FRONIUS Robacta TC 2000 Mode d’emploi
/ Perfect Charging / Perfect Welding / Solar Energy
42,0426,0135,EN 015-14082018
Robacta TC 2000
Robacta TC 2000 Twin
Robacta TC 2000 US
Robacta TC 2000 Twin US
Operating Instructions
Spare parts list
Welding torch cleaning
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Dear reader,
Introduction Thank you for the trust you have placed in our company and congratulations on buying this
high-quality Fronius product. These instructions will help you familiarise yourself with the
product. Reading the instructions carefully will enable you to learn about the many different
features it has to offer. This will allow you to make full use of its advantages.
Please also note the safety rules to ensure greater safety when using the product. Careful
handling of the product will repay you with years of safe and reliable operation. These are
essential prerequisites for excellent results.
Explanation of
safety symbols
If you see any of the symbols depicted in the "Safety rules" chapter, special care is re-
quired.
DANGER! Indicates immediate and real danger. If it is not avoided, death or se-
rious injury will result.
WARNING! Indicates a potentially dangerous situation. Death or serious injury
may result if appropriate precautions are not taken.
CAUTION! Indicates a situation where damage or injury could occur. If it is not
avoided, minor injury and/or damage to property may result.
NOTE! Indicates a risk of flawed results and possible damage to the equipment.
IMPORTANT! Indicates tips for correct operation and other particularly useful information.
It does not indicate a potentially damaging or dangerous situation.
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Contents
Safety rules ................................................................................................................................................ 7
General ................................................................................................................................................. 7
Proper use ............................................................................................................................................ 7
Environmental conditions...................................................................................................................... 8
Obligations of the operator.................................................................................................................... 8
Obligations of personnel ....................................................................................................................... 8
Specific hazards.................................................................................................................................... 8
Protecting yourself and others .............................................................................................................. 9
Risks from mains current and operating current ................................................................................... 10
EMC Device Classifications .................................................................................................................. 10
EMC measures ..................................................................................................................................... 11
Safety measures at the installation location and during transport ........................................................ 11
Safety measures in normal operation ................................................................................................... 12
Commissioning, maintenance and repair.............................................................................................. 13
Safety inspection................................................................................................................................... 13
Disposal ................................................................................................................................................ 13
Safety symbols...................................................................................................................................... 14
Data protection...................................................................................................................................... 14
Copyright............................................................................................................................................... 14
General 15
General ...................................................................................................................................................... 17
Device concept ..................................................................................................................................... 17
Application areas .................................................................................................................................. 17
Warning notices on the device.............................................................................................................. 17
Parting agent types and their use ......................................................................................................... 19
Functional principle .................................................................................................................................... 20
Functional principle ............................................................................................................................... 20
Magnetic flux densities within the cleaning coil for Robacta TC 2000, Robacta TC 2000 US .............. 21
Magnetic flux densities within the cleaning coil for Robacta TC 2000 Twin, Robacta TC 2000 Twin US 22
Scope of supply and options...................................................................................................................... 23
General ................................................................................................................................................. 23
Scope of supply .................................................................................................................................... 23
Available options................................................................................................................................... 23
Transport.................................................................................................................................................... 24
Vehicles ................................................................................................................................................ 24
Transport notices on the packaging...................................................................................................... 24
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........................... 31
Robacta TC 2000 Twin, Robacta TC 2000 Twin US connections and mechanical components ......... 32
Installation and commissioning 35
Safety......................................................................................................................................................... 37
Safety.................................................................................................................................................... 37
Before commissioning................................................................................................................................ 38
Operators, maintenance personnel....................................................................................................... 38
Setup regulations .................................................................................................................................. 38
Compressed air supply specifications................................................................................................... 38
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Mains connection .................................................................................................................................. 38
Bolting the cleaning device to the underlying surface (foundation)............................................................ 39
Screwing the cleaning device and installation stand to the underlying surface (foundation) ................ 39
Connecting the mains cable - Robacta TC 2000 US, Robacta TC 2000 Twin US .................................... 40
Connecting the mains cable.................................................................................................................. 40
Installing the wire cutter ............................................................................................................................. 42
Installing the wire cutter on the cleaning device ................................................................................... 42
Maximum wire diameter........................................................................................................................ 42
How the mechanically controlled wire cutter works ..............................................................................42
How the electrically-controlled wire cutter works .................................................................................. 43
Filling the dipping bowl with parting agent ................................................................................................. 44
Filling the dipping bowl with parting agent ............................................................................................ 44
Connecting the cleaning device to the "Robacta Reamer" parting agent container................................... 45
Connecting the cleaning device to the "Robacta Reamer" parting agent container ............................. 45
Starting up the cleaning device.................................................................................................................. 46
General ................................................................................................................................................. 46
Prerequisites for start-up....................................................................................................................... 46
Cleaning program sequence - Robacta TC 2000, Robacta TC 2000 US .................................................. 47
Program sequence with parting agent nebuliser - overview ................................................................. 47
Program sequence with parting agent nebuliser and dipping bowl - overview ..................................... 47
Cooling welding torch in the dipping bowl - detailed description........................................................... 47
Cleaning the gas nozzle tip and nozzle fitting - detailed description..................................................... 48
Spraying parting agent - detailed description........................................................................................ 48
Cleaning program sequence with parting agent nebuliser.................................................................... 49
Cleaning program sequence with dipping bowl ....................................................................................50
Cleaning program sequence - Robacta TC 2000 Twin, Robacta TC 2000 Twin US ................................. 51
Program sequence with parting agent nebuliser - overview ................................................................. 51
Program sequence with parting agent nebuliser and dipping bowl - overview ..................................... 51
Cooling welding torch in the dipping bowl - detailed description........................................................... 51
Cleaning the gas nozzle tip and nozzle fitting - detailed description..................................................... 52
Spraying parting agent - detailed description........................................................................................ 52
Cleaning program sequence with parting agent nebuliser.................................................................... 53
Cleaning program sequence with dipping bowl ....................................................................................54
Troubleshooting, maintenance and disposal 55
Safety......................................................................................................................................................... 57
Safety.................................................................................................................................................... 57
Troubleshooting ......................................................................................................................................... 58
Troubleshooting .................................................................................................................................... 58
Care, maintenance and disposal ............................................................................................................... 61
Before each start-up ............................................................................................................................. 61
Daily ...................................................................................................................................................... 61
Weekly .................................................................................................................................................. 61
Every 3 months ..................................................................................................................................... 61
Every 6 months ..................................................................................................................................... 61
Every 12 months ................................................................................................................................... 61
Disposal ................................................................................................................................................ 61
Technical data 63
Technical data............................................................................................................................................ 65
General ................................................................................................................................................. 65
Robacta TC 2000, Robacta TC 2000 Twin .......................................................................................... 65
Robacta TC 2000 US, Robacta TC 2000 Twin US ............................................................................... 65
Appendix 67
Spare parts list: Robacta TC 2000............................................................................................................. 68
Circuit diagrams: Robacta TC 2000........................................................................................................... 71
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Safety rules
General
Proper use
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 operat-
ing 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 oper-
ating instructions for all system components.
The operating instructions must always be at hand wherever the device is be-
ing used. In addition to the operating instructions, attention must also be paid
to any generally applicable and local regulations regarding accident preven-
tion 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!
The device is to be used exclusively for its intended purpose.
The device is intended solely for the electromagnetic cleaning of Fronius weld-
ing torches.
Any use above and beyond this purpose is deemed improper. The manufac-
turer 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
instructions
- 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 manufactur-
er accepts no responsibility for any damage caused through use in a domestic
setting.
The manufacturer likewise accepts no liability for inadequate or incorrect re-
sults.
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Environmental
conditions
Obligations of the
operator
Obligations of
personnel
Specific hazards
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
section "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.
Before using the device, all persons instructed to do so undertake:
- to observe the basic instructions regarding safety at work and accident
prevention
- 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.
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.
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Protecting your-
self and others Electromagnetic fields may pose as yet unknown risks to health:
- Effects on the health of persons in the vicinity, e.g. those with pacemak-
ers, metallic implants and hearing aids
- Forbidden for anyone wearing a pacemaker: people fitted with a pace-
maker must consult their doctor before working with the device or entering
its immediate vicinity
- Forbidden for anyone with metal implants: people fitted with metal im-
plants 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.
Persons involved with welding expose 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
Anyone working on the workpiece while welding is in progress must wear suit-
able protective clothing with 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 protec-
tive 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
injury.
Keep all persons, especially children, out of the working area while any devic-
es 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, me-
chanically-powered parts, compressed air/parting agent mixture ejected
from the cleaning opening, flying shavings and similar matter, etc.),
- provide suitable protective equipment or
- erect suitable safety screens/curtains.
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Risks from mains
current and oper-
ating current
EMC Device Clas-
sifications
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 dimen-
sioned 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
earthing the housing. The screws must never be replaced with different
screws unless a reliable ground conductor connection is set up.
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 sup-
plied from the public low-voltage mains.
EMC device classification as per the rating plate or technical data.
Autres manuels pour Robacta TC 2000
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Autres manuels FRONIUS Autre
