Fronius Robacta TC 2000 Operating Instructions Manual
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Robacta TC 2000
Robacta TC 2000 Twin
Robacta TC 2000 Ø35
Robacta TC 2000 LH TWIN
Robacta TC 2000 US
Robacta TC 2000 Twin US
Robacta TC 2000 Ø1.181inch US
Robacta TC 2000 LH TWIN US
42,0426,0135,EN 019-18022020
Fronius prints on elemental chlorine free paper (ECF) sourced from certified sustainable forests (FSC).
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Operating Instructions
Welding torch cleaning
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Table of Contents
Troubleshooting
Related Manuals for Fronius Robacta TC 2000
Summary of Contents for Fronius Robacta TC 2000
- Page 1 Robacta TC 2000 LH TWIN Robacta TC 2000 US Robacta TC 2000 Twin US Robacta TC 2000 Ø1.181inch US Robacta TC 2000 LH TWIN US 42,0426,0135,EN 019-18022020 Fronius prints on elemental chlorine free paper (ECF) sourced from certified sustainable forests (FSC).
- 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 23 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
Proper use The device is to be used exclusively for its intended purpose. The device is intended solely for the electromagnetic cleaning of Fronius welding torches. Any use above and beyond this purpose is deemed improper. The manufacturer shall not be held liable for any damage arising from such usage. -
Page 8: Obligations Of The Operator
Relative humidity: up to 50 % at 40 °C (104 °F) up to 90 % at 20 °C (68 °F) Keep ambient air free from dust, acids, corrosive gases and substances, etc. Can be used at altitudes of up to 2000 m (6500 ft) Obligations of the The operator must only allow persons to work with the device who: operator... -
Page 9: Risks From Mains Current And Operating Current
Magnetic fields generated by the high amperage can cause ferromagnetic parts such as spatter accumulations to be ejected from the cleaning opening. To prevent injury, never look into in the cleaning opening while the device is switched on; protective goggles with side protection must be worn at all times. -
Page 10: Emc Device Classifications
Switch off unused devices. Disconnect the mains plug before working on the device. Attach a clearly legible and easy-to-understand warning sign to the device to prevent any- one from plugging the mains plug back in and switching it on again. After opening the device: Discharge all live components Ensure that all components in the device are de-energised. -
Page 11: Safety Measures At The Installation Location And During Transport
Safety measures A device toppling over could easily kill someone. Place the device on a solid, level surface at the installation such that it remains stable location and dur- The maximum permissible tilt angle is 10°. ing transport Special regulations apply in rooms at risk of fire or explosion Observe relevant national and international regulations. -
Page 12: Commissioning, Maintenance And Repair
(e.g. relevant product standards of the EN 60 974 se- ries). 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... -
Page 13: Copyright
Copyright Copyright of these operating instructions remains with the manufacturer. The text and illustrations are all technically correct at the time of printing. We reserve the right to make changes. The contents of the operating instructions shall not provide the ba- sis for any claims whatsoever on the part of the purchaser. -
Page 15: General
General... -
Page 17: General
I/O connecting plug (X1) of the Robacta 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! types and their Parting agents are not included in the scope of supply. Parting agent types and their use: "Robacta TC Cool +" parting agent for immersing the welding torch in the dipping bowl "Robacta Reamer" parting agent for spraying the welding torch after the cleaning op- eration It is recommended that the dipping bowl should be used for: Gas-cooled welding torches... -
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 connected to both the mains power supply and the robot control. - Page 21 NOTE! If the robot control deactivates the "Quick Stop" signal during the program se- quence, the cleaning device program sequence is interrupted immediately. For safety reasons the capacitors are discharged via the cleaning coil. Automatic refilling of the dipping bowl with "Robacta TC Cool +" parting agent ensures an optimum fill level in the dipping bowl.
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Page 22: Magnetic Flux Densities Within The Cleaning Coil For Robacta Tc 2000, Robacta Tc 2000 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, Robacta TC NOTE! -
Page 23: 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! -
Page 24: 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 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 Available options... -
Page 25: 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. ►... -
Page 27: Controls, Connections And Mechanical Components
Controls, connections and mechani- cal components... -
Page 29: 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 personnel. Do not use the functions described here until you have fully read and understood the following docu- ments: ►... -
Page 30: 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 31 Roboter Not assigned +24 V HIGH - Quick Stop +24 V LOW - Quick Stop HIGH - Cleaning Start +24 V LOW - Cleaning Start Supply Voltage +24 V max. 20 mA Ready +24 V Supply Voltage max. 20 mA Fluid Level Control Supply Voltage +24 V...
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Page 32: Controls, Connections And Mechanical Components
Controls, connections and mechanical components General All functions of the cleaning unit are activated by the robot control. For adjustment, the cleaning operation can be manually triggered on the control panel. NOTE! The individual illustrations may differ slightly from your device. However, the functioning of the controls and the connections is identical. -
Page 33: Robacta Tc 2000, Robacta Tc 2000 Us Connections And Mechanical Components
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 34 Function Level sensor monitors the parting agent fill level in the dipping bowl Cleaning opening with internal parting-agent injection nozzle and brush seal for cleaning the gas nozzle and the inside of the welding torch for coating the gas nozzle and welding torch interior with parting agent NOTE! To avoid excess soiling, only use the device with the brush seal in place.
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Page 35: Robacta Tc 2000 Twin, Robacta Tc 2000 Twin Us Connections And Mechanical Components
Robacta TC 2000 Twin, Robacta TC 2000 Twin US connections and mechanical com- ponents (10) (11) Rear of device Front of device Function Level sensor monitors the parting agent fill level in the dipping bowl Cleaning opening with internal parting-agent injection nozzle... - Page 36 Drain hose for emptying the dipping bowl Parting agent nebuliser connection for connecting to the "Robacta Reamer" parting agent container, for spraying the compressed air/parting agent mixture into the cleaning opening (10) Wire cutter connection socket for electrically controlling the wire cutter (11) Compressed air connection for supplying the cleaning device with compressed air...
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Page 37: Installation And Commissioning
Installation and commissioning... -
Page 39: 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 40 WARNING! An inadequate ground conductor connection can cause serious injury or damage. The housing screws provide a suitable ground conductor connection for earthing (ground- ing) the housing and must NOT be replaced by any other screws which do not provide a reliable ground conductor connection.
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Page 41: Before Commissioning
Before commissioning Operators, main- NOTE! tenance person- The device must only be used by one person at a time. It is also necessary to ensure that no one else is within the working area of the device when the device is being used. NOTE! The device must only be serviced by one person at a time. -
Page 42: Mains Connection
Mains connection WARNING! Risk of serious injury and damage due to insufficiently dimensioned electrical in- stallations. The mains cable and its fuse must be dimensioned to suit the device being used. The tech- nical data shown on the rating plate applies. CAUTION! Risk of serious damage as a result of incorrect mains voltage. -
Page 43: Bolting The Cleaning Device To The Underlying Surface (Foundation)
Bolting the cleaning device to the underlying sur- face (foundation) Screwing the NOTE! cleaning device and installation The device should only ever be set up with the designated installation stand. stand to the un- derlying surface (foundation) NOTE! Different fixings may be required to connect the installation stand to the underlying surface (foundation) depending on the nature of this surface. -
Page 44: 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! mains cable An inadequate ground conductor connection can cause serious injury or damage. The housing screws provide a suitable ground conductor connection for earthing (ground- ing) the housing and must NOT be replaced by any other screws which do not provide a reliable ground conductor connection. - Page 45 Tightening torque = 1.3 Nm Tightening torque = 0.5 Nm...
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Page 47: Installing The Wire Cutter
Installing the wire cutter Installing the wire NOTE! cutter on the cleaning device Wire cutters for conventional applications (one wire electrode) and for twin applica- tions (two wire electrodes) are installed in the same way - as described 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 48: 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 noz- zle, the wire cutter is activated and the wire electrode is cut. NOTE! The wire electrode is cut while the torch neck is moving. -
Page 49: Filling The Dipping Bowl With Parting Agent
Filling the dipping bowl with parting agent Filling the dipping NOTE! bowl with parting agent Only use the "Robacta TC Cool +" parting agent supplied by the manufacturer. The composition of the manufacturer's parting agent is intended specifically for the Robac- ta TC. -
Page 50: 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! cleaning device to the "Robacta Only use "Robacta Reamer" parting agent supplied by the manufacturer. Reamer" parting The composition of the manufacturer's parting agent is intended specifically for the Robac- agent container ta TC. -
Page 51: Starting Up The Cleaning Device
Starting up the cleaning device General NOTE! Not coating the interior of the welding torch may result in permanent soiling of the torch when welding begins. Always wet the inside of the welding torch with the manufacturer's "Robacta Reamer" part- ing agent before starting automatic operation. -
Page 52: 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 53: Cleaning The Gas Nozzle Tip And Nozzle Fitting - Detailed Description
Cleaning the gas NOTE! nozzle tip and nozzle fitting - de- During the cleaning operation, blow out the welding torch with compressed air tailed description through the hosepack - any remaining dirt or parting agent is removed. NOTE! Ensure that the gas nozzle does not touch the housing components of the cleaning opening at any time. - Page 54 Place the welding torch in the spray position see figure NOTE! During the spraying process, ensure that compressed air is not blown out through the welding torch. Spray welding torch with parting agent for approximately 0.7 seconds Move the welding torch to the start position above the cleaning opening - approximate- ly 50 mm (1.97 in.) centrally above the middle of the cleaning opening The cleaning operation is complete and the welding torch is ready for use again Ensure that not too much parting agent has accumulated on the gas nozzle (no droplet...
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Page 55: Cleaning Program Sequence With Parting Agent Nebuliser
Cleaning program sequence with parting agent nebuliser... -
Page 56: Cleaning Program Sequence With Dipping Bowl
Cleaning program sequence with dipping bowl... -
Page 57: 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 58: Cleaning The Gas Nozzle Tip And Nozzle Fitting - Detailed Description
Cleaning the gas NOTE! nozzle tip and nozzle fitting - de- During the cleaning operation, blow out the welding torch with compressed air tailed description through the hosepack - any remaining dirt or parting agent is removed. NOTE! Ensure that the gas nozzle does not touch the housing components of the cleaning opening at any time. -
Page 59: Cleaning Program Sequence With Parting Agent Nebuliser
Ensure that not too much parting agent has accumulated on the gas nozzle (no droplet formation). If this is the case : Reduce the spray time or After the cleaning operation, blow out the welding torch with compressed air using the hosepack Cleaning program sequence with... -
Page 60: Cleaning Program Sequence With Dipping Bowl
Cleaning program sequence with dipping bowl... -
Page 61: Troubleshooting, Maintenance And Disposal
Troubleshooting, maintenance and disposal... -
Page 63: 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 64 WARNING! An inadequate ground conductor connection can cause serious injury or damage. The housing screws provide a suitable ground conductor connection for earthing (ground- ing) the housing and must NOT be replaced by any other screws which do not provide a reliable ground conductor connection.
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Page 65: 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 66 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 67 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 68: Care, Maintenance And Disposal
Care, maintenance and disposal Before each start- Check the fill level in the "Robacta Reamer" parting agent container and the dipping bowl, top up if necessary NOTE! The "Robacta TC Cool / Robacta TC Cool MD" and "Robacta Reamer" parting agents differ in their composition. -
Page 69: Every 6 Months
Robacta TC 1000 / Robacta TC 1000 ext. Open (base unit and cleaning unit) and blow clean using dry reduced compressed air Every 12 months Arrange for a safety inspection to be carried out on the cleaning device by a Fronius service engineer Disposal... -
Page 71: Technical Data
Technical data... -
Page 73: Technical Data
An inadequately dimensioned electrical installation can cause serious damage. The mains cable and its fuse must be dimensioned to suit the device being used. The tech- nical data shown on the rating plate applies. Robacta TC 2000, Mains voltage 230 V... -
Page 75: Appendix
Appendix... -
Page 76: 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 80 FRONIUS INTERNATIONAL GMBH Froniusstraße 1, A-4643 Pettenbach, Austria E-Mail: sales@fronius.com www.fronius.com Under www.fronius.com/contact you will find the addresses of all Fronius Sales & Service Partners and locations...
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