Table of contents Safety Instructions Explanation of Safety Instructions General Intended Use Environmental Conditions Obligations of the Operating Company Obligations of Personnel Particular hazard areas Personal Protection and Protection of Others EMC Device Classifications Safety Measures at the Setup Location and During Transport Safety Measures in Normal Operation Maintenance and repair Safety Inspection...
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Installing optional equipment - overview 1. Installing Touch Sense Tools required Installing Touch Sense 2. Installing the wire cutter Tools Required Additionally required Installing the Wire Cutter Operating Instructions 3. Installing the Robacta TC 2000 cleaning unit General Tools required Additionally Required Installing the Robacta TC 2000 Cleaning Unit 3.
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Change cleaning brushes and nozzle for the high-pressure gas purging Releasing Pressure before Maintenance Work Replacing the Outer Gas Nozzle Cleaning Brushes Replacing the inner gas nozzle cleaning brush Changing the nozzle for the high-pressure gas purging Appendix Technical data Detailed Information on the Optional Equipment Robacta TSS /i...
Safety Instructions Explanation of DANGER! Safety Instruc- tions 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.
The device is to be used exclusively for its intended purpose. The device is intended exclusively for the 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.”...
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.
Install the device at a minimum distance of 1 m (40 in.) away from IT equipment and con- trol 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.
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.
Robacta TSS /i with the options wire cutter and Robacta TC 2000 Applications The welding torch service station is used in automated MIG/MAG applications in a robot...
Warning Notices NOTE! on the Device The welding torch service station is equipped with warning notices and a rating plate. These warning notices and the rating plate must not be removed or painted over. Type Art.No. Chargen No. Wels - Austria 0.25 A 24 V p max...
Do not use the functions described here until you have fully read and understood the fol- lowing documents: these Operating Instructions all Operating Instructions for system components, especially the safety rules For indoor use only Wear eye protection Warning before the device switches on automatically Types of Parting NOTE! Agent and Their...
Transport Transport CAUTION! Instructions on the packaging Danger due to improper transport. This can result in damage to property. ▶ Follow the transport instructions on the device packaging. Transport WARNING! Danger from machines toppling over or falling. May result in serious injuries or death. ▶...
Operating controls, connections and mechanical components Detailed Informa- NOTE! tion on the Optional Equip- For detailed information on the optional equipment, consult the available installa- ment tion instructions or Operating Instructions for the optional equipment. Safety WARNING! Danger due to incorrect operation. This can result in severe personal injury and damage to property.
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High-pressure gas purging with parting agent The opening for the high-pressure gas purging can be enlarged by breaking away the metal parts, e.g., for oval gas nozzles. Inner gas nozzle cleaning brush for cleaning the contact tip Collecting tray Flap for parting agent container Manometer Ground connection Installation area for optional equipment...
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(11) External optional equipment connection (12) External optional equipment connection (11) (13) External optional equipment (12) (13) connection (21) (14) (14) External optional equipment (15) connection (20) (16) (19) (17) The 37-pin connections (11)–(14) for (18) external optional equipment are equal. View B (15) Compressed air connection...
Connector pin assignments and signal descriptions Safety WARNING! Danger due to incorrect operation. This can result in severe personal injury and damage to property. ▶ All functions described may only be used by trained personnel. ▶ Do not use the functions described here until you have fully read and understood the Operating Instructions.
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Signal + 24 V DC High-end gas purging (from the front) High-end gas purging (through the hosepack) External valve brush cleaning Internal valve brush cleaning Pump for parting agent Pressure switch Parting agent fill level (optional) Reserved Reserved RR Single gas nozzle free Reserved I 15 RR Single start cleaning...
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Signal + 24 V DC Occupied Occupied Occupied Occupied Occupied Occupied I 11 Signal Gas OK Single I 12 Signal Gas OK Twin I 13 RR Single gas nozzle free Reserved RR Single start cleaning Reserved Reserved Reserved I 19 Reserved I 20 Reserved...
Input and Output Signals ProfiNet, DeviceNet, ProfiBus, EtherCAT, and EtherNet IP Fieldbus Terminal The fieldbus terminals are allocated at the factory as follows: Allocation ProfiNet BK 9103 DeviceNet BK 5250 EtherCAT BK 1120 ProfiBus BK 3120 EtherNet IP BX 9105 NOTE! Further fieldbus terminals can be installed in a robot interface;...
Reserved Reserved Reserved Reserved Reserved Reserved = Robacta Reamer = Robacta TC = wire cutter Output signals Signal designation (from robot to Action welding torch service station) High-end gas purging (from the front) High High-end gas purging (through the hosepack) High External valve brush cleaning High...
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WC / RR cut wire electrode High RR clamp gas nozzle High RR cleaning motor up (stroke) High Reserved RR / TC spraying High = Robacta Reamer = Robacta TC = wire cutter...
Safety Detailed Informa- NOTE! tion on the For detailed information on the optional equipment, consult the available installa- Optional Equip- ment tion instructions or Operating Instructions for the optional equipment. Safety Please follow the safety rules below during all the tasks described in the "Installation and Commissioning"...
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WARNING! Danger due to flying parts (chips, metal particles, etc.), escaping compressed air/parting agent mixture, electrically supplied, activated options. If compressed air is supplied to the welding torch service station, serious injury can res- ult. If work needs to be carried out on the device while the welding torch service station is being supplied with compressed air or the optional equipment is being supplied with electricity: ▶...
Before installation Operating per- WARNING! sonnel, mainten- ance personnel Danger due to machines starting automatically. This can result in severe personal injury and damage to property. ▶ In all situations, the device must only ever be operated by one person. In addition, make sure that there are no other people in the device's operating area while it is in operation.
Bolting the Welding Torch Service Station to the Surface Bolting the Weld- WARNING! ing Torch Service Station to the Danger due to the welding torch service station toppling over. Surface It can cause injuries. ▶ Even out any unevenness in the floor ▶...
Installing Optional Equipment Optional Equip- Depending on the configuration, optional equipment is installed on the welding torch ser- ment on Delivery vice station on delivery. The following installation descriptions apply for a welding torch service station without optional equipment or for the retrofitting of the optional equipment. Installing The installation of the optional equipment available for the welding torch service station optional equip-...
1. Installing Touch Sense Tools required Torx screwdriver TX20 Torx screwdriver TX25 Size 17 mm wrench 4 mm Allen key Cable ties Diagonal cutting pliers Slotted screwdriver Hammer Installing Touch Knock out the side round opening Sense Remove the 6 TX25 screws 6x TX25 Remove the cover Knock out the top round opening...
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Position the Touch Sense on the plastic support 2 x TX20 Secure the Touch Sense with 2 TX20 screws Secure the cable to the bottom of the Touch Sense with a 3 mm Allen screw Insert the cable into the knocked-out opening NOTE! When installing the Touch Sense, do...
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Insert the plastic insert into the open- ing from the outside inwards Use hexagonal nuts and wrench to attach the plastic insert to the housing wall size 17 mm Arrange serrated washer and cable lug on the Allen screw according to the diagram: cable lug (1)—serrated washer (2)—...
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Position cover Install cover using 6 TX25 screws Apply cable lug of an additional cable to the screw protruding out of the housing and use the serrated washer and 8 mm hexagonal nut from the scope of supply to secure the OPT/i TSS TCP Touch Sense TX25 Use the additional cable to establish a...
2. Installing the wire cutter Tools Required Slotted screwdriver Hammer 5 mm Allen key 6 mm Allen key 10 mm wrench Additionally The following accessories are required for attaching a wire cutter to the welding torch required service station: OPT/i TSS Wire Cutter (installation set for wire cutter) ... 4,001,098,CK Installing the Knock out the opening Wire Cutter...
Lay the control cable and compressed air hose of the wire cutter backwards through the recess IMPORTANT! When positioning the wire cutter, ensure that the control cable and compressed air hose are not pinched, kinked, cut, or otherwise damaged. Position the wire cutter according to the diagram Use four 6 mm Allen screws and four washers to install the wire cutter on...
3. Installing the Robacta TC 2000 cleaning unit General A Robacta TC 2000 cleaning unit or a Robacta Reamer Twin cleaning unit can be moun- ted on the service station. Tools required Torx screwdriver TX25 6 mm Allen key Slotted screwdriver Hammer Additionally The following accessories are required for installing a Robacta TC 2000 cleaning unit on...
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Place Robacta TC 2000 cleaning unit in front of the service station IMPORTANT! When laying the control cable, ensure that the correct cable end is on the side of the TC 2000 cleaning unit. Lay mains cable and control cable in the mounting plate to the rear IMPORTANT! When positioning the Robacta TC 2000 cleaning unit, ensure...
3. Installing the Robacta Reamer Twin cleaning unit General A Robacta TC 2000 cleaning unit or a Robacta Reamer Twin cleaning unit can be moun- ted on the service station. Tools Required Torx screwdriver TX25 3 mm, 5 mm Allen key Slotted screwdriver Hammer 18 mm wrench...
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Connect the hoses together Fix the hoses in place using a cable Insert the rubber bushing into the free opening Loosen 2 Allen screws size 5 mm Remove the 3-piece clamping device element Remove countersunk Allen screw size 5 mm Remove the clamping device element...
Installing the Secure the clamping device element Twin Clamping with M8 x 25 mm countersunk Allen System screw size 5 mm Insert two 3 x 12 mm dowel pins Connect the clamping device ele- ments together Screw the clamping device elements together with two washers and two M6 x 25 mm Allen screws size 5 mm...
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Install the clamping device elements with two M6 x 16 mm Allen screws size 5 mm Make sure that there is a distance of approx. 0.5 mm between the clamping device elements. Position the housing casing Install the housing casing with five M4 x 8 mm Allen screws size 3 mm...
Installing the The Robacta Reamer Twin cleaning unit Robacta Reamer can be mounted in 3 positions on the ser- Twin cleaning vice station as shown. unit Depending on the intended mounting position, knock out the corresponding rectangular opening Position the Robacta Reamer Twin cleaning unit on the service station Possible mounting positions: Secure the Robacta Reamer Twin...
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Connect the Robacta Reamer control cable Connect the hose for the compressed air supply...
4. Installing the level sensor Tools Required Torx screwdriver TX25 5 mm wrench Installing the Pull the spring pins of the collecting Level Sensor tray to the left and right and swing col- lecting tray out Remove three TX25 screws on the left Remove three TX25 screws on the right Remove frame...
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Guide the sensor cable through the recess to the other side Attach the sensor cable to the avail- able cable piece Close flap for parting agent container IMPORTANT! When inserting the frame, ensure that the metal strap is positioned in the recess.
5. Inserting the parting agent container Inserting the Open flap for parting agent container Parting Agent Container Carefully pull hose out of the flap Insert parting agent container until it reaches the stop Open the parting agent container Insert the hose into the parting agent container Secure the cap of the hose NOTE!
6. Installing the TCP Tip Tools Required Torx screwdriver TX20 Installing the TCP TCP = Tool Center Point Instead of the Touch Sense, a TCP tip can also be fitted. This can be done without knocking out the round holes on the side and top. Use 2 TX20 screws to install the TCP tip on the service station Unscrew the protective cap for opera-...
7. Installing the Robacta Reamer V Easy / Robacta Reamer V 70 Han12P cleaning unit General In addition to the Robacta TC 2000 or Robacta Reamer cleaning units, a Robacta Reamer V Easy cleaning unit or a Robacta Reamer V 70 Han12P cleaning unit for single welding torches can be mounted on the service station.
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Position the intermediate plate over the 4 holes Example: Service station with Robacta reamer and wire cutter Place the Robacta Reamer V Easy on the intermediate plate Use four 6 mm Allen screws and four washers to install the Robacta Reamer V Easy on the service station Remove three 10 mm hexagonal bolts Remove the cover...
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Fit the new cover Install the new cover on the Robacta Reamer V Easy with three 10 mm hexagonal bolts Secure the new cover to the service station with two 6 mm Allen screws Install spool valve Size 19 mm Connect the control cable to the ser- vice station and Robacta Reamer V Easy...
Starting Up the Welding Torch Service Station General NOTE! If wetting agent has not been applied to the inside of the welding torch, this may lead to the permanent contamination of the welding torch when welding begins. Always wet the inside of the welding torch with the manufacturer's "Robacta Reamer" parting agent before starting an automatic application.
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Adjust pressure on the manometer: 5.5–6 bar Check that all equipment parts and covers are correctly installed IMPORTANT! Before welding for the first time, a complete cleaning process must be car- ried out.
Program sequence—overview Detailed Informa- NOTE! tion on the For detailed information on the optional equipment, consult the available installa- Optional Equip- ment tion instructions or Operating Instructions for the optional equipment. Program The following program sequence is described using the example of a service station with Sequence—Over- wire cutter, Robacta TC 2000 cleaning unit, and dipping bowl.
General information Wire cutter The wire cutter can be used to cut two wire electrodes with a diameter of up to 1.6 mm (0.063 in.) The opening and closing of the wire cutter is triggered by an active signal from the robot controls.
Program sequence Wire cutter pro- gram sequence Start Move to position A approx. 50 mm/1.97 in. above wire cut- ter (between blades and sheet metal 50 mm cover) 1.97 in. Speed: High-speed mode "Start wirefeeding" signal on the power source Wait approx.
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Reset external signal "Cut wire electrode" "Retract wire electrode" signal on the power source Wait approx. 2-3 seconds Reset "Retract wire electrode" signal on the power source...
TC 2000 program Move to position C sequence approx. 50 mm/1.97 in. centrally above cleaning coil 50 mm Speed: High-speed mode 1.97 in. Move into TC 2000 max. speed: 50 cm/min / 19.69 ipm Insertion depth: 54 mm / 2.13 in. *) external signal "Start cleaning"...
High-pressure Move to position D gas purging with approx. 50 mm/1.97 in. centrally above parting agent the opening for the high-pressure gas program purging sequence (1st Contact tip 1 vertical to the service sta- contact tip) tion 50 mm Speed: High-speed mode 1.97 in.
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Reset external signal "High-end gas purging (from front)" Wait 1 second Reset external signal "External valve brush cleaning"...
Outer gas Move to position E nozzles cleaning approx. 50 mm/1.97 in. centrally above brush program the outer gas nozzle cleaning brush and sequence approx. 20 mm/0.79 in. in front of the housing of the service station Position welding torch at an angle Speed: High-speed mode 50 mm 1.97 in.
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Move to position E approx. 50 mm/1.97 in. centrally above the outer gas nozzle cleaning brush and approx. 20 mm/0.79 in. in front of the housing of the service station max. speed: 50 cm/min (19.69 ipm)
Inner gas nozzle Move to position F cleaning brush approx. 50 mm/1.97 in. centrally above program the inner gas nozzle cleaning brush sequence Contact tip 1 vertical to the service sta- tion Speed: High-speed mode 50 mm 1.97 in. external signal "Internal valve brush cleaning"...
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Reset external signal "Internal valve brush cleaning"...
High-pressure Swivel to position D gas purging with Contact tip 2 vertical to the service sta- parting agent tion program max. speed: 50 cm/min (19.69 ipm) sequence (2nd contact tip) 50 mm 1.97 in. external signal "Pump for parting agent" Wait 0.2 - 0.3 seconds specification of...
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Wait 1 second Reset external signal "External valve brush cleaning" Move to position D approx. 50 mm/1.97 in. centrally above the opening for the high-pressure gas purging Contact tip 2 vertical to the service sta- tion max. speed: 50 cm/min (19.69 ipm)
Touch Sense Move to position G (option) program x mm/x in. centrally above the Touch sequence Sense option x = stick out of the wire electrodes depending on application x mm x in. Speed: High-speed mode "Wirefeeding on" signal on the power source Wait until the wire electrode touches...
Wire cutter - Inner gas nozzle cleaning brush cleaning end pro- gram sequence Move to position A approx. 50 mm/1.97 in. above wire cut- ter (between blades and sheet metal 50 mm cover) 1.97 in. Speed: High-speed mode "Start wirefeeding" signal on the power source for approx.
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Reset external signal "Cut wire electrode" End of the cleaning process Welding...
Safety Detailed Informa- NOTE! tion on the For detailed information on the optional equipment, consult the available installa- Optional Equip- ment tion instructions or Operating Instructions for the optional equipment. Safety Please follow the safety rules below during all the tasks described in the "Installation and Commissioning"...
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WARNING! Danger due to flying parts (chips, metal particles, etc.), escaping compressed air/parting agent mixture, electrically supplied, activated options. If compressed air is supplied to the welding torch service station, serious injury can res- ult. If work needs to be carried out on the device while the welding torch service station is being supplied with compressed air or the optional equipment is being supplied with electricity: ▶...
Troubleshooting Detailed Informa- NOTE! tion on the For detailed information on the optional equipment, consult the available installa- Optional Equip- ment tion instructions or Operating Instructions for the optional equipment. Troubleshooting Make a note of the serial number and configuration of the device, and provide the ser- vice team with a detailed error description if: Errors occur that are not covered in this document The troubleshooting measures provided in this document are unsuccessful...
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Cleaning brushes do not run Cause: Compressed air supply interrupted Remedy: Set up the compressed air supply Cause: Compressed air supply line faulty or dirty Remedy: Clean compressed air supply line and replace if necessary Cause: Brush motor faulty Remedy: Inform service team Cause: Valve faulty...
Service, maintenance and disposal Detailed Informa- NOTE! tion on the For detailed information on the optional equipment, consult the available installa- Optional Equip- ment tion instructions or Operating Instructions for the optional equipment. Releasing Pres- WARNING! sure before Main- tenance Work Danger due to compressed air stored at 16 bar in the pressure booster.
Open the welding torch service station and blow clean with dry and reduced com- pressed air Every 12 Months Have a Fronius service technician perform a safety inspection on the cleaning device Disposal Materials should be disposed of according to valid local and national regulations.
Change cleaning brushes and nozzle for the high- pressure gas purging Releasing Pres- WARNING! sure before Main- tenance Work Danger due to compressed air stored at 16 bar in the pressure booster. Serious injuries may result. ▶ Switch off the compressed air supply and release stored compressed air before maintenance and servicing.
Remove installation wrench Place the installation wrench behind the right-hand cleaning brush Undo the 17 mm hexagonal bolt Remove hexagonal bolt and fixing washer Remove right-hand cleaning brush Repeat steps 4 - 7 for the left-hand cleaning brush NOTE! Always replace both cleaning brushes! The assembly of the cleaning brushes is carried out in reverse order.
Press and hold locking button Remove cleaning brush from above IMPORTANT! During installation, press and hold the locking button and insert the cleaning brush until it engages. Changing the Loosen knurled screws nozzle for the Remove cover high-pressure gas purging Pull out spring bolt Remove the nozzle from above...
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Fitting the nozzle: IMPORTANT! When fitting the nozzle, ensure that: The O-ring on the nozzle is present and OK The O-ring is greased CAUTION! Danger from nozzle being thrown out of the device. An incorrectly secured nozzle can be thrown out of the device when compressed air is supplied and cause a variety of injuries.
For detailed information on the optional equipment, consult the available installa- Optional Equip- ment tion instructions or Operating Instructions for the optional equipment. Robacta TSS /i Supply voltage 24 V DC Nominal output 24 W Compressed air supply 6 bar 86.99 psi...
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FRONIUS INTERNATIONAL GMBH Froniusstraße 1 A-4643 Pettenbach AUSTRIA contact@fronius.com www.fronius.com Under www.fronius.com/contact you will find the addresses of all Fronius Sales & Service Partners and locations...
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