FRONIUS Robacta TSS /i User manual

Fronius prints on elemental chlorine free paper (ECF) sourced from certified sustainable forests (FSC).

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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

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

Installing Optional Equipment 39

Optional Equipment on Delivery 39

EN-US

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

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

EN-US

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!

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.

EN-US

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.

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.

EN-US

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.

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.

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