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
Operating Instructions
EN
42,0426,0135,EN 027-18072024
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
Safety symbols 11
Data security 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 2000US20
Magnetic flux densities within the cleaning coil for Robacta TC 2000 Twin, Robacta TC
2000 Twin US
Scope of supply and options 22
General 22
Scope of supply 22
Available options 22
Transport 23
Transport means 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 components
Installation and commissioning 37
21
34
Safety 39
Safety 39
Before commissioning 40
Operators, maintenance personnel 40
3
Setup regulations 40
Compressed air supply specifications 40
Mains connection 41
Screwing the cleaning device to the underlying surface 42
Screwing the cleaning device to the underlying surface 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
Filling the dipping bowl with parting agent 45
Filling the dipping bowl with parting agent 45
Connecting the cleaning device to the "Robacta Reamer" parting agent container 46
Connecting the cleaning device to the "Robacta Reamer" parting agent container 46
Starting up the cleaning device 47
General 47
Prerequisites for start-up 47
Gas nozzle to spool body distance control 47
Cleaning program sequence - Robacta TC 2000, Robacta TC 2000 US 48
Program sequence with parting agent nebuliser - overview 48
Program sequence with parting agent nebuliser and dipping bowl - overview 48
Cooling welding torch in the dipping bowl - detailed description 48
Cleaning the gas nozzle tip and nozzle fitting - detailed description 49
Spraying parting agent - detailed description 49
Cleaning program sequence with parting agent nebuliser 51
Cleaning program sequence with dipping bowl 52
Cleaning program sequence - Robacta TC 2000 Twin, Robacta TC 2000 Twin US 53
Program sequence with parting agent nebuliser - overview 53
Program sequence with parting agent nebuliser and dipping bowl - overview 53
Cooling welding torch in the dipping bowl - detailed description 53
Cleaning the gas nozzle tip and nozzle fitting - detailed description 54
Spraying parting agent - detailed description 54
Cleaning program sequence with parting agent nebuliser 55
Cleaning program sequence with dipping bowl 56
Troubleshooting, maintenance and disposal 57
Safety 59
Safety 59
Troubleshooting 61
Troubleshooting 61
Care, maintenance and disposal 64
Before each start-up 64
Daily 64
Weekly 64
Every 4 weeks 64
Every 6 months 65
Every 12 months 65
Disposal 65
Technical data 67
Technical data 69
General 69
Robacta TC 2000, Robacta TC 2000 Twin 69
Robacta TC 2000 US, Robacta TC 2000 Twin US 69
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 environmental protection.
All safety and danger notices on the device
must be in a legible state,
-
must not be damaged,
-
must not be removed,
-
must not be covered, pasted or painted over.
-
For the location of the safety and danger notices on the device, refer to the section headed "General" in the operating instructions for the device.
Before commissioning the device, rectify any faults that could compromise
safety.
This is for your personal safety!
5
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 setting.
The manufacturer likewise accepts no liability for inadequate or incorrect results.
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)
-
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)
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
6
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.
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.
-
Keep all covers and side panels closed.
-
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
-
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-
-
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
-
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
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 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
-
Alternatively, erect suitable safety screens/curtains.
-
Risks from mains
current and operating 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 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.
-
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 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 measures Warning, 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
-
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
-
Power, signal and data transfer lines
-
IT and telecommunications devices
-
Measuring and calibrating devices
-
Health of neighbouring persons
-
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.
-
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
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 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.
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-
-
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
10
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.
Safety inspection
Safety symbols Devices with the CE mark satisfy the essential requirements of the low-voltage
The manufacturer recommends that a safety inspection of the device is performed at least once every 12 months.
A safety inspection should be carried out by a qualified electrician
after any changes are made
-
after any additional parts are installed, or after any conversions
-
after repair, care and maintenance has been carried out
-
at least every twelve months.
-
For safety inspections, follow the appropriate national and international standards and 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.
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 security With regard to data security, the user is responsible for:
backing up any changes made to the factory settings
-
saving and retaining personal settings
-
Copyright Copyright of these operating instructions remains with the manufacturer.
Text and illustrations were accurate at the time of printing, subject to change.
We are grateful for suggestions for improvement and information regarding any
discrepancies in the operating instructions.
11
12
General
13
14
General
Device concept
Application areas
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 robot cells). In addition, the cleaning
devices have been conceived in such a
way that the installation stand and
standard I/O connecting plug (X1) of
the Robacta TC 1000 can be used with
the cleaning devices without any modifications.
Robacta TC 2000
The cleaning devices are more or less maintenance-free, as there are no mechanically stressed parts.
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 damage to property.
15
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 recommended for all applications.
17
Functional principle
5
4,5
4
3,5
3
20 25 30 35 40
45 50
(2)
(1)
Functional principle
Once the cleaning device is connected to the mains power supply, the mains
-
voltage indicator lights up. The capacitors, which store energy for the cleaning operation, are discharged and no outputs are activated.
NOTE!
Before the capacitors can be charged, the cleaning device must be connected to
both the mains power supply and the robot control. The "Quick Stop" signal
must also be set.
The device temperature is checked before the capacitors are charged. If it
-
lies within the tolerance range, the capacitors are charged in preparation for
a cleaning operation. If the operating temperature is exceeded, the overtemperature indicator lights up. Capacitor charging only begins once the temperature 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. Although 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.
18
(1) Magnetic flux density available (Tesla)
(2) Charging time (seconds)
Once the cleaning operation is complete, the program sequence restarts by
-
checking the device's temperature. If there was a problem during the cleaning operation, the "Error" signal is output. The cleaning device resumes charging the capacitors. Once ready to clean ("Ready"), a second cleaning operation can be started.
NOTE!
If the robot control deactivates the "Quick Stop" signal during the program
sequence, the cleaning device program sequence is interrupted immediately. 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
Magnetic flux
0 % 100 %
50 mm
1.97 in.
10 mm
0.39 in.
15 mm
0.59 in.
(1) (2) (3)
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.
(1) Cleaning coil
(2) Diagram showing available magnetic flux density
(3) Immersion depth of torch neck into cleaning coil
20
Magnetic flux
0 % 100 %
54 mm
2.13 in.
14 mm
0.55 in.
19 mm
0.75 in.
(1) (2) (3)
densities within
the cleaning coil
for Robacta TC
2000 Twin,
Robacta TC
2000 Twin 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.
(1) Cleaning coil
(2) Diagram showing available magnetic flux density
(3) Immersion depth of torch neck into cleaning coil
21
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.
Scope of supply
Available options
Cleaning device with dipping bowl and integrated cleaning unit
-
Standard I/O connecting plug (X1) without cable
-
Four screws for fitting the cleaning device to the installation stand
-
Available options for the cleaning device
Installation stand (available in various heights)
-
Wire cutter
-
Wire cutter installation kit
-
Parting agent nebuliser installation kit
-
Robot interface
-
22
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