FRO­NIUS Robacta TC 2000 User manual

Fronius prints on elemental chlorine free paper (ECF) sourced from certified sustainable forests (FSC).
/ Perfect Charging / Perfect Welding / Solar Energy
42,0426,0135,EN 019-18022020
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
Welding torch cleaning
EN

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EN
Dear reader,
Introduction 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. This will allow you to make full use of its advantages.
Please also note the safety rules to ensure greater safety when using the product. Careful
handling of the product will repay you with years of safe and reliable operation. These are
essential prerequisites for excellent results.
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.

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EN
Contents
Safety rules ................................................................................................................................................ 7
General ................................................................................................................................................. 7
Proper use ............................................................................................................................................ 7
Environmental conditions...................................................................................................................... 7
Obligations of the operator.................................................................................................................... 8
Obligations of personnel ....................................................................................................................... 8
Specific hazards.................................................................................................................................... 8
Protecting yourself and others .............................................................................................................. 8
Risks from mains current and operating current ................................................................................... 9
EMC Device Classifications .................................................................................................................. 10
EMC measures ..................................................................................................................................... 10
Safety measures at the installation location and during transport ........................................................ 11
Safety measures in normal operation ................................................................................................... 11
Commissioning, maintenance and repair.............................................................................................. 12
Safety inspection................................................................................................................................... 12
Disposal ................................................................................................................................................ 12
Safety symbols...................................................................................................................................... 12
Data protection...................................................................................................................................... 12
Copyright............................................................................................................................................... 13
General 15
General ...................................................................................................................................................... 17
Device concept ..................................................................................................................................... 17
Application areas .................................................................................................................................. 17
Warning notices on the device.............................................................................................................. 17
Parting agent types and their use ......................................................................................................... 19
Functional principle .................................................................................................................................... 20
Functional principle ............................................................................................................................... 20
Magnetic flux densities within the cleaning coil for Robacta TC 2000, Robacta TC 2000 US.............. 22
Magnetic flux densities within the cleaning coil for Robacta TC 2000 Twin, Robacta TC 2000 Twin US 23
Scope of supply and options...................................................................................................................... 24
General ................................................................................................................................................. 24
Scope of supply .................................................................................................................................... 24
Available options................................................................................................................................... 24
Transport.................................................................................................................................................... 25
Vehicles ................................................................................................................................................ 25
Transport notices on the packaging...................................................................................................... 25
Controls, connections and mechanical components 27
Safety......................................................................................................................................................... 29
Safety.................................................................................................................................................... 29
Standard I/O connecting plug (X1) pin assignment for robot control ......................................................... 30
General ................................................................................................................................................. 30
Standard I/O connecting plug (X1) pin assignment .............................................................................. 30
Controls, connections and mechanical components.................................................................................. 32
General ................................................................................................................................................. 32
Control panel......................................................................................................................................... 32
Robacta TC 2000, Robacta TC 2000 US connections and mechanical components........................... 33
Robacta TC 2000 Twin, Robacta TC 2000 Twin US connections and mechanical components ......... 35
Installation and commissioning 37
Safety......................................................................................................................................................... 39
Safety.................................................................................................................................................... 39
Before commissioning................................................................................................................................ 41
Operators, maintenance personnel....................................................................................................... 41
Setup regulations .................................................................................................................................. 41
Compressed air supply specifications................................................................................................... 41

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Mains connection .................................................................................................................................. 42
Bolting the cleaning device to the underlying surface (foundation)............................................................ 43
Screwing the cleaning device and installation stand to the underlying surface (foundation)................ 43
Connecting the mains cable - Robacta TC 2000 US, Robacta TC 2000 Twin US .................................... 44
Connecting the mains cable.................................................................................................................. 44
Installing the wire cutter ............................................................................................................................. 47
Installing the wire cutter on the cleaning device ................................................................................... 47
Maximum wire diameter........................................................................................................................ 47
How the mechanically controlled wire cutter works .............................................................................. 47
How the electrically-controlled wire cutter works .................................................................................. 48
Filling the dipping bowl with parting agent ................................................................................................. 49
Filling the dipping bowl with parting agent ............................................................................................ 49
Connecting the cleaning device to the "Robacta Reamer" parting agent container................................... 50
Connecting the cleaning device to the "Robacta Reamer" parting agent container ............................. 50
Starting up the cleaning device.................................................................................................................. 51
General ................................................................................................................................................. 51
Prerequisites for start-up....................................................................................................................... 51
Gas nozzle to spool body distance control ........................................................................................... 51
Cleaning program sequence - Robacta TC 2000, Robacta TC 2000 US .................................................. 52
Program sequence with parting agent nebuliser - overview ................................................................. 52
Program sequence with parting agent nebuliser and dipping bowl - overview ..................................... 52
Cooling welding torch in the dipping bowl - detailed description........................................................... 52
Cleaning the gas nozzle tip and nozzle fitting - detailed description..................................................... 53
Spraying parting agent - detailed description........................................................................................ 53
Cleaning program sequence with parting agent nebuliser.................................................................... 55
Cleaning program sequence with dipping bowl .................................................................................... 56
Cleaning program sequence - Robacta TC 2000 Twin, Robacta TC 2000 Twin US ................................. 57
Program sequence with parting agent nebuliser - overview ................................................................. 57
Program sequence with parting agent nebuliser and dipping bowl - overview ..................................... 57
Cooling welding torch in the dipping bowl - detailed description........................................................... 57
Cleaning the gas nozzle tip and nozzle fitting - detailed description..................................................... 58
Spraying parting agent - detailed description........................................................................................ 58
Cleaning program sequence with parting agent nebuliser.................................................................... 59
Cleaning program sequence with dipping bowl .................................................................................... 60
Troubleshooting, maintenance and disposal 61
Safety......................................................................................................................................................... 63
Safety.................................................................................................................................................... 63
Troubleshooting ......................................................................................................................................... 65
Troubleshooting .................................................................................................................................... 65
Care, maintenance and disposal ............................................................................................................... 68
Before each start-up ............................................................................................................................. 68
Daily ...................................................................................................................................................... 68
Weekly .................................................................................................................................................. 68
Every 3 months ..................................................................................................................................... 68
Every 6 months ..................................................................................................................................... 69
Every 12 months ................................................................................................................................... 69
Disposal ................................................................................................................................................ 69
Technical data 71
Technical data............................................................................................................................................ 73
General ................................................................................................................................................. 73
Robacta TC 2000, Robacta TC 2000 Twin .......................................................................................... 73
Robacta TC 2000 US, Robacta TC 2000 Twin US............................................................................... 73
Appendix 75
Circuit diagrams: Robacta TC 2000........................................................................................................... 76

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EN
Safety rules
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 operating instruc-
tions 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 applica-
ble 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!
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 instructions
- 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
Operation or storage of the device outside the stipulated area will be deemed as not in ac-
cordance with the intended purpose. The manufacturer shall not be held liable for any dam-
age 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)

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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
operator
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 section "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
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 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 manufactur-
er 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 your-
self 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 pacemakers,
metallic implants and hearing aids
- Forbidden for anyone wearing a pacemaker: people wearing a pacemaker must con-
sult their doctor before working with the device or entering its immediate vicinity
- Forbidden for anyone with metal implants: people who have had metal implants fitted
must consult their doctor before working with the device or entering its immediate vi-
cinity

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EN
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
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 reg-
ulation filter
- Wear regulation protective goggles with side protection behind the protective 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 injury
Keep all persons, especially children, out of the working area while any devices are in op-
eration 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, inhala-
tion 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 oper-
ating 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 dimen-
sioned. 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.

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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.
If work on live parts is required, appoint a second person to switch off the main switch at
the right moment.
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 Clas-
sifications
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 low-voltage mains.
EMC device classification as per the rating plate or technical data.
EMC measures Warning, electromagnetic field. Electromagnetic fields may pose as yet unknown 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
Supporting measures for avoidance of EMC problems:
1. Mains supply
- If electromagnetic interference arises despite the correct mains connection, addi-
tional 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:
magnetic or electronic data carriers can be damaged by the magnetic fields generated
when the device is in use.
4. Do not have any watches or pieces of metal about your person. Watches can be dam-
aged when the device is in use.

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EN
Safety measures
at the installation
location and dur-
ing transport
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.
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 ac-
cident prevention regulations. This applies especially to guidelines regarding the risks aris-
ing 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 com-
missioning the device.
Safety measures
in normal opera-
tion
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 handling part-
ing 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 accepts no
liability. In addition, no warranty claims will be entertained.
- Used parting agent must be disposed of properly in accordance with the relevant na-
tional and international regulations.

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Commissioning,
maintenance and
repair
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 manufac-
turer'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 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 di-
rectives.
Further details on safety inspection and calibration can be obtained from your service cen-
tre. They will provide you on request with any documents you may require.
Disposal Do not dispose of this device with normal domestic waste! To comply with the European
Directive on Waste Electrical and Electronic Equipment and its implementation as national
law, electrical equipment that has reached the end of its life must be collected separately
and returned to an approved recycling facility. Any device that you no longer require must
either be returned to your dealer or given to one of the approved collection and recycling
facilities in your area. Ignoring this European Directive may have potentially adverse af-
fects on the environment and your health!
Safety symbols Devices with the CE mark satisfy the essential requirements of the low-voltage and elec-
tromagnetic compatibility directives (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
Devices marked with the CSA test mark satisfy the requirements of the relevant standards
for Canada and the USA.
Data protection The user is responsible for the safekeeping of any changes made to the factory settings.
The manufacturer accepts no liability for any deleted personal settings.

13
EN
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. If you have any suggestions for
improvement, or can point out any mistakes that you have found in the instructions, we will
be most grateful for your comments.

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General

17
EN
General
Device concept
Robacta TC 2000 on optional installation stand
The cleaning devices in the Robacta TC
2000 series have been designed to clean a
variety of different welding torch geome-
tries. The components are contained in a
robust housing. The compact design me-
ans 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.
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
- 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 equip-
ment incorrectly, as this may result in serious injury and damage.

18
WARNING! Risk of serious injury from:
- the magnetic field surrounding the cleaning opening
- compressed air/parting agent mixture escaping from the cleaning open-
ing
- flying parts (shavings, etc.)
- mechanically 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 pacemaker

19
EN
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 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.

20
Functional principle
Functional princi-
ple
- 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 opera-
tion. If the operating temperature is exceeded, the overtemperature indicator lights up.
Capacitor charging only begins once the temperature has fallen to the permitted op-
erating 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 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 the exact relationship between charging time and the mag-
netic flux density available.
- 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.
Magnetic flux density available (Tesla)
Charging time (seconds)
5
4,5
4
3,5
3
2,5
20 25 30 35 40 45 50