Related Manuals for Fronius Robacta TC 2000 ext.
Summary of Contents for Fronius Robacta TC 2000 ext.
- Page 1 / Perfect Charging / Perfect Welding / Solar Energy Operating Instructions Robacta TC 2000 ext. Robacta TC 2000 ext. US Welding torch cleaning Cleaning Unit TC 2000 42,0426,0259,EA 003-13082018...
- Page 3 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.
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Page 5: Table Of Contents
Contents Safety Instructions ............................. General ..............................Intended Use............................Environmental Conditions ........................Obligations of the Operating Company....................Obligations of Personnel........................Particular hazard areas......................... Personal Protection and Protection of Others..................Dangers due to Mains Current and Operating Current ................. EMC Device Classifications ........................EMC Measures ............................. - Page 6 Setting Up and Connecting the Cleaning Device..................Installation Note ............................ Screwing the Cleaning Unit and Work Stand to the Surface (Foundation) ........... Screwing the Base Unit and Work Stand to the Surface (Foundation) ..........Connecting the Cleaning Unit to the Base Unit..................Connecting the Mains Cable on the Robacta TC 2000 ext.
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Page 7: Safety Instructions
Intended Use The device is to be used exclusively for its intended purpose. The device is intended exclusively for the electromagnetic cleaning of Fronius welding torches. Utilization for any other purpose, or in any other manner, shall be deemed to be “not in accordance with the intended purpose.”... -
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 is not re- sponsible 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) Relative humidity:... -
Page 9: Personal Protection And Protection Of Others
Personal Protec- Electromagnetic fields may cause health problems that are not yet known: tion and Protec- Effects on the health of persons close by, for example those with pace- tion of Others makers, metal implants and hearing aids General prohibition for persons with pacemakers: Persons with pacemak- ers must seek advice from their doctor before working with the device or being in the immediate vicinity of the device General prohibition for persons with metal implants: Persons with metal... -
Page 10: Dangers Due To Mains Current And Operating Current
Dangers due to An electric shock is life-threatening and may be deadly. Mains Current Do not touch voltage-carrying parts inside or outside of the device. and Operating Current All cables and leads must be secured, undamaged, insulated, and adequately dimensioned. Replace loose connections and scorched, damaged, or inade- quately dimensioned cables and leads immediately. -
Page 11: Emc Measures
EMC Measures WARNING! Electromagnetic field! Electromagnetic fields may cause health problems that are not yet known. It is the operating company’s responsibility to ensure that there is no electro- magnetic interference with electrical and electronic equipment. If electromagnetic interference is detected, the operating company is obliged to take measures to rectify the situation. -
Page 12: Safety Measures In Normal Operation
Use instructions and checks within the company to ensure that the vicinity of the workplace is always clean and organized. Only set up and operate the device in accordance with the degree of protec- tion shown on the rating plate. Install the device with an all-round clearance of at least 0.5 m (19.69 in.) to walls, neighboring devices, or other objects. -
Page 13: Maintenance And Repair
Maintenance and It is impossible to guarantee that bought-in parts are designed and manufac- repair tured to meet the demands made of them, or that they satisfy safety require- 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 60974 series). Fronius International GmbH declares that the device complies with Directive 2014/53/EU. The full text of the EU Declaration of Conformity is available on the following website: 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
General Device Concept The cleaning device consists of a base unit – the Robacta TC 2000 ext. / Robacta TC 2000 ext. US and a cleaning unit – the Cleaning Unit TC 2000 in various versions The cleaning device is designed to clean a variety of different welding torch geomet- ries. - Page 18 WARNING! Danger of serious injuries due to: The magnetic field of the cleaning aperture Compressed air/parting agent mixture discharged from the cleaning ap- erture Flying debris (chips, etc.) Moving mechanical parts During maintenance and service, keep the device de-energized and depres- surized.
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Page 19: Functional Principle
Functional principle Operating princi- As soon as the cleaning device is connected to the grid, the Grid voltage indication (page 30) lights up. The capacitors, which store the energy for the cleaning process, are discharged and no outputs are controlled. NOTE! In order for the capacitors’... -
Page 20: Representation Of The Magnetic Flux Density Within The Cleaning Coil For Single-Wire Applications
NOTE! If the robot control deactivates the ‘Quick Stop’ signal during the pro- gram sequence, the cleaning device program sequence will be aborted im- mediately. For safety reasons, the capacitors are discharged via the cleaning coil. Representation of Depending on the requirements, the insertion depth of the welding torch in the cleaning coil the Magnetic Flux can be used to regulate how strong an effect the magnetic flux density should have on the Density Within... - Page 21 Insertion depth of the Diagram of available Cleaning coil torch body into the magnetic flux density cleaning coil 100 % 19 mm 14 mm 0.75 in. 0.55 in. 54 mm 2.13 in.
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Page 22: Scope Of Supply And Options
Scope of Supply and Options General The cleaning device may be operated in conjunction with various options. Depending on the area of application, various sequences in the work process can be optimized as a re- sult. Scope of Supply Base unit (available in various versions) Standard I/O (X1) connecting plug without cable Four screws for mounting the cleaning device on the work stand Available Options... -
Page 23: Transport
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-... -
Page 25: Operating Controls, Connections And Mechanical Components
Operating controls, connections and mechanical components... -
Page 27: Safety
Safety 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 dam- age. 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 follow- ing documents: These Operating Instructions... -
Page 28: Standard I/O (X1) Connecting Plug Configuration For The Robot Control
Standard I/O (X1) Connecting Plug Configuration for the Robot Control General WARNING! An electric shock can be fatal. The cleaning device must not be sup- plied with electrical power until the installation has been completed. NOTE! To avoid any interference, keep the line length between the cleaning de- vice and the 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: Operating Controls, Connections And Mechanical Components
Operating controls, connections and mechanical components General All functions of the cleaning device are activated via the robot control. For setup operation, the cleaning process can be triggered manually on the base unit housing. NOTE! Individual images may differ slightly from your device. However, the func- tion of the operating elements and connections is identical. -
Page 31: Connections And Mechanical Components Of The Base Unit
If the button is pressed and held down, the cleaning device will carry out the following functions in sequence: Cleaning process is triggered Wire cutter is activated (if present) Compressed air/parting agent mixture is sprayed out of the cleaning aperture NOTE! Prerequisite for the cleaning device carrying out the above function: The “Quick Stop”... -
Page 32: Connections And Mechanical Components Of The Cleaning Unit
Function Cleaning unit connection socket For connecting the cleaning unit connection cable Compressed air connection For supplying the cleaning device with compressed air Device rear Connections and Function Mechanical Com- ponents of the Cleaning aperture with internal Cleaning Unit parting-agent injection nozzles and brush seal For cleaning the gas nozzle and the interior of the welding torch... - Page 33 Function Interconnecting hosepack For connecting to the base unit WARNING! Danger of serious in- jury and damage from electric shock. Once the ready to clean in- dication lights up, do not disconnect the interconnecting hosepack from the base unit. Before disconnecting the interconnecting hosepack: Disconnect the base unit power sup- Underside of the cleaning unit...
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Page 35: Installation And Startup
Installation and Startup... -
Page 37: Safety
Safety 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 seri- ous injury and damage to property. All work listed in these Operating Instructions may only be performed by trained specialist personnel. -
Page 38: Before Installation
Before installation Operating Per- NOTE! In all situations, the device must only ever be operated by one person. In sonnel, Mainte- addition, make sure that there are no other people in the device’s operating area nance Personnel while it is in operation. NOTE! In all situations, the device must only ever be maintained by one person. -
Page 39: Setting Up And Connecting The Cleaning Device
Setting Up and Connecting the Cleaning Device Installation Note NOTE! Before the definitive installation of the base unit and cleaning unit, make sure that the cleaning unit interconnecting hosepack is long enough for the planned installation positions. After the installation of the devices, the intercon- necting hosepack must rest on the ground without any tensile stress and must not be suspended in the air. - Page 40 Position the work stand (available as an option) on a level, solid and vibration-free sur- face Position the work stand in such a way that the interconnecting hosepack of the cleaning unit can be connected to the base unit Tightly screw the work stand to the surface using the selected mounting materials Position the base unit on the work stand Attach the base unit to the work stand...
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Page 41: Connecting The Cleaning Unit To The Base Unit
Connecting the Remove the cover from the cleaning unit connection socket on the rear of the base unit Cleaning Unit to Insert the connecting plug of the interconnecting hosepack into the base unit the Base Unit Tighten the screws on the connecting plug of the interconnecting hosepack to secure it in the cleaning unit connection socket WARNING! Danger of serious injury and damage from electric shock. -
Page 42: Connecting The Mains Cable On The Robacta Tc 2000 Ext. Us
Connecting the Mains Cable on the Robacta TC 2000 ext. US Connecting the WARNING! An inadequate ground conductor connection can cause serious inju- Mains Cable ry and damage to property. The housing screws provide an adequate ground con- ductor connection for grounding the housing and should not under any circumstances be replaced by other screws that do not provide a proper ground conductor connection. - Page 43 Tightening torque = 1.3 Nm Tightening torque = 0.5 Nm...
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Page 44: 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) should be installed in the same manner – Cleaning Device as described below. NOTE! The spacers, lock washers and screws for installing the wire cutter are supplied with the wire cutter. -
Page 45: Connecting The Cleaning Unit To The 'Robacta Reamer' Parting Agent Container
Connecting the Cleaning Unit to the ‘Robacta Ream- er’ Parting Agent Container Connecting the NOTE! Only use the ‘Robacta Reamer’ parting agent provided by the manufac- Cleaning Unit to turer. Its composition is specifically tailored for use with the cleaning device. Cor- the ‘Robacta rect operation is not ensured when other products are used. -
Page 46: Start Up The Cleaning Device
Start up the Cleaning Device General 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 when welding begins. Always wet the inside of the welding torch with the manufacturer’s ‘Ro- bacta Reamer’... -
Page 47: Cleaning Program Sequence For Single Wire Applications
Cleaning Program Sequence for Single Wire Appli- cations Program Se- Welding quence with Part- Clean the gas nozzle tip and nozzle fitting ing Agent Inject parting agent Atomizer – Over- Welding view Cleaning the Gas NOTE! During the cleaning process, blow out the welding torch with compressed Nozzle Tip and air via the hosepack. - Page 48 Move the welding torch to the injection position See graphic NOTE! During the injection pro- cess, do not blow out compressed air through the welding torch. Inject parting agent into the welding torch for approximately 0.7 seconds Move the welding torch to the starting position above the cleaning aperture – approx- imately 50 mm (1.97 in.) above the cleaning aperture and centrically with respect to the middle of the cleaning aperture The cleaning process is completed and the welding torch is ready for use again...
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Page 49: Cleaning Program Sequence With Parting Agent Atomizer
Cleaning Pro- gram Sequence with Parting Agent Atomizer... -
Page 50: Cleaning Program Sequence For Twin Applications
Cleaning Program Sequence for Twin Applications Program Se- Welding quence with Part- Clean the gas nozzle tip and nozzle fitting ing Agent Inject parting agent Atomizer – Over- Welding view Cleaning the Gas NOTE! During the cleaning process, blow out the welding torch with compressed Nozzle Tip and air via the hosepack. -
Page 51: Cleaning Program Sequence With Parting Agent Atomizer
Move the welding torch to the starting position above the cleaning aperture – approx- imately 50 mm (1.97 in.) above the cleaning aperture and centrically with respect to the middle of the cleaning aperture The cleaning process is completed and the welding torch is ready for use again Make sure that not too much parting agent has collected at the gas nozzle (no forma- tion of drops). -
Page 53: Troubleshooting, Maintenance, And Disposal
Troubleshooting, Maintenance, and Disposal... -
Page 55: Safety
Safety Safety Please follow the safety rules below during all the tasks described in the “Troubleshooting, Maintenance, and Disposal” chapter. WARNING! Incorrect operation and incorrectly performed work can cause seri- ous injury and damage to property. All work listed in these Operating Instructions may only be performed by trained specialist personnel. -
Page 56: Troubleshooting
Troubleshooting Troubleshooting Make a note of the serial number and configuration of the device, and provide the service team with a detailed error description if: Errors occur that are not covered in this document The troubleshooting measures provided in this document are unsuccessful Grid voltage indication does not light up Grid lead connected Cause:... - Page 57 Parting agent is not injected ‘Robacta Reamer’ parting agent container is full Cause: Injection quantity too low Remedy: Set injection quantity (injection time) Cause: Intake filter in ‘Robacta Reamer’ parting agent container dirty Remedy: Blow out the intake filter in the ‘Robacta Reamer’ parting agent container from the inside out with compressed air using the intake hose (see section Clean the intake filter in the parting agent container...
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Page 58: What To Do In The Event Of An Error
What to Do in the Event of an Error What to Do in the WARNING! Danger of serious Event of an Error damage to property and personal injury from electric shock. The cleaning device has detected a serious error if: The overtemperature indica- tion (1) and fill level indication (2) flash simultaneously... -
Page 59: Service, Maintenance And Disposal
Open the base unit and cleaning unit and blow clean with dry and reduced com- pressed air Every 12 Months Have a Fronius service technician perform a safety inspection on the cleaning device Clean the intake NOTE! Only use the ‘Robacta Reamer’ parting agent provided by the manufac- filter in the part- turer. -
Page 60: Disposal
Disposal Materials should be disposed of according to valid local and national regulations. -
Page 61: Technical Data
Technical Data... -
Page 63: Technical Data
Technical Data General NOTE! An inadequately dimensioned electrical installation can lead to serious damage. The grid lead and its fuse protection should be designed to suit the de- vice that is used. The technical data on the rating plate should be followed. Robacta TC 2000 Mains voltage 230 V... -
Page 64: Cleaning Unit Tc 2000 Lh
Dimensions l/w/h (without interconnecting hosepack and col- 340/145/300 mm lecting container for welding residues) 13.39/5.71/8.66 in. Weight 8.1 kg 17.86 lb. Cleaning Unit TC EMC device class 2000 LH Dimensions l/w/h (without interconnecting hosepack and col- 340/145/300 mm lecting container for welding residues) 13.39/5.71/8.66 in. - Page 68 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...