Explanation of safety notices6
General6
Proper use7
Environmental conditions7
Obligations of the operator7
Obligations of personnel7
Specific hazards8
Protecting yourself and others8
Risks from mains current and operating current9
EMC Device Classifications10
EMC measures10
Safety measures at the installation location and during transport10
Safety measures in normal operation11
Maintenance and repair11
Safety inspection12
Disposal12
Safety symbols12
Data protection12
Copyright12
General15
EN
General17
Device concept17
Application areas18
Warning notices on the device18
Parting agent types and their use20
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.
GeneralThe 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.
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All persons involved in commissioning, operating, maintaining and servicing the
device must:
be suitably qualified,
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have sufficient knowledge of automated welding, and
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read and carefully follow these operating instructions as well as the operat-
-
ing instructions for all system components.
The operating instructions must always be at hand wherever the device is being
used. In addition to the operating instructions, attention must also be paid to any
generally applicable and local regulations regarding accident prevention and environmental protection.
All safety and danger notices on the device
must be in a legible state,
-
must not be damaged,
-
must not be removed,
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must not be covered, pasted or painted over.
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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!
6
Proper useThe 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.
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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.
EN
Environmental
conditions
Obligations of
the operator
Operation or storage of the device outside the stipulated area will be deemed as
not in accordance with the intended purpose. The manufacturer shall not be held
liable for any damage arising from such usage.
Ambient temperature range:
during operation: 0 °C to + 40 °C (32 °F to 104 °F)
-
during transport and storage: -25 °C to +55 °C (-13 °F to 131 °F)
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Relative humidity:
up to 50 % at 40 °C (104 °F)
-
up to 90 % at 20 °C (68 °F)
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Keep ambient air free from dust, acids, corrosive gases and substances, etc.
Can be used at altitudes of up to 2000 m (6500 ft)
The operator must only allow persons to work with the device who:
are familiar with the fundamental instructions regarding safety at work and
-
accident prevention and have been instructed in how to use the device
have read and understood these operating instructions, especially the sec-
-
tion "safety rules", and have confirmed as much with their signatures
are trained to produce the required results.
-
Checks must be carried out at regular intervals to ensure that operators are
working in a safety-conscious manner.
Obligations of
personnel
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.
7
Specific hazards
Stay out of the working area of the robot.
The device must be incorporated into a higher-level safety system within a secured area.
If this area has to be accessed when setup and maintenance work is carried out,
make sure that
the entire system is switched off for the duration of the work in this area
-
and that it is prevented from starting up accidentally, e.g., as the result of a
-
control fault
In addition to these operating instructions, the safety rules issued by the robot
manufacturer must also be observed.
Covers and side panels may only be opened/removed while maintenance or repair
work is being carried out.
During operation:
Ensure that all covers are closed and all side panels are fitted properly.
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Keep all covers and side panels closed.
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Protecting yourself and others
Electromagnetic fields may pose as yet unknown risks to health:
Effects on the health of persons in the vicinity, for example, those with pace-
-
makers, metallic implants and hearing aids
Forbidden for anyone wearing a pacemaker: people wearing a pacemaker
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must consult their doctor before working with the device or entering its immediate vicinity
Forbidden for anyone with metal implants: people who have had metal im-
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plants fitted must consult their doctor before working with the device or entering its immediate vicinity
Magnetic fields generated by the high amperage can cause ferromagnetic parts
such as spatter accumulations to be ejected from the cleaning opening. To prevent injury, never look into in the cleaning opening while the device is switched
on; protective goggles with side protection must be worn at all times.
Anyone working with the device exposes themselves to numerous risks e.g.:
flying sparks and hot pieces of metal
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Arc radiation, which can damage eyes and skin
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Risk of electrocution from mains current and welding current
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Greater noise pollution
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Harmful welding fumes and gases
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Suitable protective clothing must be worn when working with the device. The
protective clothing must have the following properties:
Flame-resistant
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Insulating and dry
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Covers the whole body, is undamaged and in good condition
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Safety helmet
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Trousers with no turn-ups
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8
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
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and regulation filter
Wear regulation protective goggles with side protection behind the protect-
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ive visor
Wear stout footwear that provides insulation even in wet conditions
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Protect the hands with suitable gloves (electrically insulated and providing
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protection against heat)
Wear ear protection to reduce the harmful effects of noise and to prevent in-
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jury
Keep all persons, especially children, out of the working area while any devices
are in operation or welding is in progress. If, however, there are people in the vicinity:
make them aware of all the dangers (dazzling by arc, injury from flying
-
sparks, inhalation of harmful welding fumes, noise, possible danger from
mains or welding current, possible danger from electromagnetic fields, possible danger from the magnetic field around the cleaning opening, mechanically-powered parts, compressed air/parting agent mixture ejected from the
cleaning opening, flying shavings and similar matter, etc.),
Provide suitable protective equipment
An electric shock is potentially life threatening and can be fatal.
Do not touch live parts either inside or outside the device.
All cables and leads must be secured, undamaged, insulated and adequately dimensioned. Loose connections, scorched, damaged or inadequately dimensioned
cables and leads must be replaced immediately.
Do not sling cables or leads around the body or parts of the body.
Only switch on the device when all output connections have been established
correctly.
The device must only be operated on a mains supply with a ground conductor
and a socket with a ground conductor contact.
If the device is operated on a mains supply without a ground conductor, this will
be deemed as gross negligence. The manufacturer shall not be held liable for any
damage arising from such usage.
Arrange for the mains cable to be checked regularly by a qualified electrician to
ensure the ground conductor is functioning properly.
Switch off unused devices.
Disconnect the mains plug before working on the device.
Attach a clearly legible and easy-to-understand warning sign to the device to
prevent anyone from plugging the mains plug back in and switching it on again.
After opening the device:
Discharge all live components
-
Ensure that all components in the device are de-energised.
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If work on live parts is required, appoint a second person to switch off the main
switch at the right moment.
9
The housing screws provide an adequate ground conductor connection for earthing the housing. The screws must never be replaced with different screws unless
a reliable ground conductor connection is set up.
EMC Device
Classifications
EMC measuresWarning, electromagnetic field. Electromagnetic fields may pose as yet unknown
Devices in emission class A:
Are only designed for use in industrial settings
-
Can cause line-bound and radiated interference in other areas
-
Devices in emission class B:
Satisfy the emissions criteria for residential and industrial areas. This is also
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true for residential areas in which the energy is supplied from the public lowvoltage mains.
EMC device classification as per the rating plate or technical data.
risks to health.
It is the operator's responsibility to ensure that no electromagnetic interference
occurs in electrical and electronic devices.
If electromagnetic interference is detected, the operator is obliged to take action
to rectify the situation.
Check for possible problems, and check and evaluate neighbouring devices' resistance to interference according to national and international requirements:
Safety devices
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Power, signal and data transfer lines
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IT and telecommunications devices
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Measuring and calibrating devices
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Health of neighbouring persons
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Safety measures
at the installation location and
during transport
Supporting measures for avoidance of EMC problems:
Mains supply
1.
If electromagnetic interference arises despite the correct mains connec-
-
tion, additional measures are necessary (e.g. use of a suitable line filter)
Shielding, if necessary
2.
Shield off other nearby devices
-
Shield off entire welding installation
-
Do not have any magnetic or electronic data carriers about your person:
3.
magnetic or electronic data carriers can be damaged by the magnetic fields
generated when the device is in use.
Do not have any watches or pieces of metal about your person. Watches can
4.
be damaged when the device is in use.
A device toppling over could easily kill someone. Place the device on a solid, level
surface such that it remains stable
The maximum permissible tilt angle is 10°.
-
Special regulations apply in rooms at risk of fire or explosion
Observe relevant national and international regulations.
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Use internal work instructions and checks to ensure that the workplace environment is always clean and clearly laid out.
10
Only set up and operate the device in accordance with the degree of protection
shown on the rating plate.
When setting up the Robacta TC and cleaning unit, 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 Robacta TC and the cleaning unit must be set up at least 1 m (40 in.) away
from computers, control lines and the welding process.
Position the Robacta TC and cleaning unit to prevent welding spatter coming into
contact with the cleaning device.
Before transporting the device, allow parting agent to drain completely.
When transporting the device, observe the relevant national and local guidelines
and accident prevention regulations. This applies especially to guidelines regarding the risks arising during transport.
After transporting the device, the device must be visually inspected for damage
before commissioning. Any damage must be repaired by trained service technicians before commissioning the device.
EN
Safety measures
in normal operation
Only operate the device when all safety devices are fully functional. If the safety
devices are not fully functional, there is a risk of
injury or death to the operator or a third party,
-
damage to the device and other material assets belonging to the operator,
-
inefficient operation of the device.
-
Any safety devices that are not functioning properly must be repaired before
switching on the device.
Never bypass or disable safety devices.
Before switching on the device, ensure that no one is likely to be endangered.
Check the device at least once a week for obvious damage and proper functioning of safety devices.
Only use suitable original parting agent from the manufacturer.
-
Observe the information on the parting agent safety data sheets when hand-
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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-
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evant national and international regulations.
Maintenance and
repair
Under normal operating conditions, the device requires only a minimum of care
and maintenance. However, it is vital to observe some important points to ensure
it remains in a usable condition for many years.
Before switching on, always check the mains plug and cable as well as char-
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ger leads and charging terminals for any signs of damage.
If the surface of the device housing is dirty, clean with a soft cloth and
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solvent-free cleaning agent only
Maintenance and repair work must only be carried out by authorised personnel.
Use only original replacement and wearing parts (also applies to standard parts).
It is impossible to guarantee that bought-in parts are designed and manufactured to meet the demands made on them, or that they satisfy safety requirements.
11
Do not carry out any modifications, alterations, etc. to the device without the
manufacturer's consent.
Dispose of in accordance with the applicable national and local regulations.
Safety inspection
DisposalWaste electrical and electronic equipment must be collected separately and re-
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
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after repair, care and maintenance has been carried out
-
at least every twelve months.
-
For safety inspections, follow the appropriate national and international standards and directives.
Further details on safety inspection and calibration can be obtained from your
service centre. They will provide you on request with any documents you may require.
cycled in an environmentally responsible manner in accordance with the EU Directive and national law. Used equipment must be returned to the distributor or
through a local, authorised collection and disposal system. Proper disposal of the
old device promotes sustainable recycling of material resources. Ignoring this
may lead to potential health/environmental impacts.
Packaging materials
Collected separately. Check your municipality’s regulations. Reduce the volume
of the box.
Safety symbolsDevices 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 protectionThe user is responsible for the safekeeping of any changes made to the factory
settings. The manufacturer accepts no liability for any deleted personal settings.
CopyrightCopyright of these operating instructions remains with the manufacturer.
12
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 purchaser. 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.
EN
13
14
General
15
16
General
Device conceptThe Robacta TC can be used to clean practically every torch shape. The compact
design means it can be set up in the narrowest of spaces (for example, in robot
cells). The cleaning device is more or less maintenance-free, as there are no
mechanically stressed parts.
NOTE!
All of the components of the Robacta
TC 1000 cleaning device are contained within one housing.
EN
Robacta TC 1000 ext. (Base unit with cleaning
unit S.)
Recommended for vertical torch cleaning
NOTE!
The components of the Robacta TC
1000 ext. are divided between two
devices:
Robacta TC 1000 ext. base unit
▶
Cleaning unit S. / cleaning unit P.
▶
17
Robacta TC 1000 ext. (Base unit with cleaning unit P.)
Recommended for horizontal torch cleaning
All variants are also available in Twin and Twin Compact versions.
Application
areas
Warning notices
on the device
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
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shipyards
-
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 may result in serious injury and damage.
18
1~
50-60 Hz
U1
IP 21
230 V
I13 A
24 V
40 sec.
Ucontrol
tcycle
EN 50 178 / EN 61000-6-2/4
A-4600 Wels
www.fronius.com
Type:
Ser.No.:
Art.No.:
Robacta TC 1000
EN
WARNING! Risk of serious injury from:
the magnetic field surrounding the cleaning opening
-
compressed air/parting agent mixture escaping from the clean-
-
ing 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
19
Forbidden for anyone wearing a pacemaker. people wearing a pacemaker must consult their doctor before working with the device or
entering its immediate vicinity
Parting agent
types and their
use
NOTE!
Parting agents are not included in the scope of supply.
Parting agent types and their use:
"Robacta TC Cool +" parting agent for immersing the welding torch in the
-
dipping bowl
"Robacta Reamer" parting agent for spraying the welding torch after the
-
cleaning operation
It is recommended that the dipping bowl should be used for:
Gas-cooled welding torches
-
Water-cooled welding torches in the upper power range (hot gas nozzles)
-
Spraying the welding torch with "Robacta Reamer" parting agent is recommended for all applications.
20
Functional principle
EN
Functional principle
Once the Robacta TC is connected to the mains power supply, the Mains
a)
voltage indicator (page 28) lights up. The capacitors, which store energy for
the cleaning operation, are discharged and no outputs are activated.
NOTE!
The following prerequisites must be met before the capacitor charging process can begin
Robacta TC 1000
▶
Device connected to the mains and the robot control
▶
The Quick Stop signal has been set
▶
Robacta TC 1000 ext.
▶
Base unit connected to the mains and the robot control
▶
Cleaning unit interconnecting hosepack connected to the base unit
▶
The Quick Stop signal has been set
▶
The device temperature is checked before the capacitors are charged. If it
b)
lies within the tolerance range, the capacitors are charged.
If the operating temperature is exceeded, the Overtemperature indicator
(page 28) lights up. If this is the case, the capacitors are only charged once
the device has cooled down to the permissible operating temperature.
Once the capacitors have been charged, the Ready signal is transmitted to
c)
the robot control - the Ready-to-clean indicator (page 28) lights up. The
cleaning operation (discharge process) can now be initiated by means of the
Cleaning Start signal. For adjustment purposes, the cleaning operation can
also be manually triggered using the Discharge key button (page 28).
Once the cleaning operation is complete, the program sequence restarts by
d)
checking the device's temperature. If a problem occurred during the cleaning
operation, the Error. signal is output. The Robacta TC initiates the capacitor
charging process again. Once ready to discharge (Ready ), a second cleaning
operation can be started.
Automatic refilling of the dipping bowl from the "Robacta TC Cool / Robacta
e)
TC Cool MD" parting agent container ensures the optimum fill level. After
draining the "Robacta TC Cool / Robacta TC Cool MD" 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 (page 28) lights up. At
the same time, the Fluid Level Control signal is transmitted to the robot control.
The cleaning function of the Robacta TC remains available even if the Fill
-
level indicator (page 28) is illuminated.
NOTE!
If the robot control deactivates the Quick Stop, signal during the program sequence, the Robacta TC program sequence is interrupted immediately.
For safety reasons the capacitors are discharged via the cleaning coil.