FRO­NIUS Robacta TSS /i User manual

Fronius prints on elemental chlorine free paper (ECF) sourced from certified sustainable forests (FSC).
/ Perfect Charging / Perfect Welding / Solar Energy
Robacta TSS /i
EN-US
Operating instructions
Welding torch cleaning
42,0426,0000,EA 006-07062021

Table of contents
Safety Instructions 6
Explanation of Safety Instructions 6
General 6
Intended Use 7
Environmental Conditions 7
Obligations of the Operating Company 7
Obligations of Personnel 7
Particular hazard areas 7
Personal Protection and Protection of Others 8
EMC Device Classifications 8
Safety Measures at the Setup Location and During Transport 8
Safety Measures in Normal Operation 9
Maintenance and repair 9
Safety Inspection 9
Disposal 10
Safety Symbols 10
Data backup 10
Copyright 10
General 11
General 13
Device Concept 13
Applications 13
Warning Notices on the Device 14
Types of Parting Agent and Their Use 15
Options 15
Detailed Information on the Optional Equipment 16
Transport 17
Transport Instructions on the packaging 17
Transport 17
Operating controls, connections and mechanical components 19
Operating controls, connections and mechanical components 21
Detailed Information on the Optional Equipment 21
Safety 21
Connections and mechanical components 21
Connector pin assignments and signal descriptions 24
Safety 24
Assignment of standard I/O connection for robot control 24
Optional Connections Robot Control Unit (Fieldbus) 26
Assignment of external optional equipment connection 26
Input and Output Signals ProfiNet, DeviceNet, ProfiBus, EtherCAT, and EtherNet IP 29
Fieldbus Terminal Allocation 29
Input signals (from welding torch service station to robot) 29
Output signals (from robot to welding torch service station) 30
Installation and Startup 33
Safety 35
Detailed Information on the Optional Equipment 35
Safety 35
Before installation 37
Operating personnel, maintenance personnel 37
Setup Regulations 37
Specifications for the Compressed Air Supply 37
Bolting the Welding Torch Service Station to the Surface 38
Bolting the Welding Torch Service Station to the Surface 38
Installing Optional Equipment 39
Optional Equipment on Delivery 39
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Installing optional equipment - overview 39
1. Installing Touch Sense 40
Tools required 40
Installing Touch Sense 40
2. Installing the wire cutter 44
Tools Required 44
Additionally required 44
Installing the Wire Cutter 44
Operating Instructions 45
3. Installing the Robacta TC 2000 cleaning unit 46
General 46
Tools required 46
Additionally Required 46
Installing the Robacta TC 2000 Cleaning Unit 46
3. Installing the Robacta Reamer Twin cleaning unit 48
General 48
Tools Required 48
Additionally required 48
Removing the Injection Device and Existing Clamping System 48
Installing the Twin Clamping System 50
Installing the Robacta Reamer Twin cleaning unit 52
4. Installing the level sensor 54
Tools Required 54
Installing the Level Sensor 54
5. Inserting the parting agent container 56
Inserting the Parting Agent Container 56
6. Installing the TCP Tip 57
Tools Required 57
Installing the TCP Tip 57
7. Installing the Robacta Reamer V Easy / Robacta Reamer V 70 Han12P cleaning unit 58
General 58
Tools required 58
Additionally required 58
Installing the Reamer V Easy / Robacta Reamer V 70 Han12P cleaning unit 58
Starting Up the Welding Torch Service Station 62
General 62
Opening the Welding Torch Service Station 62
Requirements for Starting Up 62
Starting Up the Welding Torch Service Station 62
Cleaning Program Sequence 65
Program sequence—overview 67
Detailed Information on the Optional Equipment 67
Program Sequence—Overview 67
General information 69
Wire cutter 69
TC 2000 dipping bowl 69
Robacta TC 2000 69
Specification of the Parting Agent Volume 69
Cleaning End without Touch Sense Option 69
Program sequence 70
Wire cutter program sequence 70
Robacta TC 2000 dipping bowl program sequence 72
TC 2000 program sequence 73
High-pressure gas purging with parting agent program sequence (1st contact tip) 74
Outer gas nozzles cleaning brush program sequence 76
Inner gas nozzle cleaning brush program sequence 78
High-pressure gas purging with parting agent program sequence (2nd contact tip) 80
Touch Sense (option) program sequence 82
Wire cutter - cleaning end program sequence 83
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Troubleshooting, Maintenance, and Disposal 85
Safety 87
Detailed Information on the Optional Equipment 87
Safety 87
Troubleshooting 89
Detailed Information on the Optional Equipment 89
Troubleshooting 89
Service, maintenance and disposal 91
Detailed Information on the Optional Equipment 91
Releasing Pressure before Maintenance Work 91
Before Every Start-up 91
Daily 91
Weekly 92
Monthly 92
Every 6 Months 92
Every 12 Months 92
Disposal 92
Change cleaning brushes and nozzle for the high-pressure gas purging 93
Releasing Pressure before Maintenance Work 93
Replacing the Outer Gas Nozzle Cleaning Brushes 93
Replacing the inner gas nozzle cleaning brush 94
Changing the nozzle for the high-pressure gas purging 95
Appendix 97
Technical data 99
Detailed Information on the Optional Equipment 99
Robacta TSS /i 99
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Safety Instructions
Explanation of
Safety Instruc-
tions
DANGER!
Indicates an immediate danger.
▶Death or serious injury may result if appropriate precautions are not taken.
WARNING!
Indicates a possibly dangerous situation.
▶Death or serious injury may result if appropriate precautions are not taken.
CAUTION!
Indicates a situation where damage or injury could occur.
▶Minor injury or damage to property may result if appropriate precautions are not
taken.
NOTE!
Indicates the possibility of flawed results and damage to the equipment.
General The device has been manufactured using state-of-the-art technology and according to
recognized safety standards. If used incorrectly or misused, however, it can cause
- injury or death to the operator or a third party,
- damage to the device and other material assets belonging to the operating com-
pany,
- inefficient operation of the device.
All persons involved in the commissioning, operation, maintenance, and servicing of the
device must
- be suitably qualified,
- have knowledge of automated welding and
- have read these Operating Instructions and any system component operating
instructions in full and follow them carefully.
The Operating Instructions must always be at hand wherever the device is being used. In
addition to the Operating Instructions, all applicable local rules and regulations regarding
accident prevention and environmental protection must also be followed.
All safety and danger notices on the device must
- must be kept in a legible state
- not be damaged/marked
- not be removed
- not be covered, pasted, or painted over
For the location of the safety and danger notices on the device, refer to the section
headed "General" in the Operating Instructions for the device.
Before switching on the device, remove any faults that could compromise safety.
Your personal safety is at stake!
6

Intended Use 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.” The manufacturer accepts no liability for any
damage resulting from improper use.
Proper use also means
- Reading and adhering to all instructions in the Operating Instructions
- Reading and adhering to all safety instructions and danger notices
- Carrying out all the specified inspection and servicing work
The device is designed for operation in industry and business. The manufacturer shall
not be liable for any damage resulting from use in a living area.
The manufacturer shall also not be liable for faulty or incorrect work results.
Environmental
Conditions
Operation or storage of the device outside the stipulated area will be deemed as not in
accordance with the intended purpose. The manufacturer is not responsible for any dam-
age resulting from improper use.
Temperature range of the ambient air:
- During operation: 0°C to + 40°C (32°F to 104°F)
- During transport and storage: -25°C to +55°C (-13°F to 131°F)
Relative humidity:
- Up to 50% at 40°C (104°F)
- Up to 90% at 20°C (68°F)
Ambient air: free of dust, acids, corrosive gases or substances, etc.
Altitude above sea level: up to 2000 m (6500 ft.)
Obligations of the
Operating Com-
pany
The operating company must only allow persons to work with the device if they
- Are familiar with the basic occupational safety and accident prevention regulations
and are trained in handling the device
- Have read and understood these Operating Instructions, especially the section
"Safety Rules," and have confirmed this with their signature
- Are trained according to the requirements for the work results
The safety-conscious work of the personnel must be checked regularly.
Obligations of
Personnel
All persons who are assigned to work with the device must do the following before begin-
ning the work:
- Follow the basic regulations for occupational safety and accident prevention
- Read these Operating Instructions, especially the section "Safety Rules," and con-
firm that they have understood and will follow them by signing
Before leaving the workplace, ensure that no personal injury or property damage can
occur in one's absence.
Particular hazard
areas Do not linger in the operating area of the robot.
Always integrate the device into a higher-level safety system in a secured area.
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If this area has to be accessed for preparatory or maintenance work, ensure that
- the entire system is shut down for the duration of access to this area
- and remains shut down to prevent unintended operation, e.g., as a result of a control
error
In addition to these Operating Instructions, the safety rules of the robot manufacturer
must be followed.
Covers and side parts must only be opened/removed during maintenance and repair
work.
During operation:
- Ensure that all covers are closed and all side parts have been mounted properly.
- Keep all covers and side parts closed.
Personal Protec-
tion and Protec-
tion of Others
Magnetic fields generated by high amperage may eject ferromagnetic parts, such as
spatter accumulations, from the cleaning aperture. To prevent injury, always wear pro-
tective goggles with side protection and never look into the cleaning aperture when the
device is switched on.
Keep persons, especially children, away during the operation of the devices and during
the welding process. If persons are in the vicinity, however:
- Instruct them about all dangers (blinding hazard due to arcs, injury hazard due to fly-
ing sparks, welding fumes hazardous to health, noise exposure, possible hazard due
to grid current or welding current, possible hazard due to electromagnetic fields,
possible hazard due to the magnetic field of the cleaning aperture, moving mechan-
ical parts, compressed air/parting agent mixture discharged from the cleaning aper-
ture, flying chips or similar, etc.),
- Provide suitable protective equipment or
- Construct suitable protective walls and curtains.
EMC Device Clas-
sifications
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 grid.
EMC device classification as per the rating plate or technical data.
Safety Measures
at the Setup Loc-
ation and During
Transport
A toppling device can be deadly! Set up the device securely on an even, solid surface
- A tilt angle of no more than 10° is permitted.
Special regulations apply in areas at risk of fire or explosion
- Follow the appropriate national and international regulations.
Use instructions and checks within the company to ensure that the vicinity of the work-
place is always clean and organized.
Only set up and operate the device in accordance with the degree of protection shown
on the rating plate.
Install the device with an all-round clearance of at least 0.5 m (19.69 in.) to walls, neigh-
boring devices, or other objects.
8

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.
Take care to ensure that the applicable national and regional guidelines and accident
prevention regulations are observed when transporting the device, especially guidelines
concerning hazards during transport and shipment.
It is essential to conduct a visual inspection of the device to check for damage after it has
been transported but before it is commissioned. Have any damage repaired by trained
service technicians before commissioning the device.
Safety Measures
in Normal Opera-
tion
Only operate the device when all safety devices are fully functional. If the safety devices
are not fully functional, there is a danger of:
- Injury or death to the operator or a third party
- Damage to the device and other material assets belonging to the operating company
- Inefficient operation of the device
Safety devices that are not fully functional must be repaired before the device is started
up.
Never bypass or disable safety devices.
Before starting up the device, ensure that no one can be put in danger.
The device must be examined at least once a week for externally detectable damage
and functionality of the safety devices.
- Only use appropriate original parting agents from the manufacturer.
- When handling parting agents, observe the information on the parting agent safety
data sheets. The parting agent safety data sheets can be obtained from your service
center or via the manufacturer’s website.
- Do not mix parting agents from the manufacturer with other parting agents.
- If damage occurs due to the use of other parting agents, the manufacture is not
liable for this and all warranty claims are forfeited.
- Properly dispose of used parting agents according to national and international regu-
lations.
Maintenance and
repair
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 manu-
facturer'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 The manufacturer recommends that a safety inspection of the device be performed at
least every 12 months.
9
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A safety inspection by a certified electrician is recommended:
- after changes
- after alterations
- after repair, care, and maintenance
- at least every 12 months.
For the safety inspection, follow the appropriate national and international standards and
guidelines.
You can obtain more information about the safety inspection and calibration from your
service center. The service center will provide the necessary documents upon request.
Disposal Do not dispose of this device with normal domestic waste! To comply with the European
Directive on Waste Electrical and Electronic Equipment and its implementation as
national law, electrical equipment that has reached the end of its life must be collected
separately and returned to an approved recycling facility. Any device that you no longer
require must be returned to your dealer, or you must locate the approved collection and
recycling facilities in your area. Ignoring this European Directive may have potentially
adverse affects on the environment and your health!
Safety Symbols Devices with the CE label satisfy the essential requirements of the low-voltage and elec-
tromagnetic compatibility directive (e.g. relevant product standards of the EN 60974
series).
Fronius International GmbH declares that the device complies with Directive
2014/53/EU. The full text of the EU Declaration of Conformity is available on the follow-
ing website: http://www.fronius.com
Devices marked with the CSA test mark satisfy the requirements of the relevant stand-
ards for Canada and the USA.
Data backup The user is responsible for backing up any changes made to the factory settings. The
manufacturer accepts no liability for any deleted personal settings.
Copyright Copyright of these Operating Instructions remains with the manufacturer.
Text and illustrations were accurate at the time of printing. Fronius reserves the right to
make changes. The contents of the Operating Instructions shall not provide the basis for
any claims whatsoever on the part of the purchaser. If you have any suggestions for
improvement, or can point out any mistakes that you have found in the Operating
Instructions, we will be most grateful for your comments.
10

General
11

12

General
Device Concept
Robacta TSS /i with the options wire cutter and
Robacta TC 2000
The Robacta TSS /i welding torch service
station is a complete system for the clean-
ing of a wide range of MIG/MAG robot
welding torches.
All optional equipment required for effect-
ive welding torch cleaning can be installed
directly on the welding torch service sta-
tion.
Applications The welding torch service station is used in automated MIG/MAG applications in a robot
cell:
- In the automotive and supply industry
- In equipment engineering
- In chemical plant construction
- In mechanical engineering
- In rail vehicle construction
- In shipyards
13
EN-US

Warning Notices
on the Device
NOTE!
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.
U1
I 1
Wels - Austria
p
max
24 V 0.25 A
6 bar (87PSI)
Warning Notices on the Device
WARNING! Risk of serious injuries due to:
- moving mechanical parts
- compressed air/parting agent mixture discharged from the parting-agent injection
nozzles
- flying debris (chips, etc.)
- compressed air stored at 16 bar in the pressure booster
Release stored compressed air before maintenance and servicing!
During maintenance and servicing, keep the device de-energized and de-pressurized.
14

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
Agent and Their
Use
NOTE!
The parting agents are not included in the scope of supply.
Types of parting agent and their use:
- “Robacta Reamer” parting agent for spraying the welding torch after the cleaning
process
It is recommended that the welding torch be sprayed with the “Robacta Reamer” parting
agent for all applications.
Options OPT/i Robacta TSS BK Profinet 4,101,127,CK
OPT/i Robacta TSS BK Profibus 4,101,179,CK
OPT/i Robacta TSS BK DeviceNet 4,101,180,CK
OPT/i Robacta TSS BK EtherCAT 4,101,181,CK
OPT/i Robacta TSS BK Ethernet IP 4,101,236,CK
OPT/i TSS TCP Touch Sense 4,001,003,CK
OPT/i TSS/i TCP tip 4,001,072,CK
OPT/i TSS level sensor 4,001,014,CK
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Parting agent canister 10 l 42,0411,8042
Robacta TC 2000 cleaning unit *
TC 1000/2000 0.85 m connection cable 43,0004,5929
OPT/i TSS TC2000 ** 4,001,012,CK
Twin wire cutter 44,0450,1027
OPT/i TSS Wire Cutter ** 4,001,098,CK
OPT/i TSS /i parting agent screen 4,001,106,CK
Robacta Reamer cleaning unit *
OPT/i TSS Reamer Twin ** 43,0004,5928
Reamer Twin 600 mm connection cable 4,001,109
Robacta Reamer Twin cleaning unit 44,0450,1282
Robacta Reamer V Easy (Single) clean-
ing unit
44,0450,1444
Robacta Reamer V 70 Han12P cleaning
unit
44,0450,1961
OPT/i TSS Reamer Single ** 4,001,123
OPT/i TSS Reamer V70 ** 4,001,133
Reamer Single 600 mm connection cable 43,0009,6290
* depending on the system configuration
** installation set; required for the installation of the respective device
Detailed Informa-
tion on the
Optional Equip-
ment
NOTE!
For detailed information on the optional equipment, consult the available installa-
tion instructions or Operating Instructions for the optional equipment.
16

Transport
Transport
Instructions on
the packaging
CAUTION!
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.
▶When transporting the device by counterbalanced lift truck or lift truck, secure the
device to prevent it from falling
▶Do not turn, brake, or accelerate in a sudden, jerking manner
The welding torch service station can be transported as follows:
- manually, by at least two people
- on a pallet using a low lift truck
- on a pallet using a counterbalanced lift truck
The welding torch service station can be lifted from the pallet and positioned at the
installation site using a crane and two belts.
When selecting the belt length for this, ensure that the welding torch service station will
not be damaged when lifting down from the pallet.
WARNING!
Danger from falling objects.
May result in serious injuries or death.
▶The only form of crane transport permitted is lifting the device down from the pallet
using a crane and belts.
Lifting Welding Torch Service Station from the Pallet using Crane and Belts
1
1
1 2
17
EN-US

18

Operating controls, connections and
mechanical components
19

20