FRO­NIUS Robacta TC 2000 ext. User manual

/ Perfect Charging / Perfect Welding / Solar Energy
42,0426,0259,EA 003-13082018
Robacta TC 2000 ext.
Robacta TC 2000 ext. US
Cleaning Unit TC 2000
Operating Instructions
Welding torch cleaning
EN-US

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EN-US
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 familiarize yourself with the
product. Reading the instructions carefully will enable you to learn about the many different
features your Fronius product has to offer. This will allow you to make full use of its advan-
tages.
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 Instruc-
tions
If you see any of the symbols depicted in the "Safety Rules," special care is required.
DANGER! Indicates an immediate danger. Death or serious injury may result if
appropriate precautions are not taken.
WARNING! Indicates a possibly dangerous situation. Death or serious injury may
result if appropriate precautions are not taken.
CAUTION! Indicates a situation where damage or injury could occur. Minor injury
or damage to property may result if appropriate precautions are not taken.
NOTE! Indicates the possibility of flawed results and damage to the equipment.
IMPORTANT! Indicates tips for correct operation and other particularly useful information.
It does not indicate a potentially damaging or dangerous situation.

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EN-US
Contents
Safety Instructions ..................................................................................................................................... 7
General ................................................................................................................................................. 7
Intended Use......................................................................................................................................... 7
Environmental Conditions ..................................................................................................................... 8
Obligations of the Operating Company................................................................................................. 8
Obligations of Personnel....................................................................................................................... 8
Particular hazard areas......................................................................................................................... 8
Personal Protection and Protection of Others....................................................................................... 9
Dangers due to Mains Current and Operating Current ......................................................................... 10
EMC Device Classifications .................................................................................................................. 10
EMC Measures ..................................................................................................................................... 11
Safety Measures at the Setup Location and During Transport ............................................................. 11
Safety Measures in Normal Operation.................................................................................................. 12
Maintenance and repair ........................................................................................................................ 13
Safety Inspection .................................................................................................................................. 13
Disposal ................................................................................................................................................ 13
Safety Symbols ..................................................................................................................................... 14
Backup .................................................................................................................................................. 14
Copyright............................................................................................................................................... 14
General 15
General ...................................................................................................................................................... 17
Device Concept..................................................................................................................................... 17
Applications........................................................................................................................................... 17
Warning Notices on the Device............................................................................................................. 17
Functional principle .................................................................................................................................... 19
Operating principle................................................................................................................................ 19
Representation of the Magnetic Flux Density Within the Cleaning Coil for Single-Wire Applications... 20
Representation of the Magnetic Flux Density Within the Cleaning Coil for Twin Applications.............. 20
Scope of Supply and Options .................................................................................................................... 22
General ................................................................................................................................................. 22
Scope of Supply.................................................................................................................................... 22
Available Options .................................................................................................................................. 22
Transport.................................................................................................................................................... 23
Transport Equipment ............................................................................................................................ 23
Transport instructions on the packaging ............................................................................................... 23
Operating controls, connections and mechanical components 25
Safety......................................................................................................................................................... 27
Safety.................................................................................................................................................... 27
Standard I/O (X1) Connecting Plug Configuration for the Robot Control................................................... 28
General ................................................................................................................................................. 28
Standard I/O (X1) Connecting Plug Configuration ................................................................................28
Operating controls, connections and mechanical components.................................................................. 30
General ................................................................................................................................................. 30
Control panel......................................................................................................................................... 30
Connections and Mechanical Components of the Base Unit................................................................ 31
Connections and Mechanical Components of the Cleaning Unit.......................................................... 32
Installation and Startup 35
Safety......................................................................................................................................................... 37
Safety.................................................................................................................................................... 37
Before installation ...................................................................................................................................... 38
Operating Personnel, Maintenance Personnel .....................................................................................38
Setup Regulations................................................................................................................................. 38
Specifications for the Compressed Air Supply...................................................................................... 38
Grid Connection .................................................................................................................................... 38

6
Setting Up and Connecting the Cleaning Device....................................................................................... 39
Installation Note .................................................................................................................................... 39
Screwing the Cleaning Unit and Work Stand to the Surface (Foundation) ........................................... 39
Screwing the Base Unit and Work Stand to the Surface (Foundation) ................................................. 39
Connecting the Cleaning Unit to the Base Unit..................................................................................... 41
Connecting the Mains Cable on the Robacta TC 2000 ext. US................................................................. 42
Connecting the Mains Cable................................................................................................................. 42
Installing the wire cutter ............................................................................................................................. 44
Installing the Wire Cutter on the Cleaning Device ................................................................................ 44
Maximum Wire Diameter ...................................................................................................................... 44
Operating Principle of the Electrically Controlled Wire Cutter............................................................... 44
Connecting the Cleaning Unit to the ‘Robacta Reamer’ Parting Agent Container ..................................... 45
Connecting the Cleaning Unit to the ‘Robacta Reamer’ Parting Agent Container ................................ 45
Start up the Cleaning Device ..................................................................................................................... 46
General ................................................................................................................................................. 46
Requirements for Commissioning......................................................................................................... 46
Cleaning Program Sequence for Single Wire Applications........................................................................ 47
Program Sequence with Parting Agent Atomizer – Overview............................................................... 47
Cleaning the Gas Nozzle Tip and Nozzle Fitting – Detailed Description .............................................. 47
Injecting Parting Agent – Detailed Description...................................................................................... 47
Cleaning Program Sequence with Parting Agent Atomizer .................................................................. 49
Cleaning Program Sequence for Twin Applications................................................................................... 50
Program Sequence with Parting Agent Atomizer – Overview............................................................... 50
Cleaning the Gas Nozzle Tip and Nozzle Fitting – Detailed Description .............................................. 50
Injecting Parting Agent – Detailed Description...................................................................................... 50
Cleaning Program Sequence with Parting Agent Atomizer .................................................................. 51
Troubleshooting, Maintenance, and Disposal 53
Safety......................................................................................................................................................... 55
Safety.................................................................................................................................................... 55
Troubleshooting ......................................................................................................................................... 56
Troubleshooting .................................................................................................................................... 56
What to Do in the Event of an Error ........................................................................................................... 58
What to Do in the Event of an Error ...................................................................................................... 58
Service, maintenance and disposal ........................................................................................................... 59
Before Every Start-up ........................................................................................................................... 59
Daily ...................................................................................................................................................... 59
Weekly .................................................................................................................................................. 59
Every Six Months .................................................................................................................................. 59
Every 12 Months ................................................................................................................................... 59
Clean the intake filter in the parting agent container............................................................................. 59
Disposal ................................................................................................................................................ 60
Technical Data 61
Technical Data ........................................................................................................................................... 63
General ................................................................................................................................................. 63
Robacta TC 2000 ext. ........................................................................................................................... 63
Robacta TC 2000 ext. US ..................................................................................................................... 63
Cleaning Unit TC 2000.......................................................................................................................... 63
Cleaning Unit TC 2000 LH .................................................................................................................... 64
Cleaning Unit TC 2000 Twin ................................................................................................................. 64
Cleaning Unit TC 2000 Twin ................................................................................................................. 64

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EN-US
Safety Instructions
General
Intended Use
The device has been manufactured using state-of-the-art technology and ac-
cording to recognized safety standards. If used incorrectly or misused, howev-
er, it can cause
- injury or death to the operator or a third party,
- damage to the device and other material assets belonging to the operat-
ing company,
- inefficient operation of the device.
All persons involved in the commissioning, operation, maintenance, and ser-
vicing of the device must
- be suitably qualified,
- have knowledge of automated welding and
- have read these Operating Instructions and any system component oper-
ating instructions in full and follow them carefully.
The Operating Instructions must always be at hand wherever the device is be-
ing used. In addition to the Operating Instructions, all applicable local rules
and regulations regarding accident prevention and environmental protection
must also be followed.
All safety and danger notices on the device must
- must be kept in a legible state
- not be damaged/marked
- not be removed
- 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 switching on the device, remove any faults that could compromise
safety.
Your personal safety is at stake!
The device is to be used exclusively for its intended purpose.
The device is intended exclusively for the electromagnetic cleaning of Fronius
welding torches.
Utilization for any other purpose, or in any other manner, shall be deemed to
be “not in accordance with the intended purpose.” The manufacturer is not re-
sponsible for any damage resulting from improper use.
Proper use also means
- Reading and adhering to all instructions in the operating instructions
- Reading and adhering to all safety instructions and danger notices
- Carrying out all the specified inspection and servicing work
The device is designed for operation in industry and business. The manufac-
turer shall not be liable for any damage resulting from use in a living area.
The manufacturer shall also not be liable for faulty or incorrect work results.

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Environmental
Conditions
Obligations of the
Operating Com-
pany
Obligations of
Personnel
Particular hazard
areas
Operation or storage of the device outside the stipulated area will be deemed
as not in accordance with the intended purpose. The manufacturer is not re-
sponsible for any damage resulting from improper use.
Temperature range of the ambient air:
- During operation: 0°C to + 40°C (32°F to 104°F)
- During transport and storage: -25°C to +55°C (-13°F to 131°F)
Relative humidity:
- Up to 50% at 40°C (104°F)
- Up to 90% at 20°C (68°F)
Ambient air: free of dust, acids, corrosive gases or substances, etc.
Altitude above sea level: up to 2000 m (6500 ft.)
The operating company must only allow persons to work with the device if they
- Are familiar with the basic occupational safety and accident prevention
regulations and are trained in handling the device
- Have read and understood these Operating Instructions, especially the
section "Safety Rules," and have confirmed this with their signature
- Are trained according to the requirements for the work results
The safety-conscious work of the personnel must be checked regularly.
All persons who are assigned to work with the device must do the following
before beginning the work:
- Follow the basic regulations for occupational safety and accident preven-
tion
- Read these Operating Instructions, especially the section "Safety Rules,"
and confirm that they have understood and will follow them by signing
Before leaving the workplace, ensure that no personal injury or property dam-
age can occur in one's absence.
Do not linger in the operating area of the robot.
Always integrate the device into a higher-level safety system in a secured ar-
ea.
If this area has to be accessed for preparatory or maintenance work, ensure
that
- the entire system is shut down for the duration of access to this area
- and remains shut down to prevent unintended operation, e.g., as a result
of a control error
In addition to these Operating Instructions, the safety rules of the robot man-
ufacturer must be followed.
Covers and side parts must only be opened/removed during maintenance and
repair work.
During operation:
- Ensure that all covers are closed and all side parts have been mounted
properly.
- Keep all covers and side parts closed.

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EN-US
Personal Protec-
tion and Protec-
tion of Others
Electromagnetic fields may cause health problems that are not yet known:
- Effects on the health of persons close by, for example those with pace-
makers, metal implants and hearing aids
- General prohibition for persons with pacemakers: Persons with pacemak-
ers must seek advice from their doctor before working with the device or
being in the immediate vicinity of the device
- General prohibition for persons with metal implants: Persons with metal
implants must seek advice from their doctor before working with the de-
vice or being in the immediate vicinity of the device
Magnetic fields generated by high amperage may eject ferromagnetic parts,
such as spatter accumulations, from the cleaning aperture. To prevent injury,
always wear protective goggles with side protection and never look into the
cleaning aperture when the device is switched on.
You are exposed to numerous hazards while handling the device, for example:
- Flying sparks and pieces of hot metal
- Arc radiation that poses a risk of injury to the eyes and skin
- Electrical risks from mains current and welding current
- Increased noise exposure
- Harmful welding fumes and gases
Wear suitable protective clothing when dealing with the device. The protective
clothing must have the following properties:
- Flame resistant
- Insulating and dry
- Covering the entire body and in good condition with no damage
- Safety helmet
- Cuffless pants
Protective clothing involves the following:
- Protecting the face and eyes from UV radiation, heat and flying sparks
with a face guard featuring a regulation-compliant filter
- Wearing regulation-compliant protective goggles with side protection be-
hind the face guard
- Wearing rigid, wet-insulating footwear
- Protecting hands with appropriate gloves (featuring electrical insulation
and thermal protection)
- Wearing ear protection to reduce noise exposure and protect against in-
jury
Keep persons, especially children, away during the operation of the devices
and during the welding process. If persons are in the vicinity, however:
- instruct them about all dangers (blinding hazard due to arcs, injury hazard
due to flying sparks, welding fume hazardous to health, noise exposure,
possible hazard due to mains current or welding current, possible hazard
due to electromagnetic fields, possible hazard due to the magnetic field of
the cleaning aperture, moving mechanical parts, compressed air/parting
agent mixture discharged from the cleaning aperture, flying chips or sim-
ilar, etc.),
- provide suitable protective equipment, or
- construct suitable protective walls and curtains.

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Dangers due to
Mains Current
and Operating
Current
EMC Device Clas-
sifications
An electric shock is life-threatening and may be deadly.
Do not touch voltage-carrying parts inside or outside of the device.
All cables and leads must be secured, undamaged, insulated, and adequately
dimensioned. Replace loose connections and scorched, damaged, or inade-
quately dimensioned cables and leads immediately.
Do not wrap cables or leads around your body or parts of the body.
Only put the device into operation if it is correctly connected on the output side.
Operate the device only on a grid with a ground conductor and a socket with
a ground conductor contact.
Operating the device on a grid without a ground conductor is considered to be
grossly negligent. The manufacturer is not responsible for any damage result-
ing from improper use.
Have the grid and device supply lead regularly inspected by an electrician to
ensure that the ground conductor is functioning properly.
Switch off unused devices.
Before working on the device, disconnect the mains plug.
Secure the device to prevent the mains plug from being connected and the de-
vice switched on again by affixing a clearly legible and understandable warn-
ing sign.
After opening the device:
- Discharge all electrically charged components
- Ensure that all components are disconnected from the power supply
If work is needed on voltage-carrying parts, bring in a second person who will
switch off the main switch at the correct time.
The housing screws act as a ground conductor connection for grounding the
housing. The screws must not under any circumstances be replaced by other
screws without a reliable ground conductor connection.
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 sup-
plied from the public low-voltage grid.
EMC device classification as per the rating plate or technical data.

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EN-US
EMC Measures
Safety Measures
at the Setup Loca-
tion and During
Transport
WARNING! Electromagnetic field! Electromagnetic fields may cause health
problems that are not yet known.
It is the operating company’s responsibility to ensure that there is no electro-
magnetic interference with electrical and electronic equipment.
If electromagnetic interference is detected, the operating company is obliged
to take measures to rectify the situation.
Check and evaluate possible problems and the interference immunity of
equipment in the vicinity according to national and international regulations:
- Safety devices
- Grid power lines, signal lines and data transfer lines
- IT and telecommunications equipment
- Devices for measuring and calibrating
- The health of persons close by
Supporting measures to avoid EMC problems:
1. Grid power supply
- If electromagnetic interference occurs despite a grid connection that
complies with regulations, take additional measures (e.g., use a suit-
able grid filter).
2. Shield, if necessary
- Shield other devices in the vicinity
- Shield the entire welding installation
3. Do not carry magnetic or electronic data carriers:
Magnetic or electronic data carriers can be damaged due to the magnetic
fields occurring during operation of the device.
4. Do not carry watches or pieces of metal. Watches may be damaged by
the operation of the device.
A toppling device can be deadly! Set up the device securely on an even, solid
surface
- A tilt angle of no more than 10° is permitted.
Special regulations apply in areas at risk of fire or explosion
- Follow the appropriate national and international regulations.

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Safety Measures
in Normal Opera-
tion
Use instructions and checks within the company to ensure that the vicinity of
the workplace is always clean and organized.
Only set up and operate the device in accordance with the degree of protec-
tion shown on the rating plate.
Install the device with an all-round clearance of at least 0.5 m (19.69 in.) to
walls, neighboring devices, or other objects.
Install the device at a minimum distance of 1 m (40 in.) away from IT equip-
ment and control lines, as well as from the welding process.
Set up the device in such a way that welding spatter cannot hit the cleaning
device.
Before transporting the device, always completely drain the parting agent.
Take care to ensure that the applicable national and regional guidelines and
accident prevention regulations are observed when transporting the device,
especially guidelines concerning hazards during transport and shipment.
It is essential to conduct a visual inspection of the device to check for damage
after it has been transported but before it is commissioned. Have any damage
repaired by trained service technicians before commissioning the device.
Only operate the device when all safety devices are fully functional. If the safe-
ty devices are not fully functional, there is a danger of:
- Injury or death to the operator or a third party
- Damage to the device and other material assets belonging to the operat-
ing company
- Inefficient operation of the device
Safety devices that are not fully functional must be repaired before the device
is started up.
Never bypass or disable safety devices.
Before starting up the device, ensure that no one can be put in danger.
The device must be examined at least once a week for externally detectable
damage and functionality of the safety devices.
- Only use appropriate original parting agents from the manufacturer.
- When handling parting agents, observe the information on the parting
agent safety data sheets. The parting agent safety data sheets can be ob-
tained from your service center or via the manufacturer’s website.
- Do not mix parting agents from the manufacturer with other parting
agents.
- If damage occurs due to the use of other parting agents, the manufacture
is not liable for this and all warranty claims are forfeited.
- Properly dispose of used parting agents according to national and inter-
national regulations.

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EN-US
Maintenance and
repair
Safety Inspection
Disposal
It is impossible to guarantee that bought-in parts are designed and manufac-
tured to meet the demands made of them, or that they satisfy safety require-
ments.
- Use only original spare and wearing parts (also applies to standard parts).
- Do not carry out any modifications, alterations, etc. to the device without
the manufacturer's consent.
- Components that are not in perfect condition must be replaced immedi-
ately.
- 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.
The manufacturer recommends that a safety inspection of the device be per-
formed at least every 12 months.
A safety inspection by a certified electrician is recommended:
- after changes
- after alterations
- after repair, care, and maintenance
- at least every 12 months.
For the safety inspection, follow the appropriate national and international stan-
dards and guidelines.
You can obtain more information about the safety inspection and calibration from
your service center. The service center will provide the necessary documents
upon request.
Do not dispose of this device with normal domestic waste! To comply with the
European Directive on Waste Electrical and Electronic Equipment and its im-
plementation as national law, electrical equipment that has reached the end of
its life must be collected separately and returned to an approved recycling fa-
cility. Any device that you no longer require must be returned to your dealer,
or you must locate the approved collection and recycling facilities in your area.
Ignoring this European Directive may have potentially adverse affects on the
environment and your health!

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Safety Symbols
Backup The user is responsible for backing up any changes made to the factory settings. The man-
ufacturer accepts no liability for any deleted personal settings.
Copyright
Devices with the CE label satisfy the essential requirements of the low-voltage
and electromagnetic compatibility directives (e.g. relevant product standards
of the EN 60974 series).
Fronius International GmbH declares that the device complies with Directive
2014/53/EU. The full text of the EU Declaration of Conformity is available on
the following website: http://www.fronius.com
Devices marked with the CSA test mark satisfy the requirements of the rele-
vant standards for Canada and the USA.
Copyright of these operating instructions remains with the manufacturer.
Text and illustrations are technically correct at the time of going to print. The
right to make modifications is reserved. The contents of the operating instruc-
tions shall not provide the basis 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 operating instructions, we will be most
grateful for your comments.

General

17
EN-US
General
Device Concept
Base unit with cleaning unit
The cleaning device consists of
- a base unit – the Robacta TC 2000 ext.
/ Robacta TC 2000 ext. US and
- a cleaning unit – the Cleaning Unit TC
2000 in various versions
The cleaning device is designed to clean a
variety of different welding torch geomet-
ries. The components are housed in a ro-
bust housing. The compact design permits
installation in the smallest of spaces.
The cleaning device is largely maintenan-
ce-free, since there are no parts subject to
mechanical stress.
Applications The cleaning device is intended for the cleaning of welding torches in automated steel ap-
plications. The cleaning device is designed for use:
- In the automotive and supply industry
- In equipment engineering
- In chemical plant construction
- In mechanical engineering
- In rail vehicle construction
- In shipyards
Warning Notices
on the Device
The device has safety symbols and a rating plate fitted. These safety symbols and the rat-
ing plate must not be removed or painted over. The symbols warn against operating the
equipment incorrectly, as this may result in serious injury and damage to property.

18
WARNING! Danger of serious injuries due to:
- The magnetic field of the cleaning aperture
- Compressed air/parting agent mixture discharged from the cleaning ap-
erture
- Flying debris (chips, etc.)
- Moving mechanical parts
During maintenance and service, keep the device de-energized and depres-
surized.
Do not use the functions described here until you have fully read and under-
stood the following documents:
- These Operating Instructions
- All Operating Instructions for system components, especially the safety
rules
For indoor use only
Wear eye protection
Prohibition for persons with pacemakers. Persons with pacemakers must
seek advice from their doctor before working with the device or being in the
immediate vicinity of the device

19
EN-US
Functional principle
Operating princi-
ple
a) As soon as the cleaning device is connected to the grid, the Grid voltage indication
(page 30) lights up. The capacitors, which store the energy for the cleaning process,
are discharged and no outputs are controlled.
b) Before the capacitors are charged, the device temperature is checked. If it is within
tolerance, the capacitors will be charged for the cleaning process.
If the operating temperature is exceeded, the overtemperature Overtemperature in-
dication (page 30) will light up. In this case, the charging process of the capacitors
will only take place after cooling down to the permissible operating temperature.
c) After 20 seconds of charging time, the ‘Ready’ signal will be output to the robot control
– the Ready to clean indication indication (page 31) on the device will flash. As soon
as the capacitors are fully charged, the indication will light up permanently. Although
after 20 seconds the maximum magnetic flux density is not yet available to the device,
the cleaning process (discharge process) can be initiated by means of the ‘Cleaning
Start’ signal. For setup purposes, the cleaning process can be triggered manually by
means of Discharge button (page 30) on the device.
After 50 seconds of charging time, the maximum magnetic flux density is available for
the cleaning process.
For the exact ratio of charging times to available magnetic flux density, please see the
diagram below.
d) After the cleaning process has finished, the program sequence starts again with a
check of the device temperature. If a cleaning process has finished incorrectly, the ‘Er-
ror’ signal will be output. The cleaning device once again initiates the charging process
of the capacitors. If the cleaning readiness is ‘Ready’, another cleaning process can
be carried out.
NOTE! In order for the capacitors’ charging process to begin, the following pre-
requisites must be met:
- Base unit connected to the grid
- Base unit connected to the robot control
- Interconnecting hosepack of cleaning unit connected to the base unit
- The ‘Quick Stop' signal must be set
Available magnetic flux density (Tesla)
Charging time (seconds)
5
4,5
4
3,5
3
2,5
20 25 30 35 40 45 50

20
Representation of
the Magnetic Flux
Density Within
the Cleaning Coil
for Single-Wire
Applications
Depending on the requirements, the insertion depth of the welding torch in the cleaning coil
can be used to regulate how strong an effect the magnetic flux density should have on the
individual areas of the welding torch.
Representation of
the Magnetic Flux
Density Within
the Cleaning Coil
for Twin Applica-
tions
Depending on the requirements, the insertion depth of the welding torch in the cleaning coil
can be used to regulate how strong an effect the magnetic flux density should have on the
individual areas of the welding torch.
NOTE! If the robot control deactivates the ‘Quick Stop’ signal during the pro-
gram sequence, the cleaning device program sequence will be aborted im-
mediately. For safety reasons, the capacitors are discharged via the cleaning
coil.
NOTE! For the operation of the cleaning device, use the insertion depth details
for the welding torch from the program sequence.
Cleaning coil Diagram of available mag-
netic flux density
Insertion depth of the
torch body into the
cleaning coil
0 % 100 %
50 mm
1.97 in.
10 mm
0.39 in.
15 mm
0.59 in.
NOTE! For the operation of the cleaning device, use the insertion depth details
for the welding torch from the program sequence.