Operating
Instructions
Robacta TC 2000 ext.
Robacta TC 2000 ext. US
Cleaning Unit TC 2000
EN-US
Operating instructions
42,0426,0259,EA 005-27012023
Table of contents
Safety Instructions 5
Explanation of Safety Instructions 5
General 5
Intended Use 6
Environmental Conditions 6
Obligations of the Operating Company 6
Obligations of Personnel 6
Particular hazard areas 6
Personal Protection and Protection of Others 7
Dangers due to Mains Current and Operating Current 8
EMC Device Classifications 8
EMC Measures 9
Safety Measures at the Setup Location and During Transport 9
Safety Measures in Normal Operation 10
Maintenance and repair 10
Safety Inspection 10
Disposal 11
Safety symbols 11
Data backup 11
Copyright 11
General 13
General 15
Device concept 15
Applications 15
Warning notices on the device 15
Functional principle 18
Operating principle 18
Representation of the magnetic flux density within the cleaning coil for single-wire applications
Representation of the magnetic flux density within the cleaning coil for twin applications 20
Scope of Supply and Options 21
General 21
Scope of Supply 21
Available Options 21
Transport 22
Transport equipment 22
Transport Instructions on the packaging 22
19
EN-US
Operating controls, connections and mechanical components 23
Safety 25
Safety 25
Standard I/O (X1) Connecting Plug Configuration for the Robot Control 26
General 26
Standard I/O (X1) connecting plug configuration 26
Operating controls, connections and mechanical components 28
General 28
Control panel 28
Connections and mechanical components of the base unit 29
Connections and mechanical components of the cleaning unit 30
Installation and Startup 33
Safety 35
Safety 35
Before installation 36
Operating personnel, maintenance personnel 36
Setup regulations 36
Specifications for the compressed air supply 36
3
Mains connection 37
Setting Up and Connecting the Cleaning Device 38
Assembly note 38
Screwing the cleaning unit and work stand to the mounting surface (foundation) 38
Screwing the base unit and work stand to the surface (foundation) 39
Connecting the cleaning unit to the base unit 40
Connecting the Mains Cable 41
Connecting the mains cable 41
Installing the wire cutter 42
Installing the wire cutter on the cleaning device 42
Maximum Wire Diameter 42
Operating Principle of the Electrically Controlled Wire Cutter 42
Connecting the Cleaning Unit to the ‘Robacta Reamer’ Parting Agent Container 43
Connecting the cleaning unit to the 'Robacta Reamer' parting agent container 43
Start up the Cleaning Device 44
General 44
Requirements for Commissioning 44
Cleaning Program Sequence for Single Wire Applications 45
Program Sequence with Parting Agent Atomizer – Overview 45
Cleaning the Gas Nozzle Tip and Nozzle Fitting – Detailed Description 45
Injecting Parting Agent – Detailed Description 45
Cleaning Program Sequence with Parting Agent Atomizer 47
Cleaning Program Sequence for Twin Applications 48
Program Sequence with Parting Agent Atomizer – Overview 48
Cleaning the gas nozzle tip and nozzle fitting – detailed description 48
Injecting parting agent – detailed description 48
Cleaning Program Sequence with Parting Agent Atomizer 50
Troubleshooting, Maintenance, and Disposal 51
Safety 53
Safety 53
Troubleshooting 55
Troubleshooting 55
What to Do in the Event of an Error 57
What to Do in the Event of an Error 57
Service, maintenance and disposal 58
Before Every Start-up 58
Daily 58
Weekly 58
Every Six Months 58
Every 12 Months 58
Clean the intake filter in the parting agent container 58
Disposal 59
Technical data 61
Technical data 63
General 63
Robacta TC 2000 ext. 63
Robacta TC 2000 ext. US 63
Cleaning Unit TC 2000 64
Cleaning Unit TC 2000 LH 64
Cleaning Unit TC 2000 Twin 64
Cleaning Unit TC 2000 Twin 64
4
Safety Instructions
EN-US
Explanation of
Safety Instructions
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.
General The device has been manufactured using state-of-the-art technology and ac-
cording to recognized 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 the commissioning, operation, maintenance, and servicing
of the device must
be suitably qualified,
-
have knowledge of automated welding and
-
have read these Operating Instructions and any system component operating
-
instructions in full and follow them carefully.
The Operating Instructions must always be at hand wherever the device is being
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!
5
Intended Use 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 responsible 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 manufacturer
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.
Environmental
Conditions
Obligations of
the Operating
Company
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 responsible 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 regu-
-
lations and are trained in handling the device
Have read and understood these Operating Instructions, especially the sec-
-
tion "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.
Obligations of
Personnel
Particular hazard areas
6
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 prevention
-
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 damage
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 area.
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 manufacturer 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 prop-
-
erly.
Keep all covers and side parts closed.
-
EN-US
Personal Protection and Protection 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 pacemakers
-
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 im-
-
plants must seek advice from their doctor before working with the device 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 behind
-
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 injury
-
7
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 similar, etc.),
provide suitable protective equipment, or
-
construct suitable protective walls and curtains.
-
Dangers due to
Mains Current
and Operating
Current
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 inadequately
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 resulting
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
device switched on again by affixing a clearly legible and understandable warning
sign.
EMC Device
Classifications
8
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 supplied from the public lowvoltage grid.
EMC device classification as per the rating plate or technical data.
EMC Measures 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 electromagnetic 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:
Grid power supply
1.
If electromagnetic interference occurs despite a grid connection that
-
complies with regulations, take additional measures (e.g., use a suitable
grid filter).
Shield, if necessary
2.
Shield other devices in the vicinity
-
Shield the entire welding installation
-
Do not carry magnetic or electronic data carriers:
3.
Magnetic or electronic data carriers can be damaged due to the magnetic
fields occurring during operation of the device.
Do not carry watches or pieces of metal. Watches may be damaged by the
4.
operation of the device.
EN-US
Safety Measures
at the Setup
Location and
During Transport
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.
-
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 protection
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 equipment
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.
9
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.
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 danger of:
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
-
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 obtained
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 interna-
-
tional regulations.
Maintenance and
repair
Safety Inspection
It is impossible to guarantee that bought-in parts are designed and manufactured to meet the demands made of them, or that they satisfy safety requirements.
Use only original spare and wearing parts (also applies to standard parts).
-
Do not carry out any modifications, alterations, etc. to the device without the
-
manufacturer's consent.
Components that are not in perfect condition must be replaced immediately.
-
When ordering, please give the exact designation and part number as shown
-
in the spare parts list, as well as the serial number of your device.
The housing screws provide the ground conductor connection for earthing the
housing parts.
Only use original housing screws in the correct number and tightened to the specified torque.
The manufacturer recommends that a safety inspection of the device be performed 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.
-
10
For the safety inspection, follow the appropriate national and international
standards 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.
Disposal Waste electrical and electronic equipment must be collected separately and re-
cycled in an environmentally sound manner in accordance with the European Directive and national law. Used equipment must be returned to the distributor or
through a local authorized collection and disposal system. Proper disposal of the
used device promotes sustainable recycling of material resources. Failure to observe this may lead to potential health/environmental impacts.
Packaging materials
Separate collection. Check your municipality’s regulations. Reduce the volume of
the box.
Safety symbols Devices with the CE label satisfy the essential requirements of the low-voltage
and electromagnetic compatibility directive (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
EN-US
Devices marked with the CSA test mark satisfy the requirements of the relevant
standards for Canada and the USA.
Data backup The user is responsible for backing up 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.
Text and illustrations were accurate at the time of printing. Fronius reserves 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 mistakes that you
have found in the Operating Instructions, we will be most grateful for your comments.
11
12
General
13
14
General
EN-US
Device concept
Base unit with cleaning unit
Applications The cleaning device is intended for the cleaning of welding torches in automated
steel applications. 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
-
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 designs
The cleaning device is designed to
clean a variety of different welding
torch geometries. The components are
housed in a robust housing. The compact design permits installation in the
smallest of spaces.
The cleaning device is largely maintenance-free, since there are no parts
subject to mechanical stress.
Warning notices
on the device
The device has safety symbols and a rating plate fitted. These safety symbols and
the 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 to property.
15
WARNING! Risk of serious injuries due to:
The magnetic field of the cleaning aperture
-
Compressed air/parting agent mixture discharged from the
-
cleaning aperture
Flying debris (chips, etc.)
-
Moving mechanical parts
-
During maintenance and servicing, keep the device de-energized
and depressurized.
Do not use the functions described here until you have fully read
and understood the following documents:
These Operating Instructions
-
All system component Operating Instructions, especially the
-
safety rules
For indoor use only
Wear eye protection
16
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
EN-US
17
Functional principle
5
4,5
4
3,5
3
20 25 30 35 40
45 50
(2)
(1)
Operating principle
As soon as the cleaning device is connected to the grid, the 28 (page 28)
a)
lights up. The capacitors, which store the energy for the cleaning process, are
discharged and no outputs are actuated.
NOTE!
In order for the capacitors' charging process to begin, the following prerequisites 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
▶
Before the capacitors are charged, the device temperature is checked. If it is
b)
within tolerance, the capacitors will be charged for the cleaning process.
If the operating temperature is exceeded, the overtemperature 28 (page
28) will light up. In this case, the charging process of the capacitors will
only take place after cooling down to the permissible operating temperature.
After 20 seconds of charging time, the 'Ready' signal will be output to the ro-
c)
bot control - the 29 indicator (page 29) on the device will flash. As soon as
the capacitors are fully charged, the indicator 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 29 (page 29) 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.
Available magnetic flux density (Tesla)
Charging time (seconds)
18
After the cleaning process has finished, the program sequence starts again
0 % 100 %
50 mm
1.97 in.
10 mm
0.39 in.
15 mm
0.59 in.
d)
with a check of the device temperature. If a cleaning process has finished incorrectly, the 'Error' 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!
If the robot control deactivates the 'Quick Stop' signal during the program sequence, the cleaning device program sequence will be aborted immediately.
For safety reasons, the capacitors are discharged via the cleaning coil.
EN-US
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.
NOTE!
For the operation of the cleaning device, use the insertion depth details for the
welding torch from the program sequence.
Insertion depth of
the torch body into
the cleaning coil
Cleaning coil
Diagram of available
magnetic flux density
19
Representation
0 % 100 %
54 mm
2.13 in.
14 mm
0.55 in.
19 mm
0.75 in.
of the magnetic
flux density
within the cleaning coil for twin
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.
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
magnetic flux density
Insertion depth of
the torch body into
the cleaning coil
20
Scope of Supply and Options
General The cleaning device may be operated in conjunction with various options. De-
pending on the area of application, various sequences in the work process can be
optimized as a result.
EN-US
Scope of Supply
Available Options
Base unit (available in various versions)
-
Standard I/O (X1) connecting plug without cable
-
Four screws for mounting the cleaning device on the work stand
-
Available options for the cleaning device
Cleaning unit (available in various versions)
-
Work stand for the base unit (available in various heights)
-
Work stand for the cleaning unit (available in various heights)
-
Wire cutter
-
Installation kit for parting agent atomizer
-
21
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