9 27 26.1 39 25 26 4 28

Spare parts list MWR REAMER 4. Pos Ref.-No. Order Number Description 1 3000.031 C 3000.031C Clamping unit 2 4000.0008 4000.0008 Limit Switch 30vdc 200mA 4 5000.0010S 5000.0010S Pneumatic motor Spray through 6 5000.2000 2-234B-12-MP Manual Anti-spatter valve 7 5000.1111 2-4-12-v v Venturi valve 9 5000.1113 2-4-20 Anti-Spatter tank w/fittings 10 4000.0002 4000.0002 5/2 way valve 12 4-234B-16-EPV-A1 4-234B-16-EPV-A1 Solenoid valve 24VDC / Manual 14 T000.0007C T000.0007C Lifting unit 15 4000.0006 4000.0006 Control valve up 16 4000.0006 4000.0006 Control valve down 17 Air connection 21 4000.0003 5-234B-16-ES 5 Pole cable socket 22 4000.0007 5-5-234B 5 Pole machine plug Not pictured 25 3000.0030 Spray nozzle 26 26.1 500.695 3000.0035 500.695 3000.0035 Wire cutter PDA-92 (optional) Replacement cutter blades (2x) 27 5000.0009 5000.0009 Actuator valve 28 201.110 201.110 Air Filter / Regulator / Lubricator 39 See List Reamer Blade

Reamer Blades for Torch Cleaning Stations 5. Reamer blades dimensions: The reamer id. (d1) should be 1.0mm larger than the contact tip od. (D1). The reamer od. (d) should be 1.0mm smaller than the nozzle id. (D). Reamer Blade- Model A 1 Cutting Blade D D1 d d1 Order Code 10 6 9 7 600.009-07 11 6 10 7 600.010-07 12 6 11 7 600.011-07 13 6 12 7 700.012-07 13 8 12 9 700.112-09 14 6 13 7 700.013-07 14 8 13 9 700.113-09 15 8 14 9 700.014-09 15 10 14 11 700.114-11 16 8 15 9 700.015-09 16 10 15 11 700.015-11 17 10 16 11 700.016-11 18 10 17 11 700.017-11 19 10 18 11 700.018-11 20 10 19 11 700.019-11 21 10 20 11 700.020-11 22 10 21 11 700.021-11 23 10 22 11 700.022-11 Reamer Blade - Model B 2 Cutting Blades D D1 d d1 Order Code 10 6 9 7 801.100-07 11 6 10 7 801.110-07 12 6 11 7 801.211-07 13 6 12 7 801.312-07 13 8 12 9 801.112-09 14 6 13 7 801.413-07 14 8 13 9 801.113-09 15 8 14 9 801.514-09 15 10 14 11 801.114-11 16 8 15 9 801.515-09 16 10 15 11 801.115-11 17 10 16 11 801.716-11 18 10 17 11 801.817-11 19 10 18 11 801.918-11 20 10 19 11 801.019-11 Note: Reamer blade adaptors may be required when used with Tregaskiss or Abicore Binzel cleaning stations. Adaptor for Tregaskiss - Part #100.TREG Adaptor for Abicore Binzel - Part #100.ABIC

Reamer Blades Abicore/Binzel Torch Cleaning Stations 6. Reamer blades dimensions: The reamer id. (d1) should be 1.0mm larger than the contact tip od. (D1). The reamer od. (d) should be 1.0mm smaller than the nozzle id. (D). Reamer Blade Abicore Binzel-Design D D1 d d1 Order Code 10 6 9 7 700.109-07 11 6 10 7 700.110-07 12 6 11 7 700.111-07 13 6 12 7 700.212-07 13 8 12 9 700.312-09 14 6 13 7 700.213-07 14 8 13 9 700.313-09 15 8 14 9 700.214-09 15 10 14 11 700.314-11 16 8 15 9 700.215-09 16 10 15 11 700.315-11 17 10 16 11 700.116-11 18 10 17 11 700.117-11 19 10 18 11 700.118-11 20 10 19 11 700.119-11 21 10 20 11 700.120-11 22 10 21 11 700.121-11 23 10 22 11 700.122-11 If necessary you may order with the original Abicore Binzel part number. End Mill for Reamer Blades Fit Most Manufacturers Reamer Blades d [mm] A [mm] Order Code 9 15-30 702.009 10 15-30 702.010 11 15-30 702.011 12 15-30 702.012 13 15-30 702.013 14 15-30 702.014 15 15-30 702.015 16 15-30 702.016 17 15-30 702.017 18 15-30 702.018 19 15-30 702.019 20 15-30 702.020 21 15-30 702.021 22 15-30 702.022

Reamer Blades for Torch Cleaning Stations 7. MK- Reamer Blade, Adjustable D [mm] D1 [mm] Order Code 11 6 611.620 12 6 612.620 13 6 613.620 14 6-8 614.625 15 6-8 615.625 16 8-10 616.825 17 8-10 617.825 18 8-10 618.825 19 8-10 619.825 20 8-10 620.825 Reamer Blades for MK-Reamer Length Wide Order Code 65 8 100.103 35 8 100.104 Brush for Aluminium Description Order Code Brush holder 100.200 Brush 100.201 Adapter for Reamer Blades Model A + B Mfgr. A [mm] Order Code ABB Tregaskiss 100.085 100.TREG 3/8-24 m / fm 3/8-24 m / m

Reamer Nozzle Face Brush 8. Brush for Reamer Blades Model A + B, Reamer-ø d [mm] Order Code 9 9,2 100.209 10 10,2 100.210 11 11,2 100.211 12 12,2 100.212 13 13,2 100.213 14 14,2 100.214 15 15,2 100.215 16 16,2 100.216 17 17,2 100.217 18 18,2 100.218 19 19,2 100.219 20 20,2 100.220 21 21,2 100.221 22 22,2 100.222 Brushes (spare parts) (Price for 6 pcs.) Order Code ø 3 x 24 100.206 If ordering reamers for other models (for example, ABB, Abicore Binzel, Cloos, Kuka) a drawing OEM order code may be needed. Note: Prices are subject to change without notice.

MWR REAMER Wiring Schematic as of 6.10.2010 9. The MWR REAMER wiring plan allows for sinking or sourcing connections to all brands of robots.

Trouble-shooting 10. Fault Motor does not go up Motor does not go down Cause 1. No voltage to control valve 2. Valve is not reversing 3. One-Way restrictor B faulty or not properly adjusted 4. Solenoid valve not in O position with voltage disconnected 5. Leaking seals in cylinder Remedy Check 24vdc on control valve Replace faulty valve Replace restrictor Replace faulty valve Replace seals Motor does not turn No anti-spatter spray 1. Motor damaged due to water or dirt in air line 2. 5/2 way valve faulty 3. No air / Low air pressure 1. Supply tank empty 2. Wrong anti-spatter liquid 3. Spray nozzle clogged 4. 5/2 way valve faulty 5. Signal interrupter faulty Replace motor Replace valve Check air supply pressure & volume Refill supply tank Replace liquid Clean / Replace Replace valve Replace Interrupter Too much / too little anti-spatter spray 1. Control Valve not adjusted Adjust valve Robot does not go IN or OUT of cleaning position 1. Clamping Cylinder limit switch no signal Check voltage/ replace Limit switch

11. MWR-PDA92: Part # 500.695 Actuator Valve: Part # 500.695.100 Cutting Blade Set: Part # 500.695.300 Capacity.023 -.062 (0.6 1.6mm) Supplied Air: 80-120 psi clean shop air / 8 S.C.F.M. The AE-PDA92 welding wire trimming device is designed to trim cut welding wire at a predetermined length providing correct stick out at the gas shield nozzle of Robotic Mig welding torches. The MWR-PDA92 device may be actuated by robot signal to a pneumatic control device sending pressurized air to the diaphragm or, actuation may be by means of a pneumatic control mounted to the wire trimmer as shown above. Installation: 1. Mount the wire trimmer directly to the MWR REAMER nozzle cleaning station or to any remote location within reach of the robot. 2. Provide clean, lubricated, water free shop air at a rate of 80-120 psi to the air inlet of the actuator control mounted atop the wire trimmer. Note: In some cases the device may be controlled by a signal from the robot to an internal control within the cleaning station. Contact the cleaning station manufacturer for details. 3. Program the robot to slowly passing the protruding welding wire directly between the cutter blades. 4. Adjust the actuator valve arm so that the wire is trimmed in the center of the cutting blades. Maintenance: NOTE: Maintenance should only be performed after the robot cell has been shut down and locked out and only by qualified personnel. 1. Wipe down to remove excessive oil and dirt. 2. Inspect air connections, lines and fittings for damage or leaks. 3. Check alignment of cutting blades to robot wire position. 4. Check condition of cutting blades. Replace as necessary. 5. Apply a light lubricant to pivot points.