Fronius Robacta TC 2000 Operating Instructions & Spare Parts
Welding torch cleaning
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Also See for Robacta TC 2000:
- Operating instructions manual (80 pages) ,
- Operating instructions manual (76 pages)
Table of Contents
Troubleshooting
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Summary of Contents for Fronius Robacta TC 2000
- Page 1 / Perfect Charging / Perfect Welding / Solar Energy Operating Instructions Robacta TC 2000 Spare parts list Robacta TC 2000 Twin Welding torch cleaning Robacta TC 2000 US Robacta TC 2000 Twin US 42,0426,0135,EN 015-14082018...
- Page 3 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 familiarise yourself with the product. Reading the instructions carefully will enable you to learn about the many different features it has to offer.
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Page 5: Table Of Contents
Functional principle ..........................Magnetic flux densities within the cleaning coil for Robacta TC 2000, Robacta TC 2000 US ....Magnetic flux densities within the cleaning coil for Robacta TC 2000 Twin, Robacta TC 2000 Twin US 22 Scope of supply and options........................ - Page 6 Bolting the cleaning device to the underlying surface (foundation)............Screwing the cleaning device and installation stand to the underlying surface (foundation) ....Connecting the mains cable - Robacta TC 2000 US, Robacta TC 2000 Twin US ........Connecting the mains cable........................
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Page 7: Safety Rules
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 electromagnetic cleaning of Fronius weld- ing torches. Any use above and beyond this purpose is deemed improper. The manufac- turer shall not be held liable for any damage arising from such usage. -
Page 8: Environmental Conditions
Environmental Operation or storage of the device outside the stipulated area will be deemed conditions as not in accordance with the intended purpose. The manufacturer shall not be held liable for any damage arising from such usage. Ambient temperature range: 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) Relative humidity:... -
Page 9: Protecting Yourself And Others
Protecting your- Electromagnetic fields may pose as yet unknown risks to health: self and others Effects on the health of persons in the vicinity, e.g. those with pacemak- ers, metallic implants and hearing aids Forbidden for anyone wearing a pacemaker: people fitted with a pace- maker must consult their doctor before working with the device or entering its immediate vicinity Forbidden for anyone with metal implants: people fitted with metal im-... -
Page 10: Risks From Mains Current And Operating Current
Risks from mains An electric shock is potentially life threatening and can be fatal. current and oper- Do not touch live parts either inside or outside the device. ating current All cables and leads must be secured, undamaged, insulated and adequately dimensioned. -
Page 11: Emc Measures
EMC measures Warning, electromagnetic field. Electromagnetic fields may pose as yet un- known risks to health. It is the operator's responsibility to ensure that no electromagnetic interference occurs in electrical and electronic devices. If electromagnetic interference is detected, the operator is obliged to take ac- tion to rectify the situation. -
Page 12: Safety Measures In Normal Operation
Use internal directives and checks to ensure that the workplace environment is always clean and clearly laid out. Only set up and operate the device in accordance with the degree of protec- tion shown on the rating plate. When setting up the device, ensure an all-round clearance of at least 0.5 m (19.69 in.) from any surrounding objects, e.g. -
Page 13: Commissioning, Maintenance And Repair
Commissioning, It is impossible to guarantee that bought-in parts are designed and manufac- maintenance and tured to meet the demands made of them, or that they satisfy safety require- repair ments. Use only original spare and wearing parts (also applies to standard parts). Do not carry out any modifications, alterations, etc. -
Page 14: Safety Symbols
(e.g. relevant product standards of the EN 60 974 series). Fronius International GmbH hereby declares that the device is compliant with Directive 2014/53/EU. The full text on the EU Declaration of Conformity can be found at the following address: http://www.fronius.com Devices marked with the CSA test mark satisfy the requirements of the rele- vant standards for Canada and the USA. -
Page 15: General
General... -
Page 17: General
I/O connecting plug (X1) of the Robac- ta TC 1000 can be used with the cleaning devices without any modifications. Robacta TC 2000 on optional installation stand The cleaning devices are more or less maintenance-free, as there are no mechanically stressed parts. - Page 18 WARNING! Risk of serious injury from: the magnetic field surrounding the cleaning opening compressed air/parting agent mixture escaping from the cleaning open- flying parts (shavings, etc.) mechanically powered components Keep device free from current and pressure during maintenance and servic- ing.
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Page 19: Parting Agent Types And Their Use
Parting agent NOTE! Parting agents are not included in the scope of supply. types and their Parting agent types and their use: "Robacta TC Cool / Robacta TC Cool MD" parting agent for immersing the welding torch in the dipping bowl "Robacta Reamer"... -
Page 20: Functional Principle
Functional principle Functional princi- Once the cleaning device is connected to the mains power supply, the mains voltage indicator lights up. The capacitors, which store energy for the cleaning operation, are discharged and no outputs are activated. NOTE! Before the capacitors can be charged, the cleaning device must be con- nected to both the mains power supply and the robot control. -
Page 21: Magnetic Flux Densities Within The Cleaning Coil For Robacta Tc 2000, Robacta Tc 2000 Us
NOTE! If the robot control deactivates the "Quick Stop" signal during the pro- gram sequence, the cleaning device program sequence is interrupted imme- diately. For safety reasons the capacitors are discharged via the cleaning coil. Automatic refilling of the dipping bowl with "Robacta TC Cool / Robacta TC Cool MD" parting agent ensures an optimum fill level in the dipping bowl. -
Page 22: Magnetic Flux Densities Within The Cleaning Coil For Robacta Tc 2000 Twin, Robacta Tc 2000 Twin Us
Magnetic flux Depending on the application, the strength of the magnetic flux density on the individual densities within areas of the welding torch can be controlled by regulating how deeply the welding torch is the cleaning coil immersed in the cleaning coil. for Robacta TC 2000 Twin, Ro- NOTE! When using the cleaning device, refer to the program sequence for details... -
Page 23: Scope Of Supply And Options
Scope of supply and options General The cleaning device can be operated in conjunction with various options. This makes it possible to optimise various procedures in the welding process, as necessitated by the par- ticular field of application. Scope of supply Cleaning device with dipping bowl and integrated cleaning unit Standard I/O connecting plug (X1) without cable Four screws for fitting the cleaning device to the installation stand... -
Page 24: Transport
Transport Vehicles The device is to be transported by the following vehicles: on pallets using a counterbalanced lift truck on pallets using a lift truck manually WARNING! Equipment that falls or topples over can cause serious or even fatal injury. When transporting the device on a counterbalanced lift truck or lift truck, se- cure it to prevent it from falling over Do not suddenly change direction, brake or accelerate... -
Page 25: Controls, Connections And Mechanical Components
Controls, connections and mechani- cal components... -
Page 27: Safety
Safety Safety Observe the following safety rules for all work described in the "Control elements, connec- tions and mechanical components" section. WARNING! Operating the equipment incorrectly can cause serious injury and damage. The functions described must only be used by trained and qualified per- sonnel. -
Page 28: Standard I/O Connecting Plug (X1) Pin Assignment For Robot Control
Standard I/O connecting plug (X1) pin assignment for robot control General WARNING! An electric shock can be fatal. The cleaning device must remain de- energised until the installation is fully complete. NOTE! To avoid malfunctions, keep the cable length between the cleaning device and robot control as short as possible. - Page 29 Roboter Not assigned +24 V HIGH - Quick Stop +24 V LOW - Quick Stop HIGH - Cleaning Start +24 V LOW - Cleaning Start +24 V Supply Voltage max. 20 mA Ready +24 V Supply Voltage max. 20 mA Fluid Level Control Supply Voltage +24 V...
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Page 30: Controls, Connections And Mechanical Components
Controls, connections and mechanical components General All functions of the Robacta TC are activated by the robot control. For adjustment, the cleaning operation can be manually triggered on the Robacta TC housing. For easier op- eration, the Robacta TC is fitted with indicator lights. NOTE! The individual illustrations may differ slightly from your device. -
Page 31: Robacta Tc 2000, Robacta Tc 2000 Us Connections And Mechanical Components
NOTE! The cleaning device can only perform these functions if the "Quick Stop" signal is set and the capacitors are charged. Ready-to-clean indicator lights up when the device is ready to clean Robacta TC 2000, Robacta TC 2000 US connections and mechanical... -
Page 32: Robacta Tc 2000 Twin, Robacta Tc 2000 Twin Us Connections And Mechanical Components
(10) Wire cutter connection socket for electrically controlling the wire cutter (11) Compressed air connection for supplying the cleaning device with compressed air Robacta TC 2000 Twin, Robacta TC 2000 Twin US connections and mechanical com- ponents (10) - Page 33 Cleaning opening with internal parting-agent injection nozzle for cleaning the gas nozzle and the inside of the welding torch for coating the gas nozzle and welding torch interior with parting agent Dipping bowl with spill tray NOTE! If the dipping bowl is not in use, ensure that there are no parting agent residues left in the bottom.
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Page 35: Installation And Commissioning
Installation and commissioning... -
Page 37: Safety
Safety Safety Observe the following safety rules for all work described in the "Installation and start-up" section. WARNING! Incorrect operation or poorly executed work can cause serious injury or damage. All activities described in these operating instructions may only be carried out by trained and qualified personnel. -
Page 38: Before Commissioning
Before commissioning Operators, main- NOTE! The device must only be used by one person at a time. It is also necessary tenance person- to ensure that no one else is within the working area of the device when the device is being used. -
Page 39: Bolting The Cleaning Device To The Underlying Surface (Foundation)
Bolting the cleaning device to the underlying sur- face (foundation) Screwing the NOTE! The device should only ever be set up with the designated installation cleaning device stand. and installation stand to the un- NOTE! Different fixings may be required to connect the installation stand to the derlying surface underlying surface (foundation) depending on the nature of this surface. -
Page 40: Connecting The Mains Cable - Robacta Tc 2000 Us, Robacta Tc 2000 Twin Us
Connecting the mains cable - Robacta TC 2000 US, Robacta TC 2000 Twin US Connecting the WARNING! An inadequate ground conductor connection can cause serious inju- mains cable ry or damage. The housing screws provide a suitable ground conductor connec- tion for earthing (grounding) the housing and must NOT be replaced by any other screws which do not provide a reliable ground conductor connection. - Page 41 Tightening torque = 1.3 Nm Tightening torque = 0.5 Nm...
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Page 42: Installing The Wire Cutter
Installing the wire cutter Installing the wire NOTE! Wire cutters for conventional applications (one wire electrode) and for cutter on the twin applications (two wire electrodes) are installed in the same way - as de- cleaning device scribed below. Attach the wire cutter holder (1) to the cleaning device Fix the wire cutter (2) to the holder (1) using the two screws, two washers,... -
Page 43: How The Electrically-Controlled Wire Cutter Works
If a torch neck pushes the valve lever (1) to the side by more than 15° with the gas nozzle, the wire cutter is activated and the wire electrode is cut. NOTE! The wire electrode is cut while the torch neck is moving. Mechanically controlled wire cutter for conventional applications (using one wire electrode) How the electri-... -
Page 44: Filling The Dipping Bowl With Parting Agent
Filling the dipping bowl with parting agent Filling the dipping NOTE! Only use the "Robacta TC Cool / Robacta TC Cool MD" parting agent sup- bowl with parting plied by the manufacturer. The composition of the manufacturer's parting agent is agent intended specifically for the Robacta TC. -
Page 45: Connecting The Cleaning Device To The "Robacta Reamer" Parting Agent Container
Connecting the cleaning device to the "Robacta Reamer" parting agent container Connecting the NOTE! Only use "Robacta Reamer" parting agent supplied by the manufacturer. cleaning device The composition of the manufacturer's parting agent is intended specifically for to the "Robacta the Robacta TC. -
Page 46: Starting Up The Cleaning Device
Starting up the cleaning device General NOTE! Not coating the interior of the welding torch may result in permanent soil- ing of the torch when welding begins. Always wet the inside of the welding torch with the manufacturer's "Robacta Reamer" parting agent before starting automat- ic operation. -
Page 47: Cleaning Program Sequence - Robacta Tc 2000, Robacta Tc 2000 Us
Cleaning program sequence - Robacta TC 2000, Ro- bacta TC 2000 US Program se- Weld quence with part- Clean gas nozzle tip and nozzle fitting ing agent Spray parting agent nebuliser - over- Weld view Program se- Weld quence with part-... -
Page 48: Cleaning The Gas Nozzle Tip And Nozzle Fitting - Detailed Description
Cleaning the gas NOTE! During the cleaning operation, blow out the welding torch with com- nozzle tip and pressed air through the hosepack - any remaining dirt or parting agent is re- nozzle fitting - de- moved. tailed description Position the welding torch approxima- tely 50 mm (1.97 in.) centrally above the middle of the cleaning opening NOTE! If the brush seal (1) is fit-... -
Page 49: Cleaning Program Sequence With Parting Agent Nebuliser
Cleaning program sequence with parting agent nebuliser... -
Page 50: Cleaning Program Sequence With Dipping Bowl
Cleaning program sequence with dipping bowl... -
Page 51: Cleaning Program Sequence - Robacta Tc 2000 Twin, Robacta Tc 2000 Twin Us
Cleaning program sequence - Robacta TC 2000 Twin, Robacta TC 2000 Twin US Program se- Weld quence with part- Clean gas nozzle tip and nozzle fitting ing agent Spray parting agent nebuliser - over- Weld view Program se- Weld quence with part-... -
Page 52: Cleaning The Gas Nozzle Tip And Nozzle Fitting - Detailed Description
Cleaning the gas NOTE! During the cleaning operation, blow out the welding torch with com- nozzle tip and pressed air through the hosepack - any remaining dirt or parting agent is re- nozzle fitting - de- moved. tailed description Position the welding torch approxima- tely 50 mm (1.97 in.) centrally above the middle of the cleaning opening Move the welding torch vertically into... -
Page 53: Cleaning Program Sequence With Parting Agent Nebuliser
Cleaning program sequence with parting agent nebuliser... -
Page 54: Cleaning Program Sequence With Dipping Bowl
Cleaning program sequence with dipping bowl... -
Page 55: Troubleshooting, Maintenance And Disposal
Troubleshooting, maintenance and disposal... -
Page 57: Safety
Safety Safety Observe the following safety rules for all work described in the "Troubleshooting, mainte- nance and disposal" section. WARNING! Incorrect operation or poorly executed work can cause serious injury or damage. All activities described in these operating instructions may only be carried out by trained and qualified personnel. -
Page 58: Troubleshooting
Troubleshooting Troubleshooting Make a note of the serial number and configuration of the device and contact our After- Sales Service team with a detailed description of the error, if errors occur that are not listed below the troubleshooting measures listed are unsuccessful Mains voltage indicator not lit Mains cable connected Cause:... - Page 59 Fill level indicator lit A dipping bowl is not available or is not being used Cause: A parting agent nebuliser is being used Remedy: Not necessary Fill level indicator not lit The liquid in the dipping bowl is already below the optimum fill level Cause: Fill-level sensor faulty Remedy:...
- Page 60 Error is sent to the robot. Overtemperature and fill level indicators flash at the same time, no cleaning takes place Cause: Quick Stop is active (HI - Quick Stop = LO / LO - Quick Stop =HI) Remedy: Deactivate Quick Stop (HI - Quick Stop = HI / LO - Quick Stop =LO) Cause: Fault in the cleaning device Remedy:...
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Page 61: Care, Maintenance And Disposal
NOTE! Do not bring the air nozzle too close to electronic parts. Open the device and blow clean using dry reduced compressed air Every 12 months Arrange for a safety inspection to be carried out on the device by a Fronius service engineer Disposal... -
Page 63: Technical Data
Technical data... -
Page 65: Technical Data
NOTE! An inadequately dimensioned electrical installation can cause serious damage. The mains cable and its fuse must be dimensioned to suit the device be- ing used. The technical data shown on the rating plate applies. Robacta TC 2000, Mains voltage 230 V... -
Page 67: Appendix
Appendix... -
Page 68: Spare Parts List: Robacta Tc 2000
Spare parts list: Robacta TC 2000... -
Page 71: Circuit Diagrams: Robacta Tc 2000
Circuit diagrams: Robacta TC 2000 230V AC 50Hz NET CONTROL TEMP. ERROR FLUID LEVEL ERROR SINGLE SHOT BUTTON READY TRAFO_L TRAFO_N 1X12 COIL_TEMP COIL_TEMP_GND 1X13 18VAC_ST FLUID LEVEL 18VAC_ROB FLUID LEVEL 18VAC_ST 18VAC_ROB 1X10 SPRAYER_24V 1X14 SPRAYER_GND 388VAC CUTTER_24V CUTTER_GND... - Page 72 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...
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