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

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

Magnetic ﬂux densities within the cleaning coil for Robacta TC 2000, Robacta TC 2000

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 devices 23

Transport notices on the packaging 23

Controls, connections and mechanical components 25

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

Installation and commissioning 37

Safety 39

Before commissioning 40

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

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

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

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

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!

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.

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

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.

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.

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.

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