FRO­NIUS Robacta TC 2000 User manual

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
42,0426,0135,EN 025-21102022
EN Operating instructions

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
Disposal 11
Safety symbols 11
Data protection 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 2000
US
20
Magnetic flux densities within the cleaning coil for Robacta TC 2000 Twin, Robacta TC
2000 Twin US
21
Scope of supply and options 22
General 22
Scope of supply 22
Available options 22
Transport 23
Transport devices 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 compon-
ents
34
Installation and commissioning 37
Safety 39
Safety 39
Before commissioning 40
3
EN

Operators, maintenance personnel 40
Setup regulations 40
Compressed air supply specifications 40
Mains connection 41
Bolting the cleaning device to the underlying surface (foundation) 42
Screwing the cleaning device and installation stand to the underlying surface (foundation) 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
How the mechanically controlled wire cutter works 44
How the electrically-controlled wire cutter works 45
Filling the dipping bowl with parting agent 46
Filling the dipping bowl with parting agent 46
Connecting the cleaning device to the "Robacta Reamer" parting agent container 47
Connecting the cleaning device to the "Robacta Reamer" parting agent container 47
Starting up the cleaning device 48
General 48
Prerequisites for start-up 48
Gas nozzle to spool body distance control 48
Cleaning program sequence - Robacta TC 2000, Robacta TC 2000 US 49
Program sequence with parting agent nebuliser - overview 49
Program sequence with parting agent nebuliser and dipping bowl - overview 49
Cooling welding torch in the dipping bowl - detailed description 49
Cleaning the gas nozzle tip and nozzle fitting - detailed description 50
Spraying parting agent - detailed description 50
Cleaning program sequence with parting agent nebuliser 52
Cleaning program sequence with dipping bowl 53
Cleaning program sequence - Robacta TC 2000 Twin, Robacta TC 2000 Twin US 54
Program sequence with parting agent nebuliser - overview 54
Program sequence with parting agent nebuliser and dipping bowl - overview 54
Cooling welding torch in the dipping bowl - detailed description 54
Cleaning the gas nozzle tip and nozzle fitting - detailed description 55
Spraying parting agent - detailed description 55
Cleaning program sequence with parting agent nebuliser 56
Cleaning program sequence with dipping bowl 57
Troubleshooting, maintenance and disposal 59
Safety 61
Safety 61
Troubleshooting 63
Troubleshooting 63
Care, maintenance and disposal 66
Before each start-up 66
Daily 66
Weekly 66
Every 3 months 66
Every 6 months 67
Every 12 months 67
Disposal 67
Technical data 69
Technical data 71
General 71
Robacta TC 2000, Robacta TC 2000 Twin 71
Robacta TC 2000 US, Robacta TC 2000 Twin US 71
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 en-
vironmental 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 sec-
tion 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
EN

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 set-
ting.
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 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)
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 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
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.
6

Specific hazards Stay out of the working area of the robot.
The device must be incorporated into a higher-level safety system within a se-
cured 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 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 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 im-
mediate 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 en-
tering 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 pre-
vent 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
EN

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 vi-
cinity:
-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, pos-
sible danger from the magnetic field around the cleaning opening, mechanic-
ally-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 op-
erating 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 di-
mensioned. 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 earth-
ing the housing. The screws must never be replaced with different screws unless
a reliable ground conductor connection is set up.
EMC Device
Classifications
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' res-
istance 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 connec-
tion, additional measures are necessary (e.g. use of a suitable line filter)
2.Shielding, if necessary
-Shield off other nearby devices
-Shield off entire welding installation
3.Do not have any magnetic or electronic data carriers about your person:
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 damaged when the device is in use.
Safety measures
at the installa-
tion location and
during 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.
9
EN

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 regard-
ing 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 techni-
cians before commissioning 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 function-
ing 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
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 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 spe-
cified torque.
10

Safety inspec-
tion
The manufacturer recommends that a safety inspection of the device is per-
formed 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 stand-
ards 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 re-
quire.
Disposal Waste electrical and electronic equipment must be collected separately and re-
cycled in an environmentally-friendly way, in accordance with the European Dir-
ective and national legislation. Used equipment must be returned to the distrib-
utor or disposed of via an approved local collection and disposal facility. Correct
disposal of used equipment promotes the sustainable recycling of material re-
sources. Failing to dispose of used equipment correctly can lead to adverse
health and/or environmental impacts.
Packaging materials
Separate collection according to material. Check your local authority regulations.
Crush containers to reduce size.
Safety symbols Devices with the CE mark satisfy the essential requirements of the low-voltage
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 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.
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 basis for any claims whatsoever on the part of the pur-
chaser. If you have any suggestions for improvement, or can point out any mis-
takes that you have found in the instructions, we will be most grateful for your
comments.
11
EN

12

General
13

14

General
Device concept
Robacta TC 2000
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 ro-
bot 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 modi-
fications.
The cleaning devices are more or less maintenance-free, as there are no mechan-
ically 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 equipment incorrectly, as this could result in serious injury or dam-
age to property.
15
EN

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 recommen-
ded for all applications.
17
EN

Functional principle
Functional prin-
ciple
-Once the cleaning device is connected to the mains power supply, the mains
voltage indicator lights up. The capacitors, which store energy for the clean-
ing 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 overtem-
perature indicator lights up. Capacitor charging only begins once the temper-
ature 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. Al-
though 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.
5
4,5
4
3,5
3
20 25 30 35 40 45 50
(2)
(1)
(1) Magnetic flux density available (Tesla)
(2) Charging time (seconds)
18

-Once the cleaning operation is complete, the program sequence restarts by
checking the device's temperature. If there was a problem during the clean-
ing operation, the "Error" signal is output. The cleaning device resumes char-
ging the capacitors. Once ready to clean ("Ready"), a second cleaning opera-
tion can be started.
NOTE!
If the robot control deactivates the "Quick Stop" signal during the program
sequence, the cleaning device program sequence is interrupted immedi-
ately. 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
EN

Magnetic flux
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.
0 % 100 %
50 mm
1.97 in.
10 mm
0.39 in.
15 mm
0.59 in.
(1) (2) (3)
(1) Cleaning coil
(2) Diagram showing available magnetic flux density
(3) Immersion depth of torch neck into cleaning coil
20