Fronius Robacta TC 2000 Operating Instructions & Spare Parts Download Page 72

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FRONIUS INTERNATIONAL GMBH

Froniusplatz 1, A-4600 Wels, Austria

Tel: +43 (0)7242 241-0, Fax: +43 (0)7242 241-3940

E-Mail: [email protected]

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

Summary of Contents for Robacta TC 2000

Page 1: ...harging Perfect Welding Solar Energy 42 0426 0135 EN 015 14082018 Robacta TC 2000 Robacta TC 2000 Twin Robacta TC 2000 US Robacta TC 2000 Twin US Operating Instructions Spare parts list Welding torch cleaning EN ...

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Page 3: ... essential prerequisites for excellent results Explanation of safety symbols If you see any of the symbols depicted in the Safety rules chapter special care is re quired DANGER Indicates immediate and real danger If it is not avoided death or se rious injury will result WARNING Indicates a potentially dangerous situation Death or serious injury may result if appropriate precautions are not taken C...

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Page 5: ...hin the cleaning coil for Robacta TC 2000 Robacta TC 2000 US 21 Magnetic flux densities within the cleaning coil for Robacta TC 2000 Twin Robacta TC 2000 Twin US 22 Scope of supply and options 23 General 23 Scope of supply 23 Available options 23 Transport 24 Vehicles 24 Transport notices on the packaging 24 Controls connections and mechanical components 25 Safety 27 Safety 27 Standard I O connect...

Page 6: ...elding torch in the dipping bowl detailed description 47 Cleaning the gas nozzle tip and nozzle fitting detailed description 48 Spraying parting agent detailed description 48 Cleaning program sequence with parting agent nebuliser 49 Cleaning program sequence with dipping bowl 50 Cleaning program sequence Robacta TC 2000 Twin Robacta TC 2000 Twin US 51 Program sequence with parting agent nebuliser ...

Page 7: ...on the device must be in a legible state must not be damaged must not be removed must 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 commissioning the device rectify any faults that could compromise safety This is for your personal safety The device is to b...

Page 8: ...d out at regular intervals to ensure that operators are working in a safety conscious manner Before using the device all persons instructed to do so undertake to observe the basic instructions regarding safety at work and accident prevention to read these operating instructions especially the Safety rules section and sign to confirm that they have understood them and will follow them Before leavin...

Page 9: ...ess must wear suit able protective clothing with the following properties flame resistant insulating and dry covers the whole body is undamaged and in good condition safety helmet trousers with no turn ups Protective clothing refers to a variety of different items Operators should protect eyes and face from UV rays heat and sparks using a protective visor and regulation filter wear regulation prot...

Page 10: ...ctrician to ensure the ground conductor is functioning properly 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 anyone 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...

Page 11: ...eighbouring persons Supporting measures for avoidance of EMC problems 1 Mains supply If electromagnetic interference arises despite the correct mains con nection additional measures are necessary e g use of a suitable line filter 2 Shielding if necessary Shield off other nearby devices Shield off entire welding installation 3 Do not have any magnetic or electronic data carriers about your person m...

Page 12: ...missioning the device Only operate the device when all safety devices are fully functional If the safe ty devices are not fully functional there is a risk of injury or death to the operator or a third party damage to the device and other material assets belonging to the operator inefficient operation of the device Any safety devices that are not functioning properly must be repaired before switchi...

Page 13: ...ry 12 months A safety inspection should be carried out by a qualified electrician after any changes are made after any additional parts are installed or after any conversions after repair care and maintenance has been carried out at least every twelve months For safety inspections follow the appropriate national and international stand ards and directives Further details on safety inspection and c...

Page 14: ...ments of the rele vant standards for Canada and the USA The user is responsible for the safekeeping of any changes made to the fac tory settings The manufacturer accepts no liability for any deleted personal settings 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 cha...

Page 15: ...General ...

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Page 17: ...used with the cleaning devices without any modifications The cleaning devices are more or less maintenance free as there are no mechanically stressed parts Application areas The cleaning device cleans welding torches in automated steel applications It has been designed for use in the automotive and component supply industry equipment construction chemical plant construction mechanical engineering ...

Page 18: ...y powered components Keep device free from current and pressure during maintenance and servic ing Do not use the functions described here until you have thoroughly read and understood the following documents these operating instructions all the operating instructions for the system components especially the safety rules For indoor use only Wear eye protection Forbidden for anyone wearing a pacemak...

Page 19: ...r 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 Water cooled welding torches in the upper power range hot gas nozzles Spraying the welding torch with Robacta Reamer parting agent is recommended for all applications NOTE Parting agents are not included in the scope of supply ...

Page 20: ...chieved maximum magnetic flux density after just twenty seconds the cleaning op eration discharge process can still be triggered using the Cleaning Start signal For adjustment purposes the cleaning operation can also be manually triggered using the discharge button on the device The maximum magnetic flux density for cleaning is available after fifty seconds of charging See the diagram below for th...

Page 21: ...s within the cleaning coil for Robacta TC 2000 Robacta TC 2000 US Depending on the application the strength of the magnetic flux density on the individual areas of the welding torch can be controlled by regulating how deeply the welding torch is immersed in the cleaning coil NOTE If the robot control deactivates the Quick Stop signal during the pro gram sequence the cleaning device program sequenc...

Page 22: ...eas of the welding torch can be controlled by regulating how deeply the welding torch is immersed in the cleaning coil NOTE When using the cleaning device refer to the program sequence for details of the welding torch immersion depth Cleaning coil Diagram showing availa ble magnetic flux density Immersion depth of torch neck into clean ing coil 0 100 54 mm 2 13 in 14 mm 0 55 in 19 mm 0 75 in ...

Page 23: ...ar 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 Available options Available options for the cleaning device Installation stand available in various heights Wire cutter Wire cutter installation kit Parting agent nebuliser installa...

Page 24: ...ces on the packaging 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 CAUTION Risk of damage due to incorrect transport Observe the transport no tices on the device packaging ...

Page 25: ...Controls connections and mechani cal components ...

Page 26: ......

Page 27: ...ing the equipment incorrectly can cause serious injury and damage The functions described must only be used by trained and qualified per sonnel Do not use the functions described here until you have fully read and un derstood the following documents these Operating Instructions all the Operating Instructions for the system components especially the safe ty rules ...

Page 28: ... 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 WARNING Risk of serious injury and damage due to unexpected start up of the cleaning device system components Only assign the Quick Stop signal input once either HIGH Quick Stop or LOW Quick Stop NOTE Depending on the demands pla...

Page 29: ...V Roboter 24 V 24 V max 20 mA 24 V max 20 mA 24 V max 20 mA 24 V 24 V 24 V GND GND GND GND GND GND LOW Quick Stop GND HIGH Cleaning Start LOW Cleaning Start GND GND Supply Voltage Ready Supply Voltage Fluid Level Control Supply Voltage Cleaning Error C T a t c a b o R Spray In GND Wire Cutter ...

Page 30: ...riefly the cleaning device will perform the following functions 1 Cleaning is started NOTE The individual illustrations may differ slightly from your device However the functioning of the controls and the connections is identical NOTE If the capacitors in the device are charged they will discharge auto matically as soon as the device is unplugged from the mains Discharge time is approx 1 second NO...

Page 31: ...ng 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 3 Dipping bowl with spill tray 4 Standard I O connection socket X1 NOTE The cleaning device can only perform these functions if the Quick Stop signal is set and the capacitors are charged 4 5 6 2 3 1 7 7 7 7 8 9 10 11 NOTE...

Page 32: ...ion 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 Robacta TC 2000 Twin Robacta TC 2000 Twin US connections and mechanical com ponents Front of d...

Page 33: ...ing the wire cutter holder to the cleaning device 8 Drain hose for emptying the dipping bowl 9 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 clea...

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Page 35: ...Installation and commissioning ...

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Page 37: ...Before performing work on the cleaning device or any connected system components disconnect the customer s compressed air and power supplies from the cleaning device and the connected system components ensure that they remain disconnected until all work is complete using a suitable measuring instrument ensure that electrically charged com ponents e g capacitors have been discharged WARNING Wheneve...

Page 38: ...ur version of the appliance fit one that conforms to national standards NOTE 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 It is also nec essary to ensure that no one else is within the working area of the device...

Page 39: ...the in stallation stand Screw the cleaning device to the instal lation stand using the four screws sup plied with the cleaning device NOTE The device should only ever be set up with the designated installation stand NOTE Different fixings may be required to connect the installation stand to the underlying surface foundation depending on the nature of this surface The fix ings required to connect t...

Page 40: ...vide a reliable ground conductor connection CAUTION Risk of injury and damage due to short circuits Short circuits can occur between the individual phase conductors or between the phase conductors and the ground conductor unless ferrules are used Fit ferrules to all phase conductors in an exposed mains cable as well as the ground conductor NOTE Mains cables must be connected to devices in complian...

Page 41: ...41 EN 4 Tightening torque 1 3 Nm 5 Tightening torque 0 5 Nm 6 4 5 6 ...

Page 42: ...can be cut by the respective wire cutter For twin applications two wire electrodes two wire electrodes with diameters of up to 1 6 mm 0 063 in can be cut simultaneously by the respective wire cutter How the mechani cally controlled wire cutter works NOTE Wire cutters for conventional applications one wire electrode and for twin applications two wire electrodes are installed in the same way as de s...

Page 43: ...r 1 to the side by more than 15 with the gas nozzle the wire cutter is activated and the wire electrode is cut How the electri cally controlled wire cutter works The electrically controlled wire cutter opens and closes when there is an active signal from the robot control 1 NOTE The wire electrode is cut while the torch neck is moving ...

Page 44: ...rer s parting agent is intended specifically for the Robacta TC If other manufacturers products are used trouble free operation cannot be guaranteed 1 2 3 4 NOTE Carry out the following maintenance on the dipping bowl at weekly inter vals Take the spill tray out of the dipping bowl and dispose of any accumulated dirt Check the consistency of the Robacta TC Cool Robacta TC Cool MD part ing agent If...

Page 45: ...nufacturer The composition of the manufacturer s parting agent is intended specifically for the Robacta TC If other manufacturers products are used trouble free operation cannot be guaranteed NOTE The parting agent spray time must be set on the robot control A minimum spray time of 0 5 seconds can be set A spray time of approx 0 7 seconds is recommended This may vary depending on the size of the g...

Page 46: ...ainer to the cleaning de vice If using the dipping bowl the dipping bowl is filled with the Robacta TC Cool Robacta TC Cool MD parting agent If present wire cutter installed and supplied with compressed air Cleaning device connected to mains If the cleaning device has been connected to the Robacta Reamer parting agent container compressed air supply to cleaning device has been established Cleaning...

Page 47: ...orch is cooled down more The anti adhesive agent in the Robacta TC Cool Robacta TC Cool MD parting agent prevents renewed soiling After welding position the welding torch approximately 50 mm 1 97 in above the dipping bowl Dip the welding torch vertically into the dipping bowl Depending on the application hold the welding torch in the dipping bowl for approxi mately 1 4 seconds so that any air in t...

Page 48: ...t 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 NOTE During the cleaning operation blow out the welding torch with com pressed air through the hosepack any remaining dirt or parting ag...

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Page 51: ...ng torch is cooled down more The anti adhesive agent in the Robacta TC Cool Robacta TC Cool MD parting agent prevents renewed soiling After welding position the welding torch approximately 50 mm 1 97 in above the dipping bowl Dip the welding torch vertically into the dipping bowl Depending on the application hold the welding torch in the dipping bowl for approxi mately 1 4 seconds so that any air ...

Page 52: ...vantages reduced welding spatter accumulation prevents re soiling Maintain cleaning spray position see figure Spray welding torch with parting agent for approximately 0 7 seconds Move the welding torch to the start po sition above the cleaning opening approximately 50 mm 1 97 in cent rally above the middle of the cleaning opening The cleaning operation is comple te and the welding torch is ready f...

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Page 55: ...Troubleshooting maintenance and disposal ...

Page 56: ......

Page 57: ...d parts Before performing work on the cleaning device or any connected system components disconnect the customer s compressed air and power supplies from the cleaning device and the connected system components ensure that they remain disconnected until all work is complete using a suitable measuring instrument ensure that electrically charged com ponents e g capacitors have been discharged WARNING...

Page 58: ...ent of inputs B and H D and G Cause Temperature sensor is faulty Remedy Change cleaning coil Ready to clean signal not transmitted to robot control Mains voltage indicator lit overtemperature indicator lit Cause The cleaning device is overheating Remedy Allow cleaning device to cool down Once the permitted operating tempera ture has been reached charging of the capacitors starts again The cleaning...

Page 59: ... hose see Connecting the cleaning device to the Robacta Reamer parting agent con tainer Cause Compressed air supply interrupted Remedy Establish the compressed air supply Cause Compressed air supply line faulty or dirty Remedy Clean compressed air supply line replace if necessary Cause Faulty vacuum pump Remedy Contact After Sales Service arrange for vacuum pump to be replaced Cause Faulty solenoi...

Page 60: ... 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 Disconnect the cleaning device from the mains and wait for approx 1 minute before reconnecting it to the mains Contact After Sales Service if this does not remedy the situation ...

Page 61: ... the Robacta Reamer parting agent container Check the condition of the brush seal above the cleaning opening Replace the brush seal if worn not applicable for twin devices Every 3 months Drain all the parting agent from the dipping bowl Take the spill tray out of the dipping bowl and dispose of any accumulated dirt Clean the dipping bowl and spill tray Fill the dipping bowl with new parting agent ...

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Page 63: ...Technical data ...

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Page 65: ...from 20 s Dipping bowl minimum capacity 0 75 l 0 20 gal Degree of protection IP 21 Dimensions l w h 330 250 422 mm 12 99 9 84 16 61 in Weight without Robacta TC Cool Robacta TC Cool MD part ing agent 24 4 kg 53 79 lb EMC emission class A Mark of conformity CE CSA Mains voltage 110 V Mains voltage tolerance 5 5 Mains frequency 50 60 Hz Nominal output 180 W Mains fuse protection slow blow 10 A Compr...

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Page 67: ...Appendix ...

Page 68: ...68 Spare parts list Robacta TC 2000 ...

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Page 71: ...m 4 4m 3 3m 2m 1m 2 1 A1 CLEANRO2 L N PE L2 T1 230V L1 NC NC FLUID LEVEL FLUID LEVEL NC NC NC NC NC A2 230V AC 50Hz NC NC 5V 5V 5V NET CONTROL TEMP ERROR FLUID LEVEL ERROR GND SINGLE SHOT BUTTON 5V READY TRAFO_L TRAFO_N 18 2VAC 388VAC 18 2VAC 388VAC COIL_TEMP COIL_TEMP_GND 18VAC_ST 18VAC_ROB 18VAC_ROB 18VAC_ST SPRAYER_24V SPRAYER_GND CUTTER_GND CUTTER_24V FAN_24V FAN_GND NC NC NC LEVEL SENSOR SPRA...

Page 72: ... 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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