Operating
Instructions
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
Operating Instructions
EN
42,0426,0135,EN 027-18072024
Contents
Safety rules 5
Explanation of safety notices 5
General 5
Proper use 6
Environmental conditions 6
Obligations of the operator 6
Obligations of personnel 6
Specific hazards 7
Protecting yourself and others 7
Risks from mains current and operating current 8
EMC Device Classifications 9
EMC measures 9
Safety measures at the installation location and during transport 9
Safety measures in normal operation 10
Commissioning, maintenance and repair 10
Safety inspection 11
Safety symbols 11
Data security 11
Copyright 11
General 13
General 15
Device concept 15
Application areas 15
Warning notices on the device 15
Parting agent types and their use 17
Functional principle 18
Functional principle 18
Magnetic flux densities within the cleaning coil for Robacta TC 2000, Robacta TC 2000US20
Magnetic flux densities within the cleaning coil for Robacta TC 2000 Twin, Robacta TC
2000 Twin US
Scope of supply and options 22
General 22
Scope of supply 22
Available options 22
Transport 23
Transport means 23
Transport notices on the packaging 23
Controls, connections and mechanical components 25
Safety 27
Safety 27
Standard I/O connecting plug (X1) pin assignment for robot control 28
General 28
Standard I/O connecting plug (X1) pin assignment 28
Controls, connections and mechanical components 30
General 30
Control panel 30
Robacta TC 2000, Robacta TC 2000 US connections and mechanical components 32
Robacta TC 2000 Twin, Robacta TC 2000 Twin US connections and mechanical components
Installation and commissioning 37
21
34
Safety 39
Safety 39
Before commissioning 40
Operators, maintenance personnel 40
3
Setup regulations 40
Compressed air supply specifications 40
Mains connection 41
Screwing the cleaning device to the underlying surface 42
Screwing the cleaning device to the underlying surface 42
Connecting the mains cable 43
Connecting the mains cable 43
Installing the wire cutter 44
Installing the wire cutter on the cleaning device 44
Maximum wire diameter 44
Filling the dipping bowl with parting agent 45
Filling the dipping bowl with parting agent 45
Connecting the cleaning device to the "Robacta Reamer" parting agent container 46
Connecting the cleaning device to the "Robacta Reamer" parting agent container 46
Starting up the cleaning device 47
General 47
Prerequisites for start-up 47
Gas nozzle to spool body distance control 47
Cleaning program sequence - Robacta TC 2000, Robacta TC 2000 US 48
Program sequence with parting agent nebuliser - overview 48
Program sequence with parting agent nebuliser and dipping bowl - overview 48
Cooling welding torch in the dipping bowl - detailed description 48
Cleaning the gas nozzle tip and nozzle fitting - detailed description 49
Spraying parting agent - detailed description 49
Cleaning program sequence with parting agent nebuliser 51
Cleaning program sequence with dipping bowl 52
Cleaning program sequence - Robacta TC 2000 Twin, Robacta TC 2000 Twin US 53
Program sequence with parting agent nebuliser - overview 53
Program sequence with parting agent nebuliser and dipping bowl - overview 53
Cooling welding torch in the dipping bowl - detailed description 53
Cleaning the gas nozzle tip and nozzle fitting - detailed description 54
Spraying parting agent - detailed description 54
Cleaning program sequence with parting agent nebuliser 55
Cleaning program sequence with dipping bowl 56
Troubleshooting, maintenance and disposal 57
Safety 59
Safety 59
Troubleshooting 61
Troubleshooting 61
Care, maintenance and disposal 64
Before each start-up 64
Daily 64
Weekly 64
Every 4 weeks 64
Every 6 months 65
Every 12 months 65
Disposal 65
Technical data 67
Technical data 69
General 69
Robacta TC 2000, Robacta TC 2000 Twin 69
Robacta TC 2000 US, Robacta TC 2000 Twin US 69
4
Safety rules
Explanation of safety notices
DANGER!
Indicates immediate danger.
If not avoided, death or serious injury will result.
▶
WARNING!
Indicates a potentially hazardous situation.
If not avoided, death or serious injury may result.
▶
CAUTION!
Indicates a situation where damage or injury could occur.
If not avoided, minor injury and/or damage to property may result.
▶
NOTE!
Indicates a risk of flawed results and possible damage to the equipment.
General The device is manufactured using state-of-the-art technology and according to
recognised safety standards. If used incorrectly or misused, however, it can
cause:
injury or death to the operator or a third party,
-
damage to the device and other material assets belonging to the operating
-
company,
inefficient operation of the device.
-
All persons involved in commissioning, operating, maintaining and servicing the
device must:
be suitably qualified,
-
have sufficient knowledge of automated welding, and
-
read and carefully follow these operating instructions as well as the operat-
-
ing instructions for all system components.
The operating instructions must always be at hand wherever the device is being
used. In addition to the operating instructions, attention must also be paid to any
generally applicable and local regulations regarding accident prevention and environmental protection.
All safety and danger notices 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!
5
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.
Proper use includes:
carefully reading and following all the instructions given in the operating in-
-
structions
studying and obeying all safety and danger notices carefully
-
performing all stipulated inspection and servicing work.
-
The device is designed for use in industry and the workshop. The manufacturer
accepts no responsibility for any damage caused through use in a domestic setting.
The manufacturer likewise accepts no liability for inadequate or incorrect results.
Environmental conditions
Obligations of the operator
Operation or storage of the device outside the stipulated area will be deemed 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:
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)
The operator must only allow persons to work with the device who:
are familiar with the fundamental instructions regarding safety at work and
-
accident prevention and have been instructed in how to use the device
have read and understood these operating instructions, especially the sec-
-
tion "safety rules", and have confirmed as much with their signatures
are trained to produce the required results.
-
Checks must be carried out at regular intervals to ensure that operators are
working in a safety-conscious manner.
Obligations of personnel
6
Before using the device, all persons instructed to do so undertake:
to observe the basic instructions regarding safety at work and accident pre-
-
vention
to read these operating instructions, especially the "Safety rules" section and
-
sign to confirm that they have understood them and will follow them.
Before leaving the workplace, ensure that people or property cannot come to any
harm in your absence.
Specific hazards
Stay out of the working area of the robot.
The device must be incorporated into a higher-level safety system within a secured area.
If this area has to be accessed when setup and maintenance work is carried out,
make sure that
the entire system is switched off for the duration of the work in this area
-
and that it is prevented from starting up accidentally, e.g., as the result of a
-
control fault
In addition to these operating instructions, the safety rules issued by the robot
manufacturer must also be observed.
Covers and side panels may only be opened/removed while maintenance or repair
work is being carried out.
During operation:
Ensure that all covers are closed and all side panels are fitted properly.
-
Keep all covers and side panels closed.
-
Protecting yourself and others
Electromagnetic fields may pose as yet unknown risks to health:
Effects on the health of persons in the vicinity, for example, those with pace-
-
makers, metallic implants and hearing aids
Forbidden for anyone wearing a pacemaker: people wearing a pacemaker
-
must consult their doctor before working with the device or entering its immediate vicinity
Forbidden for anyone with metal implants: people who have had metal im-
-
plants fitted must consult their doctor before working with the device or entering its immediate vicinity
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.
Anyone working with the device exposes themselves to numerous risks e.g.:
flying sparks and hot pieces of metal
-
Arc radiation, which can damage eyes and skin
-
Risk of electrocution from mains current and welding current
-
Greater noise pollution
-
Harmful welding fumes and gases
-
Suitable protective clothing must be worn when working with the device. The
protective clothing must have 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
-
7
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 protective goggles with side protection behind the protect-
-
ive visor
Wear stout footwear that provides insulation even in wet conditions
-
Protect the hands with suitable gloves (electrically insulated and providing
-
protection against heat)
Wear ear protection to reduce the harmful effects of noise and to prevent in-
-
jury
Keep all persons, especially children, out of the working area while any devices
are in operation or welding is in progress. If, however, there are people in the vicinity:
make them aware of all the dangers (dazzling by arc, injury from flying
-
sparks, inhalation of harmful welding fumes, noise, possible danger from
mains or welding current, possible danger from electromagnetic fields, possible danger from the magnetic field around the cleaning opening, mechanically-powered parts, compressed air/parting agent mixture ejected from the
cleaning opening, flying shavings and similar matter, etc.),
Provide suitable protective equipment
-
Alternatively, erect suitable safety screens/curtains.
-
Risks from mains
current and operating current
An electric shock is potentially life threatening and can be fatal.
Do not touch live parts either inside or outside the device.
All cables and leads must be secured, undamaged, insulated and adequately dimensioned. Loose connections, scorched, damaged or inadequately dimensioned
cables and leads must be replaced immediately.
Do not sling cables or leads around the body or parts of the body.
Only switch on the device when all output connections have been established
correctly.
The device must only be operated on a mains supply with a ground conductor
and a socket with a ground conductor contact.
If the device is operated on a mains supply without a ground conductor, this will
be deemed as gross negligence. The manufacturer shall not be held liable for any
damage arising from such usage.
Arrange for the mains cable to be checked regularly by a qualified electrician 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 de-energised.
-
If work on live parts is required, appoint a second person to switch off the main
switch at the right moment.
8
The housing screws provide an adequate ground conductor connection for earthing the housing. The screws must never be replaced with different screws unless
a reliable ground conductor connection is set up.
EMC Device Classifications
EMC measures Warning, electromagnetic field. Electromagnetic fields may pose as yet unknown
Devices in emission class A:
Are only designed for use in industrial settings
-
Can cause line-bound and radiated interference in other areas
-
Devices in emission class B:
Satisfy the emissions criteria for residential and industrial areas. This is also
-
true for residential areas in which the energy is supplied from the public lowvoltage mains.
EMC device classification as per the rating plate or technical data.
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 action
to rectify the situation.
Check for possible problems, and check and evaluate neighbouring devices' resistance to interference according to national and international requirements:
Safety devices
-
Power, signal and data transfer lines
-
IT and telecommunications devices
-
Measuring and calibrating devices
-
Health of neighbouring persons
-
Safety measures
at the installation location and
during transport
Supporting measures for avoidance of EMC problems:
Mains supply
1.
If electromagnetic interference arises despite the correct mains connec-
-
tion, additional measures are necessary (e.g. use of a suitable line filter)
Shielding, if necessary
2.
Shield off other nearby devices
-
Shield off entire welding installation
-
Do not have any magnetic or electronic data carriers about your person:
3.
magnetic or electronic data carriers can be damaged by the magnetic fields
generated when the device is in use.
Do not have any watches or pieces of metal about your person. Watches can
4.
be damaged when the device is in use.
A device toppling over could easily kill someone. Place the device on a solid, level
surface such that it remains stable
The maximum permissible tilt angle is 10°.
-
Special regulations apply in rooms at risk of fire or explosion
Observe relevant national and international regulations.
-
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 protection
shown on the rating plate.
9
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. walls, other devices or objects.
The device must be set up at least 1 m (40 in.) away from computers, control
lines and the welding process.
Position the device to prevent welding spatter coming into contact with the
cleaning device.
Before transporting the device, allow parting agent to drain completely.
When transporting the device, observe the relevant national and local guidelines
and accident prevention regulations. This applies especially to guidelines regarding the risks arising during transport.
After transporting the device, the device must be visually inspected for damage
before commissioning. Any damage must be repaired by trained service technicians before commissioning the device.
Safety measures
in normal operation
Only operate the device when all safety devices are fully functional. If the safety
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
switching on the device.
Never bypass or disable safety devices.
Before switching on the device, ensure that no one is likely to be endangered.
Check the device at least once a week for obvious damage and proper functioning of safety devices.
Only use suitable original parting agent from the manufacturer.
-
Observe the information on the parting agent safety data sheets when hand-
-
ling parting agent. The parting agent safety data sheets may be obtained
from your service centre or downloaded from the manufacturer's website.
Do not mix the manufacturer's parting agent with other parting agents.
-
If damage results from using a different parting agent, the manufacturer ac-
-
cepts no liability. In addition, no warranty claims will be entertained.
Used parting agent must be disposed of properly in accordance with the rel-
-
evant national and international regulations.
Commissioning, maintenance and repair
10
It is impossible to guarantee that bought-in parts are designed and manufactured to meet the demands made of them, or that they satisfy safety requirements.
Use only original spare and wearing parts (also applies to standard parts).
-
Do not carry out any modifications, alterations, etc. to the device without the
-
manufacturer's consent.
Components that are not in perfect condition must be replaced immediately.
-
When ordering, please give the exact designation and part number as shown
-
in the spare parts list, as well as the serial number of your device.
The housing screws provide the ground conductor connection for earthing the
housing parts.
Only use original housing screws in the correct number and tightened to the specified torque.
Safety inspection
Safety symbols Devices with the CE mark satisfy the essential requirements of the low-voltage
The manufacturer recommends that a safety inspection of the device is performed at least once every 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 standards and directives.
Further details on safety inspection and calibration can be obtained from your
service centre. They will provide you on request with any documents you may require.
and electromagnetic compatibility directives (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 relevant
standards for Canada and the USA.
Data security With regard to data security, the user is responsible for:
backing up any changes made to the factory settings
-
saving and retaining personal settings
-
Copyright Copyright of these operating instructions remains with the manufacturer.
Text and illustrations were accurate at the time of printing, subject to change.
We are grateful for suggestions for improvement and information regarding any
discrepancies in the operating instructions.
11
12
General
13
14
General
Device concept
Application areas
The cleaning devices in the Robacta TC
2000 series have been designed to
clean a variety of different welding
torch geometries. The components are
contained in a robust housing. The
compact design means it can be set up
in the narrowest of spaces (e.g. in robot cells). In addition, the cleaning
devices have been conceived in such a
way that the installation stand and
standard I/O connecting plug (X1) of
the Robacta TC 1000 can be used with
the cleaning devices without any modifications.
Robacta TC 2000
The cleaning devices are more or less maintenance-free, as there are no mechanically stressed parts.
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
-
rolling stock construction
-
shipyards
-
Warning notices on the device
The device is fitted with safety symbols and a rating plate. The safety symbols
and rating plate must not be removed or painted over. The symbols warn against
operating the equipment incorrectly, as this could result in serious injury or damage to property.
15
WARNING! Risk of serious injury from:
The magnetic field surrounding the cleaning opening
-
Compressed air/parting agent mixture escaping from the
-
cleaning opening
Flying parts (shavings, etc.)
-
Mechanically powered components
-
Keep device free from current and pressure during maintenance
and servicing.
Do not use the functions described here until you have fully read
and understood the following documents:
These Operating Instructions
-
All the Operating Instructions for the system components, es-
-
pecially the safety rules
For indoor use only
Wear eye protection
16
Forbidden for anyone wearing a pacemaker
Parting agent types and their use
NOTE!
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 operation
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.
17
Functional principle
5
4,5
4
3,5
3
20 25 30 35 40
45 50
(2)
(1)
Functional principle
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. The "Quick Stop" signal
must also be set.
The device temperature is checked before the capacitors are charged. If it
-
lies within the tolerance range, the capacitors are charged in preparation for
a cleaning operation. If the operating temperature is exceeded, the overtemperature indicator lights up. Capacitor charging only begins once the temperature has fallen to the permitted operating temperature.
The "Ready" signal is output to the robot control after twenty seconds of
-
charging - the "Ready-to-discharge" indicator on the device begins to flash.
When the capacitors are fully charged, the light remains permanently on. Although the device has still not achieved maximum magnetic flux density
after just twenty seconds, the cleaning operation (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 the exact relationship between charging time and
the magnetic flux density available.
18
(1) Magnetic flux density available (Tesla)
(2) Charging time (seconds)
Once the cleaning operation is complete, the program sequence restarts by
-
checking the device's temperature. If there was a problem during the cleaning operation, the "Error" signal is output. The cleaning device resumes charging the capacitors. Once ready to clean ("Ready"), a second cleaning operation can be started.
NOTE!
If the robot control deactivates the "Quick Stop" signal during the program
sequence, 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. After draining the
"Robacta TC Cool +" parting agent container, the fill level in the dipping bowl
drops. The level sensor detects that the level has dropped too low and the
fill level indicator lights up. At the same time, the "Fluid level control" signal
is transmitted to the robot control.
The device cleaning function remains available even if the fill level indic-
-
ator is illuminated.
19
Magnetic flux
0 % 100 %
50 mm
1.97 in.
10 mm
0.39 in.
15 mm
0.59 in.
(1) (2) (3)
densities 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!
When using the cleaning device, refer to the program sequence for details of the
welding torch immersion depth.
(1) Cleaning coil
(2) Diagram showing available magnetic flux density
(3) Immersion depth of torch neck into cleaning coil
20
Magnetic flux
0 % 100 %
54 mm
2.13 in.
14 mm
0.55 in.
19 mm
0.75 in.
(1) (2) (3)
densities within
the cleaning coil
for Robacta TC
2000 Twin,
Robacta TC
2000 Twin 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!
When using the cleaning device, refer to the program sequence for details of the
welding torch immersion depth.
(1) Cleaning coil
(2) Diagram showing available magnetic flux density
(3) Immersion depth of torch neck into cleaning coil
21
Scope of supply and options
General The cleaning device may be operated in conjunction with various options. De-
pending on the area of application, various sequences in the work process can be
optimized as a result.
Scope of supply
Available options
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 for the cleaning device
Installation stand (available in various heights)
-
Wire cutter
-
Wire cutter installation kit
-
Parting agent nebuliser installation kit
-
Robot interface
-
22
Transport
Transport means The device is to be transported by the following means:
On pallets using a counterbalanced lift truck
-
On pallets using a lift truck
-
Manually
-
WARNING!
Danger from falling devices and objects.
This can result in serious injury and damage to property.
Secure the device to prevent it from falling over while being transporting on
▶
a counterbalanced lift truck or lift truck.
Avoid sudden changes in direction, braking or acceleration.
▶
Transport notices on the
packaging
CAUTION!
Danger due to improper transport.
This can result in damage to property.
Observe the transport notices on the device packaging.
▶
23
24
Controls, connections and mechan-
ical components
25
26
Safety
Safety Observe the following safety rules for all work described in the "Control ele-
ments, connections and mechanical components" chapter.
WARNING!
Danger from incorrect operation and work that is not carried out properly.
This can result in serious personal injury and damage to property.
All the work and functions described in this document must only be carried
▶
out by technically trained and qualified personnel.
Read and understand this document in full.
▶
Read and understand all safety rules and user documentation for this device
▶
and all system components.
27
Standard I/O connecting plug (X1) pin assignment for robot control
General
Standard I/O
connecting plug
(X1) pin assignment
WARNING!
Danger from electric current.
This can result in serious personal injury and damage to property.
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.
The standard I/O connecting plug (X1) for connecting the cleaning device to the
robot control is part of the scope of supply. Adapt the cable harness to the connection technology on the robot control.
WARNING!
Danger due to unexpectedly activated cleaning device/unexpectedly activated
system components.
This can result in serious personal injury and damage to property.
Only assign the Quick Stop signal input with HIGH or
▶
Only assign the Quick Stop signal input with LOW
▶
NOTE!
Depending on the demands placed on the robot application, not all input and
output signals (commands) need to be used.
The underlined I/O signals in the following figure represent the minimum command subset required in all applications.
28
R
S
T
Not assigned
HIGH - Quick Stop
+24 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
CT atcaboR
Spray In
GND
Wire Cutter
Standard I/O connecting plug (X1) pin assignment
29
Controls, connections and mechanical compon-
(1)
(2)
(3) (4)
(5)
ents
General All functions of the cleaning unit are activated by the robot control. For adjust-
ment, 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.
Control panel
(1) Mains voltage indicator
lights up when the device is powered by mains voltage
NOTE!
If the capacitors in the device are charged, they will discharge automatically as
soon as the device is unplugged from the mains. Discharge time is approx. 1
second.
(2) Overtemperature indicator
lights up when the device overheats
NOTE!
One more cleaning operation can be carried out after this indicator lights up.
Only once the device has cooled back down to the operating temperature will
the device recharge in preparation for the next cleaning operation.
(3) Fill level indicator
will come on
if the fill level in the dipping bowl drops below minimum
-
if the dipping bowl is not used, hence there is no parting agent in the
-
dipping bowl
30
NOTE!
If the dipping bowl in use, it should be refilled with parting agent as soon as the
fill level indicator lights up.
NOTE!
The cleaning function of the Robacta TC remains available even if the fill level
indicator is illuminated.
(4) Discharge key
press the key briefly; the cleaning device will perform the following functions:
Cleaning is started
1.
press and hold the key; the cleaning device will perform the following
functions in sequence:
Cleaning is started
1.
Wire cutter is activated
2.
Compressed air/parting agent mixture is sprayed out of the cleaning
3.
opening
NOTE!
The cleaning device can only perform these functions if the "Quick Stop" signal
is set and the capacitors are charged.
(5) Ready-to-clean indicator
lights up when the device is ready to clean
31
Robacta TC
(4)
(5)
(2)
(3)
(1)
(6)
(6)
(6)
(6)
(7)
(8)
(9)
(10)
2000, Robacta
TC 2000 US connections and
mechanical components
Front of device
Rear of device
(1) Level sensor
monitors the parting agent fill level in the dipping bowl
(2) 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.
(3) 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.
NOTE!
Ensure that there is always sufficient parting agent in the dipping bowl when in
use (i.e. ensure that the fill level indicator never lights up).
32
(4) Standard I/O (X1) connection
(5) Mains cable connection
(6) Recesses for the wire cutter holder
for attaching the wire cutter holder to the cleaning device
(7) Drain hose
for emptying the dipping bowl
(8) 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
(9) Wire cutter connection
(11)
(12)
for electrically controlling the wire cutter
(10) Compressed air connection
for supplying the cleaning device with compressed air
(11) Installation stand (option)
(12) Spatter tray for welding
residues
33
Robacta TC
(4)
(5)
(2)
(3)
(1)
(6)
(6)
(6)
(6)
(7)
(8)
(9)
(10)
2000 Twin,
Robacta TC
2000 Twin US
connections and
mechanical components
Front of device
Rear of device
(1) Level sensor
monitors the parting agent fill level in the dipping bowl
(2) 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
(3) 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.
NOTE!
Ensure that there is always sufficient parting agent in the dipping bowl when in
use (i.e. ensure that the fill level indicator never lights up).
(4) Standard I/O (X1) connection
(5) Mains cable connection
34
(6) Recesses for the wire cutter holder
for attaching the wire cutter holder to the cleaning device
(7) Drain hose
for emptying the dipping bowl
(8) 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
(9) Wire cutter connection
for electrically controlling the wire cutter
(10) Compressed air connection
(11)
(12)
for supplying the cleaning device with compressed air
(11) Installation stand (option)
(12) Spatter tray for welding
residues
35
36
Installation and commissioning
37
38
Safety
Safety Observe the following safety rules for all work described in the "Installation and
commissioning" chapter.
WARNING!
Danger from incorrect operation and work that is not carried out properly.
This can result in serious personal injury and damage to property.
All the work and functions described in this document must only be carried
▶
out by a trained Fronius service technician.
Read and understand this document in full.
▶
Read and understand all safety rules and user documentation for this device
▶
and all system components.
WARNING!
Risk of machines starting automatically.
This can result in serious injury and damage to property.
In addition to this document, observe all user documentation of the robot
▶
manufacturer.
Ensure that all protective measures have been taken and will remain in place
▶
in the working area of the robot.
WARNING!
Danger from electric current and mechanically powered parts.
This can result in serious injury and damage to property.
Before working on the cleaning device or the associated system components,
▶
disconnect the customer's compressed air and power supply from the cleaning device and the associated system components.
Ensure that they remain disconnected until all work is complete.
▶
WARNING!
Danger from the magnetic field of the cleaning opening, from compressed air/
parting agent mixture escaping from the cleaning opening, from moving parts,
from flying parts or shavings or from activated wire cutters as a result of a
voltage and/or compressed air supply to the cleaning device.
This can result in serious injury and damage to property.
If work has to be performed on the cleaning device while it is being supplied with
voltage and/or compressed air:
Keep ferromagnetic parts away from the device (e.g. tools).
▶
Keep body parts such as fingers, hands and hair, as well as objects and cloth-
▶
ing away from the cleaning opening.
Wear ear protection.
▶
Wear protective goggles with side protection.
▶
39
Before commissioning
Operators, maintenance personnel
Setup regulations
WARNING!
Risk of machines starting automatically.
This can result in serious injury and damage to property.
The device must only be operated by one person.
▶
Nobody may be in the working area of the device while it is in operation.
▶
The device must only be serviced or maintained by one person.
▶
Nobody else may be within the radius of the device while it is being worked
▶
on.
The device is tested to IP 21, meaning:
protection against penetration by solid foreign bodies with diameters > 12.5
-
mm (0.49 in.)
protection against vertically falling drops of water
-
The device must not be set up and operated outdoors. The built in electrical
parts must be protected from direct wetting.
NOTE!
The device must be set up at least 1 m (40 in.) away from computers, control
lines and the welding process.
Compressed air
supply specifications
NOTE!
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. walls, other devices or objects.
NOTE!
Position the device to prevent welding spatter coming into contact with the
cleaning device.
To ensure that the cleaning device functions correctly, the following compressed
air supply specifications must be met:
Establish compressed air supply using a pressure limiter and compressed air
-
filter
Provide compressed air quality conforming to ISO 8573-1:2001, class 7 4 3,
-
instrument air
-
Solid particle concentration £ 10 mg/m
Vapour pressure dew point £ + 3 °C
-
-
Oil concentration £ 1 mg/m
3
3
40
Mains connection
CAUTION!
Danger due to insufficiently dimensioned electrical installations.
This can result in damage to property.
Dimension the mains lead and its fuse to suit the local power supply.
▶
The technical data shown on the rating plate applies.
CAUTION!
Danger from incorrect mains voltage.
This can result in damage to property.
If the mains voltage lies outside the tolerances given in the technical data,
▶
do not under any circumstances connect the device to the mains.
The cleaning device is designed to be operated at the mains voltage indicated on
the rating plate. The fuse protection required for the mains lead can be found in
the "Technical data" section. If there is no mains cable or mains plug on your version of the appliance, fit one that conforms to national standards.
41
Screwing the cleaning device to the underlying
4
4
4
4
surface
Screwing the cleaning device to the underlying surface
Different fixings may be required to screw the installation stand to the underlying
surface depending on the nature of the surface.
IMPORTANT! The required fixings are not included in the scope of supply of the
cleaning device or the installation stand.
The screws included in the scope of supply of the installation stand are not suitable for fixing the installation stand to the underlying surface.
WARNING!
Danger from devices falling or toppling over.
This can result in serious injury and damage to property.
Only set up the device with an assembly stand provided for this purpose.
▶
The installer is responsible for selecting the right type of fixing.
▶
IMPORTANT! Position the installation stand in such a way that the distance the
robot has to travel to the cleaning device on the installation stand is as short as
possible
Place the installation stand on a level, firm and vibration-free surface
1
Screw the installation stand to the underlying surface using the appropriate
2
fixings
Position the cleaning device on the
3
installation stand
Use the 4 screws supplied with the
4
installation stand to secure the
cleaning device to the installation
stand.
42
Connecting the mains cable
1
Connecting the mains cable
Connect the mains cable:
1
Plug in the mains cable
-
Turn the mains cable 45° to
-
the right until you hear it latch
into place
43
Installing the wire cutter
Installing the wire cutter on the cleaning device
To install a wire cutter on the cleaning device, the wire cutter mounting set is required.
The installation of the wire cutter on the cleaning device is described in the installation instructions 42,0410,1960 included with the set.
The installation instructions are available as follows:
QR code https://...
Wire Cutter Mounting Set Installation Instructions
HTML
https://manuals.fronius.com/html/4204101960
Wire Cutter Mounting Set Installation Instructions
PDF
https://www.fronius.com/welding-technology/downloads
Find downloads: 42,0410,1960
Maximum wire diameter
The installation instructions can also be made available in printed form on request.
For conventional applications (one wire electrode), wire electrodes with a diameter of up to 1.6 mm (0.063 in.) 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.
44
Filling the dipping bowl with parting agent
3 421
Filling the dipping bowl with
parting agent
NOTE!
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 Robacta TC. If other manufacturers' products are used, trouble-free operation cannot be guaranteed.
Fold out the container holder containing the empty "Robacta TC Cool +"
1
parting agent container
Remove the empty "Robacta TC Cool +" parting agent container and dispose
2
of it according to national regulations
Open a new "Robacta TC Cool +" parting agent container and put it into the
3
holder
Fold the container holder containing the full "Robacta TC Cool +" parting
4
agent container carefully back above the dipping bowl
The optimum fill-level is regulated automatically
-
NOTE!
Carry out the following maintenance on the dipping bowl at weekly intervals:
Take the spill tray out of the dipping bowl and dispose of any accumulated
▶
dirt
Check the consistency of the "Robacta TC Cool +" parting agent. If the
▶
"Robacta TC Cool +" parting agent is thick, add fresh water and stir to mix in
Check the level sensor in the dipping bowl for dirt and clean if necessary
▶
NOTE!
Carry out the following maintenance on the dipping bowl every three 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
▶
Take care never to damage the level sensor when performing maintenance work.
45
Connecting the cleaning device to the "Robacta
2
7
3
4
1
5
6
Reamer" parting agent container
Connecting the cleaning device to the "Robacta Reamer" parting agent container
NOTE!
Only use "Robacta Reamer" parting agent supplied by the manufacturer.
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.
1
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 gas nozzle.
46
Starting up the cleaning device
General
Prerequisites for start-up
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" parting agent before starting automatic operation.
To achieve the best cleaning results, please note the following:
Apply an even layer of parting agent to the inside of the torch
-
Follow the cleaning sequences as described below
-
Keep to the specified cleaning positions
-
Blow out the welding torch with compressed air during the cleaning opera-
-
tion (however not when parting agent is being actively sprayed into the torch
interior)
NOTE!
Single, small bits of welding spatter cannot be removed by the cleaning device.
However, these small pieces do not influence the welding process.
The following requirements must be met before the cleaning device is started up:
Cleaning device is bolted to underlying surface
-
If present, connect the "Robacta Reamer" parting agent container to the
-
cleaning device
If using the dipping bowl, the dipping bowl is filled with the "Robacta TC
-
Cool +" 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 device connected to robot control
-
Gas nozzle to
spool body distance control
When the welding torch is in the spool (correct insertion depth), the torch must
be free to move in every direction.
To check whether the torch has sufficient freedom of movement, it must have to
be firmly pressed by hand in 4 directions before it will touch the spool wall.
47
Cleaning program sequence - Robacta TC 2000,
max. 75 mm
(2.95 in.)
(1)
Robacta TC 2000 US
Program sequence with
parting agent
nebuliser - overview
Program sequence with
parting agent
nebuliser and
dipping bowl overview
Cooling welding
torch in the dipping bowl - detailed description
Weld
1.
Clean gas nozzle tip and nozzle fitting
2.
Spray parting agent
3.
Weld
4.
Weld
1.
Cool welding torch in dipping bowl
2.
Clean gas nozzle tip and nozzle fitting
3.
Spray parting agent
4.
Weld
5.
Immersing the hot welding torch in the "Robacta TC Cool / Robacta TC Cool MD"
parting agent has the following benefits:
The spatter that has accumulated on the gas nozzle is loosened
-
The welding 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
1
torch approximately 50 mm (1.97
in.) above the dipping bowl
Depending on the application, hold the welding torch in the dipping bowl for
3
approximately 1 - 4 seconds so that any air in the torch can escape and the
torch can cool sufficiently
Raise the welding torch back to its original position above the dipping bowl
4
Allow the welding torch to drip for approximately 1 - 4 seconds or blow down
5
it with compressed air using the hosepack before bringing it back to its original position for cleaning
NOTE!
Do not dip the welding torch more
than 75 mm (2.95 in.) into the dipping
bowl. The gas holes (1) must remain
dry.
Dip the welding torch vertically in-
2
to the dipping bowl
48
Cleaning the gas
60 mm
( 2.36 in.)
50 mm
( 1.97 in.)
(1)
nozzle tip and
nozzle fitting detailed description
NOTE!
During the cleaning operation, blow out the welding torch with compressed air
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.
Position the welding torch approx-
1
imately 50 mm (1.97 in.) centrally
above the middle of the cleaning
opening
NOTE!
If the brush seal (1) is fitted, note the
changed reference point when positioning the welding torch.
Move the welding torch vertically into the cleaning position
2
see figure
-
Begin cleaning and hold the welding torch for approximately 1 second in the
3
cleaning position
Spraying parting agent - detailed description
Applying parting agent evenly has the following advantages:
reduced welding spatter accumulation
-
prevents re-soiling
-
NOTE!
If the brush seal (1) is fitted, note the changed reference point when positioning
the welding torch.
NOTE!
Ensure that the gas nozzle does not touch the housing components of the cleaning opening at any time.
49
75 mm
( 2.95 in.)
65 mm
( 2.56 in.)
(1)
Place the welding torch in the
1
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
2
agent for approximately 0.7
seconds
Move the welding torch to the start position above the cleaning opening - ap-
3
proximately 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
4
(no droplet formation). If this is the case :
Reduce the spray time or
-
After the cleaning operation, blow out the welding torch with com-
-
pressed air using the hosepack
50
Cleaning program sequence
with parting
agent nebuliser
Start
"Welding torch
cleaning" program
Move to position C
Move to position E
Set 1
Wait 0.5 s
Set 2
Wait 0.5 s
Reset 1
Set 1/Reset 1
Blow compressed air through torch
Set 2/Reset 2
"Start cleaning" signal
Set 3/Reset 3
"Spray parting agent" signal
Reset 2
Move to position F
Set 3
Wait 0.7 s
Reset 3
Move to position C
End
51
Cleaning program sequence
with dipping
bowl
Start
"Welding torch
cleaning" program
Move to position A
Move to position B
Set 1/Reset 1
Blow compressed air through welding torch
Set 2/Reset 2
"Start cleaning" signal
Set 3/Reset 3
"Spray parting agent" signal
Wait 1 - 4 s
Move to position A
Wait 1 - 4 s
Move to position C
Move to position E
Set 1
Wait 0.5 s
Set 2
Wait 0.5 s
V
= 10 cm/s
max
(236.22 ipm)
Reset 1
Reset 2
Move to position F
Set 3
Wait 0.7 s
Reset 3
Move to position C
End
52
Cleaning program sequence - Robacta TC 2000
max. 75 mm
(2.95 in.)
(1)
Twin, Robacta TC 2000 Twin US
Program sequence with
parting agent
nebuliser - overview
Program sequence with
parting agent
nebuliser and
dipping bowl overview
Cooling welding
torch in the dipping bowl - detailed description
Weld
1.
Clean gas nozzle tip and nozzle fitting
2.
Spray parting agent
3.
Weld
4.
Weld
1.
Cool welding torch in dipping bowl
2.
Clean gas nozzle tip and nozzle fitting
3.
Spray parting agent
4.
Weld
5.
Immersing the hot welding torch in the "Robacta TC Cool / Robacta TC Cool MD"
parting agent has the following benefits:
The spatter that has accumulated on the gas nozzle is loosened
-
The welding 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
1
torch approximately 50 mm (1.97
in.) above the dipping bowl
Depending on the application, hold the welding torch in the dipping bowl for
3
approximately 1 - 4 seconds so that any air in the torch can escape and the
torch can cool sufficiently
Raise the welding torch back to its original position above the dipping bowl
4
Allow the welding torch to drip for approximately 1 - 4 seconds or blow down
5
it with compressed air using the hosepack before bringing it back to its original position for cleaning
NOTE!
Do not dip the welding torch more
than 75 mm (2.95 in.) into the dipping
bowl. The gas holes (1) must remain
dry.
Dip the welding torch vertically in-
2
to the dipping bowl
53
Cleaning the gas
55 mm
(2.17 in.)
55 mm
(2.17 in.)
nozzle tip and
nozzle fitting detailed description
NOTE!
During the cleaning operation, blow out the welding torch with compressed air
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.
Position the welding torch approx.
1
50 mm (1.97 in.) centrally above
the middle of the cleaning opening
Move the welding torch vertically
2
into the cleaning/spray position
see figure
-
Begin cleaning and wait for approx.
3
1 second
Spraying parting agent - detailed description
Applying parting agent evenly has the following advantages:
reduced welding spatter accumulation
-
prevents re-soiling
-
NOTE!
Ensure that the gas nozzle does not touch the housing components of the cleaning opening at any time.
Maintain cleaning/spray position
1
see figure
-
NOTE!
Do not blow compressed air through
the welding torch during the spraying
process.
Spray welding torch with parting
2
agent for approx. 0.7 seconds
54
Move the welding torch to the start position above the cleaning opening - ap-
3
prox. 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
4
(no droplet formation). If this is the case:
Reduce the spray time or
-
After the cleaning operation, blow out the welding torch with com-
-
pressed air using the hosepack
Cleaning program sequence
with parting
agent nebuliser
Start
"Welding torch
cleaning" program
Move to position C
Move to position E
Set 1
Wait 0.5 s
Set 2
Wait 0.5 s
Reset 1
Set 1/Reset 1
Blow compressed air through welding torch
Set 2/Reset 2
"Start cleaning" signal
Set 3/Reset 3
"Spray parting agent" signal
Reset 2
Set 3
Wait 0.7 s
Reset 3
Move to position C
End
55
Cleaning program sequence
with dipping
bowl
Start
"Welding torch
cleaning" program
Move to position A
Move to position B
Set 1/Reset 1
Blow compressed air through welding torch
Set 2/Reset 2
"Start cleaning" signal
Set 3/Reset 3
"Spray parting agent" signal
Wait 1 - 4 s
Move to position A
Wait 1 - 4 s
Move to position C
Move to position E
Set 1
Wait 0.5 s
Set 2
Wait 0.5 s
V
= 10 cm/s
max
(236.22 ipm)
Reset 1
Reset 2
Set 3
Wait 0.7 s
Reset 3
Move to position C
End
56
Troubleshooting, maintenance and
disposal
57
58
Safety
Safety Observe the following safety rules for all work described in the "Troubleshooting,
maintenance and disposal" chapter.
WARNING!
Danger from incorrect operation and work that is not carried out properly.
This can result in serious personal injury and damage to property.
All the work and functions described in this document must only be carried
▶
out by a trained Fronius service technician.
Read and understand this document in full.
▶
Read and understand all safety rules and user documentation for this device
▶
and all system components.
WARNING!
Risk of machines starting automatically.
This can result in serious injury and damage to property.
In addition to this document, observe all user documentation of the robot
▶
manufacturer.
Ensure that all protective measures have been taken and will remain in place
▶
in the working area of the robot.
WARNING!
Danger from electric current and mechanically powered parts.
This can result in serious injury and damage to property.
Before working on the cleaning device or the associated system components,
▶
disconnect the customer's compressed air and power supply from the cleaning device and the associated system components.
Ensure that they remain disconnected until all work is complete.
▶
WARNING!
Danger from the magnetic field of the cleaning opening, from compressed air/
parting agent mixture escaping from the cleaning opening, from moving parts,
from flying parts or shavings or from activated wire cutters as a result of a
voltage and/or compressed air supply to the cleaning device.
This can result in serious injury and damage to property.
If work has to be performed on the cleaning device while it is being supplied with
voltage and/or compressed air:
Keep ferromagnetic parts away from the device (e.g. tools).
▶
Keep body parts such as fingers, hands and hair, as well as objects and cloth-
▶
ing away from the cleaning opening.
Wear ear protection.
▶
Wear protective goggles with side protection.
▶
59
CAUTION!
Danger from inadequate ground conductor connections.
This can result in injury and damage to property.
The housing screws provide a suitable ground conductor connection for
▶
earthing the housing.
The housing screws must never be replaced with different screws unless a re-
▶
liable ground conductor connection is established.
60
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:
Remedy:
"Ready-to-clean" signal not transmitted to robot control
Mains voltage indicator lit
Cause:
Remedy:
Cause:
Remedy:
Cause:
Remedy:
Ready-to-clean signal not transmitted to robot control
Mains voltage indicator lit, overtemperature indicator lit
Cause:
Remedy:
Faulty mains cable
Check mains cable
Quick Stop is active (HI - Quick Stop = LO / LO - Quick Stop =HI)
Deactivate Quick Stop (HI - Quick Stop = HI / LO - Quick Stop =LO)
Supply to I/O standard connection socket (X1) is faulty
Depending on the connection socket, check the assignment of inputs
"B" and "H" / "D" and "G"
Temperature sensor is faulty
Change cleaning coil
The cleaning device is overheating
Allow cleaning device to cool down. Once the permitted operating
temperature has been reached, charging of the capacitors starts
again. The cleaning device is then ready to clean again
Fill level indicator lit
The liquid in the dipping bowl is below the optimum fill level
Cause:
Remedy:
Fill level indicator lit
The "Robacta TC Cool / Robacta TC Cool MD" parting agent container is not yet
empty
Cause:
Remedy:
Cause:
Remedy:
"Robacta TC Cool / Robacta TC Cool MD" parting agent container is
empty
Replace "Robacta TC Cool / Robacta TC Cool MD" parting agent container
Level sensor is dirty
Clean level sensor with fresh water
Level sensor faulty
Contact After-Sales Service
61
Fill level indicator lit
A dipping bowl is not available or is not being used
Cause:
Remedy:
Fill level indicator not lit
The liquid in the dipping bowl is already below the optimum fill level
Cause:
Remedy:
The parting agent does not spray
The "Robacta Reamer" parting agent container is full
Cause:
Remedy:
Cause:
Remedy:
Cause:
Remedy:
A parting agent nebuliser is being used
Not necessary
Fill-level sensor faulty
Contact After-Sales Service
Not enough spray
Adjust spray amount (spray time)
Dirty suction filter in "Robacta Reamer" parting agent container
Blow compressed air through the suction filter in the "Robacta Ream-
er" parting agent container from the inside outwards using the suction hose
(see section Connecting the cleaning device to the "Robacta Ream-
er" parting agent container on page 46)
Compressed air supply interrupted
Establish the compressed air supply
Cause:
Remedy:
Cause:
Remedy:
Cause:
Remedy:
Parting agent does not spray
Cause:
Remedy:
Cause:
Remedy:
Pores in the weld seam
Cause:
Remedy:
Compressed air supply line faulty or dirty
Clean compressed air supply line, replace if necessary
Faulty vacuum pump
Contact After-Sales Service (arrange for vacuum pump to be re-
placed)
Faulty solenoid valve
Contact After-Sales Service (arrange for solenoid valve to be re-
placed)
The "Robacta Reamer" parting agent container is empty
Fill with parting agent
Interconnecting hosepack damaged
Contact After-Sales Service
Too much parting agent inside the welding torch
Remove parting agent residue by blowing out the torch interior. En-
sure supply of compressed air
62
Cause:
Remedy:
Too much parting agent inside the welding torch
Reduce amount of parting agent spray (shorten duty cycle of pump
for parting agent)
Error is sent to the robot. Overtemperature and fill level indicators flash at the
same time, no cleaning takes place
Cause:
Remedy:
Quick Stop is active (HI - Quick Stop = LO / LO - Quick Stop =HI)
Deactivate Quick Stop (HI - Quick Stop = HI / LO - Quick Stop =LO)
Cause:
Remedy:
Fault in the cleaning device
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
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Care, maintenance and disposal
Before each start-up
Daily
Weekly
Check the fill level in the "Robacta Reamer" parting agent container and the
-
dipping bowl; top up if necessary
NOTE!
The "Robacta TC Cool+" and "Robacta Reamer" parting agents differ in their
composition.
Use the appropriate medium depending on the application concerned.
▶
NOTE!
Clean the device using solvent-free cleaning products only.
Remove any deposits of parting agent or contaminants from the outside of
-
the base and cleaning units.
Empty the spatter tray for welding residues.
-
Take the spill tray out of the dipping bowl and dispose of any accumulated
-
soiling.
Check the consistency of the "Robacta TC Cool+" parting agent.
-
If the "Robacta TC Cool+" parting agent is viscous, add fresh water and stir
to mix with the parting agent.
Check the level sensor in the dipping bowl for soiling and clean if necessary.
-
Clean the cleaning opening on the inside.
-
Check the "Robacta Reamer" and "Robacta TC Cool+" parting agent contain-
-
ers for soiling and clean if necessary.
Blow compressed air through the suction filter in the "Robacta Reamer" part-
-
ing agent container from the inside outwards using the suction hose
(see section "Connecting the cleaning device to the "Robacta Reamer" parting agent container" from page 46)
Check the condition of the brush seal above the cleaning opening.
-
Replace the brush seal if worn (not applicable for twin devices).
Every 4 weeks
64
NOTE!
Take care never to damage the level sensor when performing maintenance work.
Change parting agent:
Drain all the parting agent from the dipping bowl
1
Take the spill tray out of the dipping bowl and dispose of any accumulated
2
soiling
Clean the dipping bowl and spill tray
3
Fill the dipping bowl with new parting agent
4
Every 6 months
NOTE!
Do not bring the air nozzle too close to electronic parts when cleaning with compressed air.
Open the cleaning device (base unit and cleaning unit) and blow clean using
-
dry reduced compressed air
Every 12 months
Disposal Waste electrical and electronic equipment must be collected separately and re-
Arrange for a safety inspection to be carried out on the cleaning device by a
-
Fronius service technician.
cycled in an environmentally responsible manner in accordance with the EU Directive and national law. Used equipment must be returned to the distributor or
through a local, authorised collection and disposal system. Correct disposal of
the used device promotes sustainable recycling of resources and prevents negative effects on health and the environment.
Packaging materials
Collect separately
-
Observe locally valid regulations
-
Compress the cardboard box to reduce volume
-
65
66
Technical data
67
68
Technical data
General
Robacta TC 2000, Robacta TC 2000 Twin
CAUTION!
Danger due to insufficiently dimensioned electrical installations.
This can result in damage to property.
Dimension the mains lead and its fuse to suit the device being used.
▶
The technical data shown on the rating plate applies.
Mains voltage 230 V
Mains voltage tolerance -10% / +10%
Mains frequency 50/60 Hz
Nominal output 180 W
Mains fuse protection (slow-blow) 10 A
Compressed air supply 6 bar
86.99 psi
Minimum cleaning interval from 20 s
Dipping bowl minimum capacity 0.75 l
0.20 gal.
Degree of protection IP 21
Robacta TC 2000 US, Robacta TC 2000 Twin US
Dimensions l/w/h 330 / 250 / 422 mm
12.99 / 9.84 / 16.61
in.
Weight (without "Robacta TC Cool / Robacta TC Cool
MD" parting agent)
EMC emission class A
Mark of conformity CE, CSA
Performance Level c
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
Compressed air supply 6 bar
24.4 kg
53.79 lb.
86.99 psi
Minimum cleaning interval from 20 s
Dipping bowl minimum capacity 0.75 l
0.20 gal.
Degree of protection IP 21
69
Dimensions l/w/h 330 / 250 / 422 mm
12.99 / 9.84 / 16.61
in.
Weight (without "Robacta TC Cool / Robacta TC Cool
MD" parting agent)
EMC emission class A
Mark of conformity CE, CSA
Performance Level c
24.4 kg
53.79 lb.
70
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