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TƝƠƑƖƇƓƠƤƗƑƓŷƓƜƢƓƠƈSC 2013
 Document name Document number Language
Assembly instructions Torch Service Center TSC2013 3HDA000057A8519-003 001 (EN)

Revision Date Description

00 04-04-2014 1. Edition
01 20-01-2017 - New cover
- Colour in the representations changed from RAL2010 to RAL7012
- Changes made in chapter:
1.6 Technical data (current, weight)
2.2 Technical data (current, weight, colour)
2.7 Maintenance (spray nozzle, milling unit, release agent tank)
5 Safety Data Sheet (Release Agent)
02 12-06-2017 Changes made in chapter:
2.2.1 TSC 2013 (new)
2.2.2 Milling cutter (new)
2.2.3 Spacer plates (new)
5.1 Dimension sheet gas nozzle (new)
03 14-06-2018 - New cover sheet and backside
- Changes made in chapter:
4.8.3 EIO Configuration (new)
04 26-03-2019 - Cover page 2: Table with revision descriptions added
- Font changed to ABB voice
- Change in chapter 2.6: Software option changed from "653-1 ABB
TC96" to "653-3 ABB TSC2013".
- Supplement in chapter 3.6.3 Mounting the wire cutter: Thread locker
for thread pieces added
05 24-09-2021 - Change of name to ABB AG (from 09/2021)
- Declaration of incorporation new (ABB AG)
- Safety data sheet AS 72-K updated

The information in this manual is subject to change without notice and should not be constructed as a
commitment by ABB. ABB assumes no responsibility for any errors that may appear in this manual.
Except as may be expressly stated anywhere in this manual, nothing herein shall be construed as any kind
of guarantee or warranty by ABB for losses, damages to persons or property, fitness for a specific purpose
or the like.
In no event shall ABB be liable for incidental or consequential damages arising from use of this manual and
products described herein.
This manual and parts thereof must not be reproduced or copied without ABB´s written permission.
Keep for future reference.
Additional copies of this manual may be obtained from ABB.
This document is the English translation of the German Original Assembly instructions.

®Copyright 2014-2021 ABB. All rights reserved.

ABB AG
Grüner Weg 6
D-61169 Friedberg
Germany

Fon: +49 6031 85-0

Fax: +49 6031 85-297
Assembly Instructions
Inhalt

Torch Service Center TSC 2013

TC 2013 / TSC 2013
Document: 3HDA000057A8519-001

Contents
1 Torch Service Center - TSC 2013 . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
1.1 Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
1.1.1 Designated use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
1.1.2 Non-designated use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

1.2 Installation declaration for TC/TSC 2013. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

1.3 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

1.3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
1.3.2 Sources of danger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
1.3.3 Safety measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
1.3.4 Possible dangers due to fire. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
1.3.5 Possible dangers due to release agent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

1.4 Transport and storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

1.4.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
1.4.2 Transport and packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
1.4.3 Damage in transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
1.4.4 Storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
1.4.5 Packaging/disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

1.5 Structure and function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

1.5.1 Torch cleaner TC 2013. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
1.5.2 Wire cutter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
1.5.3 TCP gauging (BullsEye®) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

1.6 Technical data of TSC 2013 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14

2 Torch cleaner TC 2013 .................................. 2-1

2.1 Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.1.1 Designated use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.1.2 Non-designated use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

2.2 Technical data of TC 2013 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

2.2.1 Torch cleaning device TC 2013 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.2.2 Milling cutter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.2.3 Spacer plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

2.3 Structure and function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

2.3.1 Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
2.3.2 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
2.3.3 Replacement parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

2.4 Assembly and disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

2.4.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
2.4.2 Setting up and securing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

Contents 3HDA000057A8519-001 I-3

2.4.3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
2.4.4 Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
2.4.5 Setting of spray mechanism. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
2.4.6 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
2.4.7 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

2.5 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

2.5.1 Instructions for commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
2.5.2 Function test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
2.5.3 Switching on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
2.5.4 Modes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
2.5.5 Sequence of operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17

2.6 Program sequence for torch cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19

2.6.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
2.6.2 Program examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
2.6.3 Configuration for TC 2013 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
2.6.4 Sequence of torch cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24

2.7 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27

2.8 Spare and wearing parts for TC 2013 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29

2.8.1 TC 2013 without wire cutter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29
2.8.2 TC 2013 with wire cutter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32

2.9 Pneumatic plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35

2.10 Electrical circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36

3 Wire cutter ............................................ 3-1

3.1 Designated use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3.2 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3.3 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

3.4 Ignition behaviour / availability of the system . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

3.5 Function and structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

3.6 Assembly of the wire cutter on the TC 2013 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

3.6.1 Preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.6.2 Disassembly of clamping cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.6.3 Assembly of wire cutter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

3.7 Corrective and preventive maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

4 TCP gauging (BullsEye®) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.1.1 Designated use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.1.2 TCP (tool center point). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4.2 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

4.2.1 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.2.2 Connection data electrics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.2.3 System requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Contents 3HDA000057A8519-001 I-4

4.3 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

4.4 Features of TCP gauging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

4.5 Structure and function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

4.5.1 TCP gauging as standalone device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
4.5.2 TCP gauging with stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

4.6 Functional description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

4.6.1 Examples of operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4.6.2 TCP deviation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

4.7 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

4.7.1 Subsequent assembly on the TC 2013 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
4.7.2 Assembly of TCP gauging with stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
4.7.3 Assembly site and alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

4.8 Using for the first time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

4.8.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
4.8.2 Installation of Software BullsEye®10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
4.8.3 EIO Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

4.9 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

4.9.1 Switching on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
4.9.2 Function test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

4.10 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

4.11 Spare parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14

5 Appendix. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.1 Dimension sheet Gas nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

5.2 Safety Data Sheet Release Agent AS 72-K .............................. 5-3

Contents 3HDA000057A8519-001 I-5

Contents 3HDA000057A8519-001 I-6
 Overview
These assembly instructions describe the Torch Service Center TSC 2013, the torch cleaning
station TC 2013 and the add-on modules wire cutter and TCP measurement.
Please take information on each assembly from the corresponding chapter of the assembly
instructions.

Chapter 1 Torch Service Center - TSC 2013

Chapter 2 Torch cleaner TC 2013
Chapter 3 Wire cutter
Chapter 4 TCP gauging (BullsEye®)

NOTICE
It is essential to read these assembly instructions
before using the TC/TSC 2013 for the first time, to
ensure safe handling of the product.

They should be read by all personnel who work with

this component or with systems this component is
Assembly instructions

built into.

The owner must make the assembly instructions avail-

able to the operator and make sure that the operator
has read and understood them.

Safety instructions must be followed!

These assembly instructions contain information on

• the mechanical structure of the TC/TSC 2013,
• assembly,
• electrical installation,
• operation, maintenance and repair.
Use these operating instructions
• in assembly of the TC/TSC 2013 (this also includes transport),
• in setting up and connecting,
• in using for the first time.
The documents on handover correspond to the latest position at the time of first use.
Only these operating instructions are relevant for the clarification of technical issues and
ordering of spare parts.
ABB does not accept liability if faults, damage, operating breakdowns and resultant pro-
duction failures occur through non-compliance with these assembly instructions.

Torch Service Center - TSC 2013 3HDA000057A8519-001 1-1

 Area of use
The TC/TSC 2013 is a tool of the robot and is controlled by the robot. It is used in robotic
MIG/MAG welding units
The quality, performance and functionality of the TSC 2013 are only attained if it is used in
welding units designed by ABB. The TC/TSC 2013 may only be used in the intended area of
use (warranty!).
ABB reserves the right to make technical modifications necessary to improve the TC/TSC
2013. Deviations from the contents or from the illustrations in these operating instructions
are therefore possible.

Warranty
Warranty claims can be made in the case of
• designated use
• proper operation
• compliance with maintenance instructions
• use of genuine spare parts
• compliance with safety instructions.

NOTICE

Assembly instructions
Product liability and warranty are invalidated by unau-
thorised interventions and non-designated use!

The warranty covers elimination of faults and the use of parts which are shown to have
become faulty or unusable due to material, design or production faults. Replaced parts
become the property of the supplier.
Excluded from the warranty are
– wearing parts,
– lubricants,
– external cable connections,
– cables subjected to torsion and bending etc.
Also excluded is damage due to causes for which the manufacturer is not responsible such
as
– force majeure,
– natural wear and tear,
– improper handing,
– interventions by third parties,
– excessive loading,
– unsuitable equipment and ambient conditions which do not meet ABB guide values.
In the event of malfunctions within the warranty periods the faulty item is to be sent to ABB.
Notes attached by you on the fault that has occurred make it easier for our servicing depart-
ment to eliminate the damage.

1-2 3HDA000057A8519-001 Torch Service Center - TSC 2013

 Target group
These assembly instructions are aimed at all persons who work on the system/machine or
its components. Specialist knowledge on the operation of the system/machine is assumed
for an understanding of the assembly instructions.
Establishment of areas of activity, duties and skills is the responsibility of the operator of
the system/machine. It should be ensured that only qualified personnel instructed by him
work on the system and its components.

Requirements
Each person working on an ABB industrial robot must be trained by ABB and have the nec-
essary knowledge on mechanical, pneumatic and electrical work,
The robot manuals must therefore also be made available to the reader of these instruc-
tions.

Reference manuals Document number

General safety information - IRC5 3HAC 031045-003
Safety information for emergencies - IRC5 3HAC 027098-003
Operating instructions - First steps, IRC5 and RobotStudio 3HAC 027097-003
Operating Instructions - Control IRC5 with FlexPendant 3HAC 16590-003

Copyright
For copyright reasons we must point out that these assembly instructions may only be
Assembly instructions

used for internal company purposes.

The document, or parts thereof, may not be reproduced or copied without prior permission
from ABB. For competition reasons the documents or parts thereof must not be divulged
to third parties.

ABB AG
Grüner Weg 6 Postfach 100 152
61169 Friedberg 61141 Friedberg
Telephone: +49 (0) 6031 85-0
Fax: +49 (0) 6031 85-297

Torch Service Center - TSC 2013 3HDA000057A8519-001 1-3

 Assembly instructions

1-4 3HDA000057A8519-001 Torch Service Center - TSC 2013

 Use

1 Torch Service Center - TSC 2013

TSC means: T= Torch, S= Service, C= Center

1.1 Use

1.1.1 Designated use

The TSC 2013 is a compact, multi-functional torch service station and is used exclusively in
automatic robot gas-shielded arc welding for torch cleaning, wire cutting and TCP gauging.

Intended place of installation:

In the working range of an industrial robot.

Service life:
20 years

NOTICE
Designated use also includes following all advice in
Assembly instructions

the installation instructions and complying with the

maintenance specifications.

1.1.2 Non-designated use

Any usage of the TC 2013 deviating from designated use is regarded as non-designated use.
The TSC 2013 must only be used in accordance with the operating conditions and perfor-
mance data stipulated in the installation instructions.
Other or more extensive use or unauthorised reconstruction or modification of the TSC
2013 is deemed as not being in accordance with designated use.

NOTICE
Product liability and warranty are invalidated by unau-
thorised interventions and non-designated use!

Torch Service Center - TSC 2013 3HDA000057A8519-001 1-5

Installation declaration for TC/TSC 2013

1.2 Installation declaration for TC/TSC 2013

Declaration of incorporation
according to the EU Machinery Directive 2006/42/EC, Annex II 1. B
for partly completed machinery
Translation

Manufacturer
ABB AG

Grüner Weg 6

DE - 61169 Friedberg

Person established in the Community authorised to compile the relevant technical documentation
Andreas Stark

ABB AG

Grüner Weg 6

DE - 61169 Friedberg

Assembly instructions
Description and identification of the partly completed machinery
Product / Article Torch Service Center

Type TC/TSC 2013

Project number 2205900025_2

Order 2205900025

Model 2013

Function Cleaning and measuring of shielding gas welding torches

It is declared that the following essential requirements of the Machinery Directive 2006/42/EC have been
fulfilled:
1.1.3, 1.1.5, 1.1.7, 1.1.8, 1.3., 1.3.1, 1.3.2, 1.3.4, 1.3.7, 1.3.8, 1.3.9, 1.5.1, 1.5.3, 1.5.6, 1.5.7, 1.5.8, 1.6.1, 1.6.3, 1.6.5, 3.4, 3.4.2, 3.5.2,
3.5.3, 4.1.2.1, 4.1.2.3

It is also declared that the relevant technical documentation has been compiled in accordance with part B
of Annex VII.

It is expressly declared that the partly completed machinery fulfils all relevant provisions of the following
EU Directives or Regulations:
2006/42/EC Directive 2006/42/EC of the European Parliament and of the Council of 17 May 2006 on machinery, and
amending Directive 95/16/EC (recast) (1)
Published in L 157/24 of 09.06.2006
2014/30/EU Directive 2014/30/EU of the European Parliament and of the Council of 26 February 2014 on the
harmonisation of the laws of the Member States relating to electromagnetic compatibility (recast)
Published in 2014/L 96/79 of 29.03.2014

Reference to the harmonised standards used, as referred to in Article 7 (2):

EN ISO 10218-2:2011 Robots and robotic devices - Safety requirements for industrial robots - Part 2: Robot systems and
integration (ISO 10218-2:2011)
EN ISO 10218-1:2011 Robots and robotic devices - Safety requirements for industrial robots - Part 1: Robots (ISO 10218-1:2011)

EN ISO 12100:2010-11 Safety of machinery - General principles for design - Risk assessment and risk reduction (ISO 12100:2010)

EN 60204-1:2018 Safety of machinery - Electrical equipment of machines - Part 1: General requirements (IEC 60204-1:2016,
modified)
EN ISO 13857:2019 Safety of machinery — Safety distances to prevent hazard zones being reached by upper and lower limbs
(ISO 13857:2019)

Page 1/2

1-6 3HDA000057A8519-001 Torch Service Center - TSC 2013

 Installation declaration for TC/TSC 2013

Declaration of incorporation
according to the EU Machinery Directive 2006/42/EC, Annex II 1. B
for partly completed machinery
Translation

The manufacturer or his authorised representative undertake to transmit, in response to a reasoned request by the national authorities,
relevant information on the partly completed machinery. This transmission takes place
electronic transfer

This does not affect the intellectual property rights!

Important note! The partly completed machinery must not be put into service until the final machinery into
which it is to be incorporated has been declared in conformity with the provisions of this Directive, where
appropriate.
Assembly instructions

Friedberg, 2021-09-15

Place, Date Signature Signature

Bernd Körber Thomas Dedecke
Commercial Manager Robotics Division Product Manager

Page 2/2

Torch Service Center - TSC 2013 3HDA000057A8519-001 1-7

Safety

1.3 Safety

1.3.1 General

WARNING
In all work on the TSC 2013 the system must be
switched off and protected against being switched
back on.

Higher-level instructions and directions on safety

contained in the operating instructions
for the welding system must be observed.

The operator of the TSC 2013 torch cleaner is responsible for the proper setting-up, instal-
lation and use of the unit, as specified by the manufacturer. The standards and safety reg-
ulations of the country concerned must be complied with.
The operator of the TSC 2013 bears responsibility for the safety precautions for personnel
who work with the system or are in its vicinity.
The TSC 2013 is generally integrated into a welding robot system and connected to this by
electric wiring.

Assembly instructions
Safety instructions for standing in the working range of an industrial robot must be strictly
complied with.
The system must only be put to use for the first time by appropriately trained personnel.
The system must not put to use until it has been established that it is ready for use and
meets the requirements of the European Community's Machinery Directive.
Persons must only remain in the working range of the robot for as long as is necessary.

1.3.2 Sources of danger

The TSC 2013 is installed in the working range of the industrial robot. Robots have a very
high diversity of movement and operate with high accelerations. In automatic operation
the robot is program-controlled and may also start up unexpectedly after being at rest for
a prolonged period. Persons struck by the motion of a robot may suffer severe and fatal
injuries.

WARNING
Warning - the machine may start up unexpectedly!

1.3.3 Safety measures

The operator has to identify the dangers that may occur in connection with the welding sys-
tem and estimate and minimise the associated risks.
Technical protective measures are to be selected and designed for the work to be per-
formed which enable programming, setting up, maintenance, testing, fault-tracing and
elimination of faults in safe conditions.

1-8 3HDA000057A8519-001 Torch Service Center - TSC 2013

 Safety

Personal protective equipment, e.g. safety shoes, protective clothing, protective goggles
and gloves are to be worn.

1.3.4 Possible dangers due to fire

WARNING
There is a danger of fire in welding due to flying
sparks!

Do no use any release agent for the spraying device other than that specified by the manu-
facturer!
Remove combustible material/packaging material from the system!

1.3.5 Possible dangers due to release agent

There is a safety data sheet for the release agent for spraying the gas nozzle in accordance
with Regulation (EC) No 1907/2006 (REACH) (Section 5 Appendix).

NOTICE
Assembly instructions

The release agent AS 72-K does not contain any chem-

ical substances subject to the duty of notification
under Regulation No 1907/2006 (REACH).

Torch Service Center - TSC 2013 3HDA000057A8519-001 1-9

Transport and storage

1.4 Transport and storage

1.4.1 General

CAUTION
Danger of injury due to unsuitable means of transport
and lifting implements.

The load must be adequately secured in transport!

NOTICE
Exercise great caution with the TC/TSC2013. Even
minor damage can have a substantial adverse impact
on function.

Do not throw, do not drop!

Assembly instructions
1.4.2 Transport and packaging
Before dispatch by ABB, each TSC 2013 or separately ordered assembly is checked for dam-
age and completeness.
Protective packaging made of re-usable material is intended for transport.
The transport packaging is selected depending on the assembly to be supplied and number
of units (Table 1-1).
The TSC 2013 is packed singly lying in a carton.
Several units are screwed standing on a wooden pallet and protected by a wooden crate
against damage in transport.

The transport pallets are suitable for transporting with fork-lift truck.

1-10 3HDA000057A8519-001 Torch Service Center - TSC 2013

 Transport and storage

Table 1-1 Transport weight and packaging

Pos. Qty Components Transport Packaging

[units] weight
[kg]

1 1 TSC 2013 - complete 35 Carton

8 TSC 2013 - complete approx. Pallet with wooden crate

350

2 1 TC 2013 27 Carton

10 TC 2013 approx. Pallet with wooden crate

365

3 1 Wire cutter 1.5 Carton

10 Wire cutter approx. 17 Carton

4 1 TCP gauging (Bulls Eye) 1.5 Carton

10 TCP gauging (Bulls Eye) approx. 17 Carton

5 1 TCP gauging with stand 10 Carton

10 TCP gauging with stand approx. Pallet with wooden crate

180
Assembly instructions

1.4.3 Damage in transport

If the TSC 2013 or separately ordered assemblies have been damaged in transport, the
transport company must be informed immediately for an expert assessment and a con-
cealed damage claim must be made.

1.4.4 Storage
The following should be observed in prolonged storage of the TSC 2013:
• storage as far as possible in the original packaging (carton or wooden pallet).
• Lubricate all bare steel parts lightly with commercial, silicone-free corrosion protection
oil.
• Seal compressed air connections/plug connectors with protective caps.
• Protect stored parts against moisture.

1.4.5 Packaging/disposal
The transport packaging made available by ABB is used as packaging for the storage of sys-
tem components. Disposal takes place only in accordance with contractual agreements
entered into.

Torch Service Center - TSC 2013 3HDA000057A8519-001 1-11

Structure and function

1.5 Structure and function

The TSC 2013 consists of three assemblies, which are also available separately.

Assembly instructions
1. Torch cleaner TC 2013
2. Wire cutter
3. TCP gauging

The TSC 2013 fulfils the following functions:

• cleaning the torch gas nozzle of weld spatter and spraying with release agent,
• shortening of the welding wire using a wire cutter,
• automatic measurement and adjustment of the robot tool center point - TCP.

Functional description
Torch cleaning is performed fully automatically by a rotating tool (milling cutter) in the TC
2013 torch cleaner (1). The welding torch is clamped in a holding mechanism (V-block) for
this purpose. The external surface of the contact tip nozzle and the internal surface of the
gas nozzle are then cleared of weld spatter in one operation. The cleaned gas nozzle is then
wetted with silicone-free liquid weld spatter release agent to prevent early deposition of
new weld spatter.
The torch then automatically runs back to the wire cutter (2). There the protruding welding
wire end is introduced between fixed and mobile blades and then automatically cut.
Finally the tool center point is automatically measured in TCP measurement (3) and re-
adjusted if necessary.

1-12 3HDA000057A8519-001 Torch Service Center - TSC 2013

 Structure and function

1.5.1 Torch cleaner TC 2013

The TC 2013 torch cleaner is used to clean the gas nozzle which is contaminated with weld
spatter during the welding process. Subsequent spraying of the gas nozzle with a release
agent prevents early contamination of the gas nozzle.

NOTICE
A detailed description can be found in Chapter 2
Torch cleaner TC 2013.

1.5.2 Wire cutter

The write cutter can be used to shorten the welding wire to a particular wire length. It is an
add-on module for the TC 2013 torch cleaner and is also actuated from the latter.

NOTICE
A detailed description can be found in Chapter 3 Wire
cutter.
Assembly instructions

1.5.3 TCP gauging (BullsEye®)

TCP measurement is used to measure and adjust the robot tool center point (TCP) It is
available as an add-on module for the TC 2013 or a standalone version (with stand).

NOTICE
A detailed description can be found in Chapter 4 TCP
gauging (BullsEye®).

Torch Service Center - TSC 2013 3HDA000057A8519-001 1-13

Technical data of TSC 2013

1.6 Technical data of TSC 2013

Control voltage 24VDC

Max. current consumption 0,4 A
Air connection G 1/8" at 6-10 bar
Clamping cylinder Ø 65 x 34 mm stroke F = 1227N at 5 bar
Gas nozzle external diameter min. Ø 20 mm adjustable using different
max. Ø 34 mm spacer plate thicknesses

Milling cutter, V-block and spacer plate for standard torches PKH and PKI 500 (404.15.70) with torch
external diameter Ø 28 mm.

(Please enquire about milling cutter, V-block and spacer plate for special torches).

Air motor n = 950 / min

Md = 3 Nm
Stroke = 45 mm
Shaft end Ø 9x16 length
Air consumption 25 litres/cycle
Max. welding wire diameter for cutting d= 1.00 mm, steel at min. air pressure 5 bar
d= 1.2 mm, aluminium at min. air pressure 5 bar
d= 1.2 mm, steel at min. 6 bar air pressure

Dimensions approx. 430 mm x 300 mm

Assembly instructions
approx. 100 mm height
Weight 34 kg

Rating plate
There is a rating plate on the TC 2013 with the following particulars:

*
* Note: This number of sequential and is issued individually for each delivered TC 2013.

1-14 3HDA000057A8519-001 Torch Service Center - TSC 2013

 Technical data of TSC 2013

Dimensions of TSC 2013

Protective sleeve 3
Adjusting tip

11
Assembly instructions

A A

A-A ( 1 : 5 )

Spacer plate

Wire cutter Spray head Clambing cylinder Milling cutter

Pos. Assembly Article No

1 Torch cleaner TC 2013 3HDA000057A5527
2 Wire cutter 3HDA000000A9289
3 TCP measurement 3HDA000000A9324

Weight: 32 kg without release agent

Torch Service Center - TSC 2013 3HDA000057A8519-001 1-15

Technical data of TSC 2013

Assembly instructions

1-16 3HDA000057A8519-001 Torch Service Center - TSC 2013

 Use

2 Torch cleaner TC 2013

TC 2013 means T = Torch; C = Cleaner; 2013 = Generation 2013

The TC 2013 torch cleaner is an assembly which, unlike the TSC 2013, is supplied without a
wire cutter and TCP gauging.

2.1 Use

2.1.1 Designated use

The TC 2013 torch cleaner is intended only for automatic cleaning of the contact tip and gas
nozzle on the torch of a MIG/MAG robotic torch cleaning unit and for automatic spraying of
a liquid weld spatter release agent.

Intended place of installation:

In the working area of an industrial robot.

Service life:
20 years
Assembly instructions

NOTICE
Designated use also includes observance of all notes
in the installation instructions and compliance with the
maintenance specifications.

2.1.2 Non-designated use

Any usage of the TV 3013 deviating from designated use is regarded as non-designated use.
The TC 2013 must only be used in accordance with the operating conditions and perfor-
mance data stipulated in the installation instructions.
Other or more extensive use or unauthorised conversions or modification of the TC 2013 are
deemed not to be in accordance with designated use.
Non-designated use invalidates the ABB warranty.

NOTICE
Product liability and and warranty are invalidated by
unauthorised interventions and non-designated use.

The warranty covers elimination of faults and the use of parts which are shown to have
become faulty or unusable due to material, design or production faults. Replaced parts
become the property of the supplier.

Torch cleaner TC 2013 3HDA000057A8519-001 2-1

Technical data of TC 2013

2.2 Technical data of TC 2013

Control voltage 24VDC

Max. current consumption 0,4 A
Air connection G 1/8" at 5-10 bar
Clamping cylinder Ø 65 x 34 mm stroke F = 1227N at 5 bar
Gas nozzle external diameter min. Ø 20 mm adjustable using different
max. Ø 34 mm spacer plate thicknesses

Milling cutters, V-blocks and spacer plates for standard torches PKH and PKI 500 (404.15.70) with
torch external diameter Ø 28 mm.

(Please enquire about milling cutters, V-plates and and spacer plates for special torches).

Air motor n = 950 / min

Md = 3 Nm
Stroke = 45 mm
Shaft end Ø 9x16 length
Air consumption 25 litres/cycle
Max. welding wire diameter for cutting d= 1.0 mm, steel at min. air pressure 5 bar
d= 1.2 mm, aluminium at min. air pressure 5 bar
d= 1.2 mm, steel at min. 6 bar air pressure

Dimensions approx. 430 mm x 300 mm

Assembly instructions
approx. 100 mm height
Colour RAL 7012 / Basalt grey surfaces made of aluminium
and high-grade steel are
excepted
Weight 32 kg

Rating plate
There is a rating plate on the TC 2013 with the following particulars:

* Note This number is sequential and is issued individually for each delivered TC 2013.

2-2 3HDA000057A8519-001 Torch cleaner TC 2013

 Technical data of TC 2013

2.2.1 Torch cleaning device TC 2013

Figure 2-1 Dimensions TC 2013

Protective sleeve
Adjusting tip
Assembly instructions

Spacer plate

Clambing Milling
Spray head
cylinder cutter

Torch cleaner TC 2013 3HDA000057A8519-001 2-3

Technical data of TC 2013

2.2.2 Milling cutter

The milling cutter represented in Figure 2-1 for removing welding spatters is selected into
dependence of the type of the gas nozzle.

NOTICE
In principle, the TSC 2013 is delivered without milling
cutter. This must separately be ordered from ABB as a
spare part.

NOTICE
For the choice of a suitable milling cutter the mea-
sures as well as the construction of the gas nozzle are
needed (see Figure 2-2).

Figure 2-2 Dimensions of the gas nozzle

Contact tube Contact tube Contact tube

Assembly instructions
prodruding flush inwards

Outside diameter gas nozzle Ø X [mm]

Outside diameter contact tube Ø Y [mm]
Inside diameter gas nozzle Ø Z [mm]
Distance of leading edge to nozzle stick A [mm]
Contact tube prodruding
Contact tube flush
Contact tube inwards
Distance of leading edge to contact tube B [mm]

NOTICE
The available values are to write down on the Dimen-
sion sheet Gas nozzle (see Chapter 5 Appendix) and
have to be transmitted to ABB AG.

2-4 3HDA000057A8519-001 Torch cleaner TC 2013

 Technical data of TC 2013

2.2.3 Spacer plates

The spacer plate represented in Figure 2-1 is selected into dependence of the used gas noz-
zle diameter.

NOTICE
The gas nozzle diameter has to be transmitted to ABB
AG as in Section 2.2.2 "Milling cutter" described.

Spacer plates are available in the following strengths:

Table 2-1 Replacement spacer plates

Gas nozzle Strength
external diameter
[mm] [mm]
Ø 16 12.50
Ø 17 11.85
Ø 18 11.20
Ø 19 10.55
Ø 20 9.90
Ø 21 9.25
Assembly instructions

Ø 22 8.60
Ø 23 7.95
Ø 24 7.30
Ø 25 6.65
Ø 26 6.00
Ø 27 5.35
Ø 28 4.70
Ø 29 4.05
Ø 30 3.40
Ø 31 2.75
Ø 32 2.10
Ø 33 1.45
Ø 34 0.80

NOTICE
Instructions for changing spacer plate and milling cut-
ter you find in Section 2.3.3 "Replacement parts".

Torch cleaner TC 2013 3HDA000057A8519-001 2-5

Structure and function

2.3 Structure and function

The function of the TC 2013, unlike the complete TSC 2013, contains only the cleaning/mill-
ing of the torch and subsequent spraying of liquid weld spatter release agent.
The wire-cutting and TCP gauging functions are included in the basic unit.
The wire-cutting add-on module and TCP gauging are available as optional extras and can
be retrofitted at any time.

2.3.1 Structure

8*

7*

2a

Assembly instructions
5
6

2b
4

2c

3
1

Pos. Name
1 Stand
2a Pneumatic clamping cylinder with
2b V-block and
2c spacer plate
3 Motor pack consisting of air motor and feed unit
4 Milling cutter
5 Spray device
6 Ventilation circuit with valves and maintenance unit

7* Wire cutter Option

8* TCP gauging Option

2-6 3HDA000057A8519-001 Torch cleaner TC 2013

 Structure and function

2.3.2 Function
Torch cleaning is performed fully automatically by a rotating tool (milling cutter). The weld-
ing torch is clamped in a holding mechanism (V-block) for this purpose. The external surface
of the contact tip nozzle and the internal surface of the gas nozzle are then cleared of weld
spatter in one operation.
The cleaned gas nozzle is then wetted with silicone-free liquid weld spatter release agent
to prevent early deposition of new weld spatter (see Chapter 5 Appendix).
The spraying cycle and spraying time (quantity) are set in the robot program. The feed rate
for the cleaning tool is set on the choke in the cast block.

2.3.2.1 Stand (Pos. 1)

The TC 2013 is fitted as standard with an

adjustable stand for floor assembly.
This consists of a height-adjustable rectan-
gular tube (1) with a foot attachment (2) for
floor assembly.
The TC 2013 is set to minimum height on 1
delivery.
The operator must set and then peg the opti-
Assembly instructions

mum height on the spot.

3
2

WARNING
Danger of crushing when adjusting stand height.

The stand of the TSC is made of hollow sections allowing height adjustment. The connect-
ing line can be passed through the hollow section. There is an opening (3) to pass the line
out of the stand at the bottom.
This opening (3) must not gripped when adjusting the stand height as this can lead to seri-
ous injury.

Torch cleaner TC 2013 3HDA000057A8519-001 2-7

Structure and function

Height adjustment without TCP gauging

It is recommended that the optimum height

is determined depending on the center of the
fulcrum of robot axis 2 (guide value).
Optimum height means that the robot arm
reaches the TC2013 by the shortest route and
can swivel in horizontally with minimal height
movement.

Axi
s2

Height adjustment with TCP gauging

The height should, as a rule, be set approx.

200 mm lower than in the case of the TC 2013
without TCP gauging.

Assembly instructions
2.3.2.2 Clamping cylinder with V-block (Pos. 2a....2c)
The welding torch is pressed against the clamping V-block (2b) by pneumatic clamping cyl-
inder (2a) and is thus firmly clamped in during milling. As the welding torch is clamped cen-
trally with respect to the milling cutter, the V-block must be set to the appropriate torch
diameter with a suitable spacer plate (2c) (for selection of spacer plates see Table 2-1).

2.3.2.3 Motor pack (Pos. 3)

The air motor is integrated into the pneumatic feed cylinder and thus forms a common
motor pack. The shaft end of the air motor carries the milling cutter.

2.3.2.4 Milling cutter (Pos. 4)

There are suitable milling cutters for the welding cutter nozzles concerned for internal and
external cleaning.

2-8 3HDA000057A8519-001 Torch cleaner TC 2013

 Structure and function

2.3.2.5 Spray device (Pos. 5)

The spray device consists of a 3/2-way valve, the spray head and a release agent tank with
liquid sensor. The spray device wets the cleaned gas nozzle with release agent free of sili-
cone and solvent. This prevents the early deposition of weld spatter.

2.3.2.6 Ventilation circuit with valves and maintenance unit (Pos. 6)

For explanations on the ventilation circuit, see Section 2.9 "Pneumatic plan".

2.3.2.7 Wire cutter (Pos. 7*) - Option

The wire cutter is an add-on module for the TC 2013 and can be retrofitted at any time.
The cutting plate is mechanically connected to the clamping cylinder of the TC 2013 and
does not require any additional control elements.

With the wire cutter the

– welding wire is cut to the desired length,
– bent or excessively projecting wire is cut off,
– the end of the wire is cut off before each torch
cleaning and where appropriate before each
TCP gauging,
Assembly instructions

– and slag formed at the end of the wire is cut off.

As a result arc ignition behaviour is improved and
availability is increased.

Subsequent addition to TC 2013

Instructions for retrofitting of the wire cutter can be found in Chapter 3.6 Assembly of the
wire cutter on the TC 2013.

2.3.2.8 TCP gauging (Pos. 8*) - Option

TCP gauging is an add-on module for the TC 2013 and can be retrofitted at any time.

TCP gauging is used solely to gauge and adjust the

robot tool center point (TCP).
Deviations of the torch TCP are gauged. If the toler-
ance is exceeded, the torch system of coordinates
is automatically corrected.

Torch cleaner TC 2013 3HDA000057A8519-001 2-9

Structure and function

Subsequent addition to TC 2013

Instructions for retrofitting of TCP gauging can be found in Chapter 4.7 Assembly.

2.3.3 Replacement parts

The replacement parts include:
• Milling cutter (can be ordered individually)
• Replacement spacer plate for the clamping V-block (can be ordered individually)
• Release agent tank (1 litre silicone-free weld spatter release agent)

2.3.3.1 Replacing milling cutter

1. Remove protective cover (1).

2. On the milling cutter detach threaded pin
M 5x6 and pull off milling cutter.
3. Put on new milling cutter and tighten
with threaded pin M 5x6.
4. Re-attach the protective cover (1) after 1
replacing the milling cutter.

Assembly instructions
NOTICE
At the factory the motor shaft is drilled approx. 1 mm
deep through the core hole in assembly of the first
milling cutter in order to safely rule out axial migra-
tion of the milling cutter.

2.3.3.2 Replacing spacer plate

1. The clamping V-block is screwed on with

2 cheese-head screws and pegged.
Detach screws (1) and pins (2).
2. Take off clamping V-block (3) and spacer
plate (4). 3
3. Select new spacer plate (see Table 2-1) 2
and screw back on clamping V-block and 4
peg. 1

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 Assembly and disassembly

NOTICE
The center misalignment of the torch nozzle must
then be corrected in the robot program.

2.4 Assembly and disassembly

2.4.1 General
The TC 2013 is supplied fully assembled.
Each individual unit is tested after manufacturing and provided with a serial number. The
test results are recorded.
After receipt of the delivery, the TC 2013 is to be examined for any damage in transport and
for completeness on the basis of the delivery note.

WARNING
Assembly instructions

Before work is undertaken on the TC 2013 the power

supply to the system is to be disconnected and pro-
tection against switching back on is to be ensured.

All hoses must be pressureless and empty.

2.4.2 Setting up and securing

1. The TC 2013 is to be set up vertically at a suitable place in the robot welding system.
Suitable means:
• within the working range of the robot,
• outside the interference edges of a tool clamping mechanism,
• outside the interference edges of a rotary positioner / turntable
• The basic position of the robot is preferably defined with the arrangement of the TC
2013.

CAUTION
There is a danger of the TC 2013 tipping over, and it
should therefore be secured immediately after being
set up.

A steel plate or a concrete floor with a quality of at least B 25 is necessary as a base. The
base must be a continuous unit. Setting up over an expansion joint is not permitted.
2. Screwing and pinning of the baseplate of the TC 2013 with the base (4 x M 12 screws).
3. Determination and setting of optimum height and subsequent pegging.

Torch cleaner TC 2013 3HDA000057A8519-001 2-11

Assembly and disassembly

4. Connect grounding cable (threaded drilled hole M8 in the lower area of the stand).
5. Connect compressed air.
6. Connect power supply .
7. Unscrew release agent tank and connect filled position sensor.

2.4.3 Installation

2.4.3.1 Electrical installation

WARNING
Electrical installation must only be performed by qual-
ified personnel!

NOTICE
The attached electrical circuit diagram must be
observed in installation! (see Chapter 2.10 Electrical
circuit diagram).

Assembly instructions
The grounding actions performed must be checked by
measurements and recorded.

It must be ensured in installation of the TC 2013

• that the cables do not rest on sharp edges,
• that the cables as far as possible are laid in a cable duct,
• the of risk of tripping is minimised.

Before electrical installation work is performed on the TC 2013

• disconnect the power supply to the control part,
• turn off the main on/off switch,
• safely turn off the air supply to the TC 2013,
• keep the system pressureless.

2.4.3.2 Pneumatic installation

CAUTION
Installation of the pneumatics must only be per-
formed by qualified personnel!

The TC 2013 is to connected so that the valves are not

electrically live in an emergency stop.

2-12 3HDA000057A8519-001 Torch cleaner TC 2013

 Assembly and disassembly

NOTICE
The attached pneumatic diagram must be observed in
installation! (see Chapter 2.9 Pneumatic plan).

The connection of compressed air takes place at the push-in fitting or the screw-in thread
G 1/8" at the filter regulator.

Air quality
The compressed air must comply with „class 4“ or better in accordance with to ISO 8573-
1:2010.

Operating pressure
The operating pressure for the TC 2013 must be at least 5 bar and must not exceed 10 bar.
It acts in the same way for all air consumers on the unit.

• The operating pressure is set on the main- 1

tenance unit (1) for the complete unit and
should no longer be changed.
• The quantity of oil through-flow at the
oiler should be one drop per 6-10 cleaning
Assembly instructions

cycles and the air motor and the pneu-

matic cylinders should be adequately
lubricated.

2.4.4 Setting

2.4.4.1 Setting of milling cutter

Cleaning time and milling cutter feed are directly related. If the milling cutter feed is at its
maximum, the cleaning time should be programmed one second longer. Complete cleaning
is achieved in a shorter time.

Torch cleaner TC 2013 3HDA000057A8519-001 2-13

Assembly and disassembly

• Milling cutter fed and milling cutter speed

are set on the air exhaust throttle valve (1)
.
• The cleaning time is controlled through
the cleaning program in the robot control.
• The feed rate is approx. 20 mm/sec, i.e.
approx. 2-2.5 sec is to be set for 45 mm
stroke.
• The completed stroke is reported by the
sensor.
1

2.4.5 Setting of spray mechanism

1. Check level of liquid in release agent tank 2

(1) and if necessary top up or replace bot-

Assembly instructions
tle.
2. Set system pressure of 6 bar in the pres-
sure control valve (2).

3. The degree of nebulisation is set on the

setting screw (3). 3
4. Slowly open setting screw until optimum
nebulisation is reached.
5. The amount of spray is regulated by the
software using the spraying time.
Note: Quantity sprayed and spraying time should
be kept as small as possible to avoid an excess of
release agent (drips onto weld seam impairs
seam quality).

2-14 3HDA000057A8519-001 Torch cleaner TC 2013

 Assembly and disassembly

2.4.6 Disassembly

CAUTION
Before the TC 2013 is disassembled the unit must be
completely switched off and protected against being
turned back on!

All lines must be pressureless and empty.

1. Disconnect power supply.

2. Disconnect compressed air connection.
3. Detach grounding cable.
4. Detach filled position sensor and unscrew release agent tank.
5. Remove screws and pins from the baseplate of the stand.
6. Take off TC 203 and carefully place on a suitable surface.

2.4.7 Disposal
Current directives and laws on waste must be observed.
Assembly instructions

• Framework Waste Directive 2008/98/EC.

• Waste Shipments Regulation 2006/1013/EC.
• German Recycling and Waste Disposal Act (KrWG)
Waste within the meaning of the Recycling and Waste Disposal Act (KrWG) is all materials
or objects which their owner disposes of, wishes to dispose of or has to dispose of. Waste
for recycling is waste which is recycled; waste which is not recycled is waste for disposal.
The disposal of waste should preferably take place within the country. Waste avoidance
takes precedence over waste recycling.

NOTICE
The operator is obliged to comply with applicable fed-
eral, state and municipal regulations for disposal and
scrapping.

Environmentally hazardous materials are to be dis-

posed of in accordance with local regulations and
ordinances.

Torch cleaner TC 2013 3HDA000057A8519-001 2-15

Commissioning

2.5 Commissioning

2.5.1 Instructions for commissioning

Before operating for the first time it should be checked that
• all components are correctly assembled and attached,
• all electrical connections are correctly made,
• all pneumatic connections are correctly dimensioned and connected,
• all supply lines have been installed,
• the functioning of all safety devices has been ensured,
• there is sufficient oil in the oiler,
• there is sufficient release agent in the release agent tank,

WARNING
Danger from incorrect connections/settings and non-
functioning/missing safety devices.

Assembly instructions
2.5.2 Function test
A function test in manual mode is to be performed during commissioning of the TC 2013.

WARNING
Tests may only be performed in manual mode and only
by qualified personnel.

Ensure in testing or programming work that the welding torch is correctly introduced into
the TC 2013 by the robot.
Ensure in testing the TC 2013 in connection with a welding torch that no weld spatter, metal
chips or debris from a broken milling cutter of spray fluid enter the eyes.

CAUTION
Wear suitable protective goggles!

Do not place fingers in the rotating milling cutter or in

the clamping device (V-block)!

Danger due to unexpected starting of the milling cut-

ter!

2-16 3HDA000057A8519-001 Torch cleaner TC 2013

 Commissioning

2.5.3 Switching on
The TC 2013 is ready for operation when the robot control is switched on.

CAUTION
Danger of electric shock!

Make sure that all live components are properly cov-

ered.

2.5.4 Modes
The welding system is designed for automatic operation.
The program specified for the TC 2013 is designed for automatic operation.
It is possible to choose between manual and automatic on the mode selector switch of the
system.

2.5.5 Sequence of operation

Assembly instructions

The robot is in the basic setting. The welding torch is generally inside the torch cleaner,
above the spray head.

2.5.5.1 Cleaning
After a cleaning program contained in the robot is called up
• the welding torch is run into the cleaning position of the torch cleaner,
• the clamping cylinder fixes the torch in the V-block as soon as the welding torch has
reached the cleaning position,
• the tool air motor starts to turn,
• the tool unit with the milling cutter runs vertically from above into the torch and cleans
the gas nozzle and contact tip nozzle.
• If there is a blow-out valve, the chips remaining in the torch can be blown out.
Machining time and tool feed are directly related. If the milling cutter feed is at its maxi-
mum, the machining time should be programmed one second longer. Complete cleaning is
not achieved if the machining time is shorter.
The sensor reports the start of cleaning.
If the cleaning time defined in the cleaning program has ended, the tool unit, then the tool
motor and afterwards the clamping cylinder are returned to the starting position.

Recommendation:
Simultaneous blowing out and cleaning!

Torch cleaner TC 2013 3HDA000057A8519-001 2-17

Commissioning

2.5.5.2 Spraying
If the clamping cylinder is in the basic setting, the program receives a signal message from
a switch. This feedback starts the next spraying program.
• The robot runs the cleaned welding torch into the spray position.
• The spraying device wets the torch head with an anti-adhesion fluid which prevents early
deposition of new weld spatter.
• The period of spraying is fixed in the program. Two short sprays is better than one long
spray. The spraying process is over when the time runs out.
• If there is no wire-cutting program, the robot runs into the basic setting and reports end
of program and readiness to start for continued running through the welding program.
• The screen of the spray nozzle can be removed for cleaning purposes.

2.5.5.3 Wire cutting (option)

The robot is in the basic setting. The welding torch is generally inside the torch cleaner,
above the spray head.
After a wire-cutting program contained in the rotor is called
• the cutting knife is opened
• the clamping cylinder also closes automatically, as the two motions are linked.

• The welding torch runs to the desired wire

Assembly instructions
length distance (e.g. 10 mm) above the knife into
the wire-cutting position of the torch cleaner.
• The wire feed advances a welding wire surplus
length of at least 20 mm!
Wire length distance
(A surplus wire length of at least 20 mm is neces-
sary to avoid disturbance of operation due to
wire waste.) Surplus wire length
>20mm

• The knife closes and cuts the welding wire to the desired wire length distance. The knife
and clamping cylinder are then back in their basic position.
• The robot runs into the basic setting and reports end of program and readiness to start
for continued running through the welding program.
A detailed description of the wire cutter can be found in Chapter 3 Wire cutter.

2.5.5.4 TCP gauging (option)

Gauging of the TCP (Tool Center Point) is optionally included in the robot program and is
performed automatically. It is recommended that the TCP is also re-gauged after each
torch cleaning operation.
A detailed description of TCP gauging can be found in Chapter 4 TCP gauging (BullsEye®).

2-18 3HDA000057A8519-001 Torch cleaner TC 2013

 Program sequence for torch cleaning

2.6 Program sequence for torch cleaning

Configuration, programming and sequence of the torch cleaning station are described
below.
The rapid instructions, which allow for simple use of the torch cleaning station, are made
available with the option "653-3 ABB TSC2013".

NOTICE
The detailed description of this option can be found in
the operating instructions "3HCA024847-001 Torch
Services", which are supplied with the RobotWare
documentation.

If this software option is not present in your robot system, the movements and signal
sequences as well as optional error management must be programmed manually

2.6.1 General
The TC 2013 torch cleaning system has an EA interface, which can depict the following sig-
nal conditions:
Assembly instructions

• digital input clamping element open

• digital input clamping element closed
• digital input milling cutter in upper end position
• digital input milling cutter in lower end position
• digital input release agent present
• digital output, start of torch cleaning (milling cutter in) or wire cutting (dual function)
• digital output torch blow-off (depending on welding equipment used)
• digital output spraying
The software option "653-3 ABB TSC2013" makes separate rapid instructions available for
torch cleaning, torch blow-out/spraying and shortening of the welding wire. The operator
or programmer does not have to take account of the activation of inputs and outputs. This
is taken over by rapid instructions. The necessary signals merely need to be defined and
correctly reported in the configuration.
The following instructions are available.
• MoveMechCleanL / MoveMechCleanJ for torch cleaning
• MoveSprayL / MoveSprayJ for spraying of the release agent
• MoveWireCutL / MoveWireCutJ for shortening of the welding wire

Torch cleaner TC 2013 3HDA000057A8519-001 2-19

Program sequence for torch cleaning

2.6.2 Program examples

Program example Torch cleaning/Torch spraying:

Assembly instructions
Program example Welding wire shortening:

2-20 3HDA000057A8519-001 Torch cleaner TC 2013

 Program sequence for torch cleaning

2.6.3 Configuration for TC 2013

2.6.3.1 Configuration for torch cleaning

The configuration for torch cleaning can take place via RobotStudio or directly via the Flex-
Pendant of robot control. The configuration is produced in the process configuration data-
base (Proc.cfg).

RobotStudio - view of the configuration for torch cleaning (Torch services mech clean properties)
Assembly instructions

Parameter view in a text editor:

Torch cleaner TC 2013 3HDA000057A8519-001 2-21

Program sequence for torch cleaning

2.6.3.2 Configuration for wire cutting

RobotStudio - view of the configuration for wire cutting (Torch services wirecut properties)

Assembly instructions
Parameter view in a text editor:

2-22 3HDA000057A8519-001 Torch cleaner TC 2013

 Program sequence for torch cleaning

2.6.3.3 Configuration torch spraying

RobotStudio - view of the configuration for torch spraying (Torch services spray properties)
Assembly instructions

Parameter view in a text editor:

Torch cleaner TC 2013 3HDA000057A8519-001 2-23

Program sequence for torch cleaning

2.6.4 Sequence of torch cleaning

The instruction "MoveMechCleanL" moves the robot via a preliminary position directly to
the cleaning position and checks whether the milling cutter in the lower end position and
the clamping element is open. In the case of incorrect signal states an operator dialogue is
automatically opened on the FlexPendant and operator interaction is necessary. In the case
of correct signal states the cleaning sequence is started. The set time for torch cleaning
does not start until the milling cutter has reached the upper end position. After the end of
the cleaning time the clamping element is opened and the robot returns to the preliminary
position.
Note: The milling cutter must be set so that it has reached the upper end position in 30 sec-
onds, as an error message otherwise appears.

Operator interaction in faulty signal states of the milling cutter

Assembly instructions
If here is no release agent in the tank or the level of release agent is too low, an error mes-
sage occurs, however the robot program is not interrupted.

Result log - message

2-24 3HDA000057A8519-001 Torch cleaner TC 2013

 Program sequence for torch cleaning

2.6.4.1 Sequence of torch cleaning without software option "653-3 ABB TSC2013"

Example of a possible sequence for torch cleaning without software option "653-
3 ABB TSC2013":
1. Robot runs into a safe position close to the cleaning position.
2. Checking of the signal statuses "clamping elements open" and "milling cutter in lower
end position"
3. Robot runs into cleaning station.
4. Setting of the output "start of cleaning".
5. Checking of the signal statuses "clamping elements closed" and "milling cutter in lower
end position".
6. Milling (waiting time).
7. Resetting of the output "start of cleaning".
8. Checking of the signal status "clamping elements open" and "milling cutter in lower end
position"
9. Robot runs out of the cleaning station into a safe position.

2.6.4.2 Sequence of wire cutting without software option "653-3 ABB TSC2013"

Example of a possible sequence for shortening of welding wire without software

Assembly instructions

option "653-3 ABB TSC2013":

The output for cleaning of the welding torch (milling cutter) is used at the same time for
shorting of the welding wire. The same applies to the "clamping element opened/closed"
signals.
1. Robot runs into a safe position close to the wire cutter.
2. Setting of the output "start of cleaning".
3. Checking of the signal state "clamping element closed" (wire cutter open).
4. Robot runs into the position for shortening of the welding wire.
5. Resetting of the output "start of cleaning" (cutting of wire end).
6. Checking of the signal state "clamping element closed" (wire cutter open).
7. Robot runs into a safe position.

Torch cleaner TC 2013 3HDA000057A8519-001 2-25

Program sequence for torch cleaning

2.6.4.3 Sequence of spraying without software option "653-3 ABB TSC2013"

Example of a possible sequence for spraying of the release agent without soft-
ware option "653-3 ABB TSC2013":
1. Robot runs into a safe position close to the spraying position.
2. Robot runs into the precise spraying position.
3. Setting of the output "release agent spraying".
4. Waiting time for release agent spraying.
5. Resetting of the output "release agent spraying".
6. Robot runs into a safe position.
In all the sequences listed above only the sequence with correct signal states is explained.
An error strategy is to be planned for the event of faults.

NOTICE
The existing program serves only as a model!

The customer-specific program is dependent on the

type of system.

Assembly instructions
2.6.4.4 Trial run
The following should be fulfilled in the trial run:
1. Ensure that there is no compressed air on the TC 2013. Uncontrolled movements are
consequently avoided.
2. Then run through the sub-program for torch cleaning step by step.
3. After the trial run switch the compressed air back on run through the program in auto-
matic mode.
4. Check the welding torch position inside the torch cleaner (milling cutter fracture pos-
sible).
• Contact tip nozzle, gas nozzle and milling cutter must move in clamped condition.
• Contact tip, gas nozzle and milling cutter must not stick.

CAUTION
Wear suitable protective goggles! The miller cutter
may break. Spray fluid may enter the eyes.

Do not hold fingers in the rotating milling cutter or in

the clamping device (V-block)!

Danger from unexpected starting of the milling cut-

ter!

2-26 3HDA000057A8519-001 Torch cleaner TC 2013

 Maintenance

2.7 Maintenance

WARNING
Before servicing and maintenance work the TC 2013 is
to be made pressure-less and disconnected from the
power supply and protected against being switched
back on.

The TC 2013 torch cleaning station is largely maintenance-free due to the use of high-qual-
ity components. The frequency of individual checks and maintenance work is guided by the
particular conditions of use of the TC 2013.
We recommend the following maintenance plan to guarantee perfect functioning of the TC
2013.
I

Interval Machine part Activity Remark

daily TSC 2013 Visual inspection

weekly Spray nozzle - Test,

- Clean when required

Milling cutter unit - Test, Do not use compressed

Assembly instructions

- Clean when required air

Maintenance unit Values see Chapter 2.2

pressure regulator Check pressure Technical data of TC
2013

Maintenance unit Mineral oil to DIN 51524-

oiler Check fill-up quantity HLP 32

Release agent container - Check fill-up quantity ABB ordering No

- Visual inspection on 0.743.505.003 **
damage
- Exchange when
required

Cutting knife - Clean with brush and Grease

grease lightly
- Check on wear

Milling cutter Check on wear, damage

and firm seating

Wire collecting container Regularly empty

monthly Emergency stopping Test emergency stop-

devices ping devices for func-
tion.

Maintenance unit
air filter Check on pollution

Cable and connector Check for damage and

buckling.

V-block TC 2013 Check on wear

2 annual Release agent container Exchange of the con- ABB ordering No

tainer 0.743.505.003 **

Torch cleaner TC 2013 3HDA000057A8519-001 2-27

Maintenance

*) Mineral oil in accordance with DIN 51524-HLP 32, viscosity 32 cST at 40°C
**) Use only AS 72-K genuine spatter release agent!

Assembly instructions

2-28 3HDA000057A8519-001 Torch cleaner TC 2013

 Spare and wearing parts for TC 2013

2.8 Spare and wearing parts for TC 2013

2.8.1 TC 2013 without wire cutter

3 22 23 4 5 10 9

15

16

6
Assembly instructions

1
19

2 15 18

16

19 15 3

16

12

14

11

13

20 8 15 17 21

16

Torch cleaner TC 2013 3HDA000057A8519-001 2-29

Spare and wearing parts for TC 2013

Pos. Qty Name ABB Article No Spare part Wearing

part
1 1 Spray head TC 2013 3HDA000000A927 x
1
2 1 Motor pack for milling cutter 3HDA000000A927 x
7
3 1 Clamping unit TC 2013 3HDA000057A667 x
0
4 1 V-block TC 2013 0.743.800.040 x

5 1 spacer plate x
torch-dependent replacement part
Gas nozzle Ø 16 mm 0.746.124.001

to to

Gas nozzle Ø 16 mm 0.746.124.019

6 1 Spray nozzle screen 3HDA000057A4597 x

7 1 Milling cutter
(torch-dependent wearing part) torch-dependent x
8 1 Throttle hollow screw

Assembly instructions
G1/8” - Type C 3HDA000057A534 x
Article No 304005-3 4
ITV GmbH
9 1 Filter regulating valve
LFR-1/8-D-7-MINI 3HDA000057A5023 x
Festo AG & Co. KG
10 1 Oiler
LOE-1/8-D-MINI 3HDA000057A5022 x
Festo AG & Co. KG
11 1 Solenoid valve
VSVA-B-M52-MD-D1-1R5L 3HDA000057A501 x
Festo AG & Co. KG 4
12 1 Solenoid valve
MDH-3/2-24DC 3HDA000057A5015 x
Festo AG & Co. KG
13 1 Connecting line
NEBU-M12W5-K-0.5-N-LE3 3HDA000057A5229 x
Festo AG & Co. KG
14 1 Socket
KMC-1-24DC-25-LED 3HDA000057A504 x
Festo AG & Co. KG 0

15 1 Sensor holder
SMBZ-8-125/320 3HDA000057A509 x
Festo AG & Co. KG 5
16 1 Sensor
SME-8M-DS-24V-K-2.5-OE 3HDA000057A509 x
Festo AG & Co. KG 4
17 1 Sensor
CBN10-F46-E2 3HDA000057A5153 x
Pepperl+Fuchs GmbH
18 1 Screw-in silencer
"Legris" G1/4 - 0670 00 13 3HDA000057A5027 x
Parker Hannifin GmbH

2-30 3HDA000057A8519-001 Torch cleaner TC 2013

 Spare and wearing parts for TC 2013

Pos. Qty Name ABB Article No Spare part Wearing

part
19 1 Miniature silencer
"Legris" G1/8 - 0677 00 10 3HDA000057A5155 x
Parker Hannifin GmbH
20 1 Cable
14G 0.5mm² 3HDA000057A5224 x
HELUKABEL GmbH
21 1 litre Release agent - 3850 0.743.505.003 x
(in original container)
22 1 Adjusting injector for reference 0.746.335.025 x
points
23 1 Protective sleeve for adjusting 0.746.335.026 x
syringe
Assembly instructions

Torch cleaner TC 2013 3HDA000057A8519-001 2-31

Spare and wearing parts for TC 2013

2.8.2 TC 2013 with wire cutter

Assembly instructions

2-32 3HDA000057A8519-001 Torch cleaner TC 2013

 Spare and wearing parts for TC 2013

Pos. Qty Name ABB Article No Spare part Wearing

part
1 1 Spray head TC 2013 3HDA000000A927 x
1
2 1 Motor pack for milling cutter 3HDA000000A927 x
7
3 1 Wire cutter - TSC 2013 3HDA000000A928 x
9
4 1 V-block TC 2013 0.743.800.040 x

5 1 spacer plate x
torch-dependent replacement part
Gas nozzle Ø 16 mm 0.746.124.001
to to
Gas nozzle Ø 16 mm 0.746.124.019
6 1 Spray nozzle screen 3HDA000057A4597 x

7 1 Milling cutter
(torch-dependent wear part) torch-dependent x
8 1 Throttle hollow screw
G1/8” - Type C 3HDA000057A534 x
Article No 304005-3 4
Assembly instructions

ITV GmbH
9 1 Filter regulating valve
LFR-1/8-D-7-MINI 3HDA000057A5023 x
Festo AG & Co. KG
10 1 Oiler
LOE-1/8-D-MINI 3HDA000057A5022 x
Festo AG & Co. KG
11 1 Solenoid valve
VSVA-B-M52-MD-D1-1R5L 3HDA000057A501 x
Festo AG & Co. KG 4
12 1 Solenoid valve
MDH-3/2-24DC 3HDA000057A5015 x
Festo AG & Co. KG
13 1 Connecting line
NEBU-M12W5-K-0.5-N-LE3 3HDA000057A5229 x
Festo AG & Co. KG
14 1 Socket
KMC-1-24DC-25-LED 3HDA000057A504 x
Festo AG & Co. KG 0

15 1 Sensor holder
SMBZ-8-125/320 3HDA000057A509 x
Festo AG & Co. KG 5
16 1 Sensor
SME-8M-DS-24V-K-2.5-OE 3HDA000057A509 x
Festo AG & Co. KG 4
17 1 Sensor
CBN10-F46-E2 3HDA000057A5153 x
Pepperl+Fuchs GmbH
18 1 Screw-in silencer
"Legris" G1/4 - 0670 00 13 3HDA000057A5027 x
Parker Hannifin GmbH

Torch cleaner TC 2013 3HDA000057A8519-001 2-33

Spare and wearing parts for TC 2013

Pos. Qty Name ABB Article No Spare part Wearing

part
19 1 Miniature silencer
"Legris" G1/8 - 0677 00 10 3HDA000057A5155 x
Parker Hannifin GmbH
20 1 Cable
14G0.5mm² 3HDA000057A5224 x
HELUKABEL GmbH
21 1 litre Weld spatter release agent 0.743.505.003 x
(in original container)

Assembly instructions

2-34 3HDA000057A8519-001 Torch cleaner TC 2013

 Pneumatic plan

2.9 Pneumatic plan

Clambing cylinder and

Wire cutter (optionally) Feed cylinder Air motor Spray device
Assembly instructions

Torch cleaner TC 2013 3HDA000057A8519-001 2-35

2-36
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Torch cleaner TC 2013

Assembly instructions
 Designated use

3 Wire cutter
The wire cutter is an option for the TC 2013 and can be retrofitted at any time. A wire cutter
conversion cut – Article No 3HDA000057A8405 is needed for this purpose.

Note: The wire cutter is already contained in the TSC 2013 (Torch Service Center).
Figure 3-1 TC 2013 with wire cutter

Wire cutter
Assembly instructions

3.1 Designated use

The wire cutter is used for automatic cutting of the welding wire. It only works on combina-
tion with a TC 2013, as it is actuated by the latter.
The wire cutter can be retrofitted on the TC 2013 at any time.

3.2 Technical data

Air pressure 5-10bar

Clamping cylinder - diameter 45mm
Stroke 36mm
Clamping force (at 5 bar) 790N
Max. welding wire diameter for cutting d= 1.0mm Steel at minimum 5bar air pres-
d= 1.2mm Aluminium sure
d= 1.2mm Steel at minimum 6bar air pres-
sure
Weight approx. 1.5kg

Wire cutter 3HDA000057A8519-001 3-1

Safety instructions

Supply data

Control voltage 24V DC

Compressed air connection G 3/8 inch
Compressed air 6 bar unoiled

3.3 Safety instructions

Proceed with the utmost caution when work has to be carried out on the wire cutter (clean-
ing, replacement of the blades etc.).
Very high forces act in wire cutting as the blades are pressed together using clamping cyl-
inders.

CAUTION
Danger of injury!

Do not place fingers in blades!

3.4 Ignition behaviour / availability of the system

Assembly instructions
The ignition behaviour and availability of the welding system can be provided by
– cutting off bent or excessive length of emerging wire,
– cutting off the wire end before each torch clean and before each TCP measurement,
– cutting off slag formed at the end of the wire.

3.5 Function and structure

The wire cutter consists of the following components:

1. cylinder, complete (already present on

the TC 2013),
2. housing, complete with cutting plate, 2
seal and cover
3. piston-side cutting plate, complete with
carrier and shaft 1 3
4. 2 sensors.
4

3-2 3HDA000057A8519-001 Wire cutter

 Assembly of the wire cutter on the TC 2013

Sequence of operation
The robot is in the cleaning position in this process. The welding torch is generally inside
the torch cleaner, above the spray head.
• The blade opens after a wire-cutting program stored in the robot is called. The clamping
cylinder therefore also closes automatically, as the two motions are linked.

• The welding torch runs to the desired wire

length distance (e.g. 10 mm) above the knife into
the wire-cutting position of the torch cleaner.
• The wire feed advances a welding wire surplus
length of at least 20 mm!
Wire length distance
(A surplus wire length of at least 20 mm is neces-
sary to avoid interfering with operation due to
wire waste.) Surplus wire length
20mm

• The knife closes and cuts the welding wire to the desired wire length distance. The knife
and clamping cylinder are then back in their home position.

3.6 Assembly of the wire cutter on the TC 2013

Assembly instructions

If a wire cutter is subsequently to be installed on the TC 2013, a "wire cutter conversion kit"
(Article No 3HDA000057A8405) is needed, consisting of:

1. lid
2. drive shaft 2
3. housing
6 4
4. cover
5. carrier for blade 5 1
6. cutting plate set
3
7. wire capture container
7

3.6.1 Preparations
The following are needed for assembly of the wire cutter on the TC 2013:
– 1 set of Allen keys
– 1 open-end wrench (wrench width 10 mm).

Wire cutter 3HDA000057A8519-001 3-3

Assembly of the wire cutter on the TC 2013

– Thread locker ("LOCTITE 243" or "PETEC thread locker Supersolid"/article no. 930250).

CAUTION
Before reconstructing, make sure that the air and
power supplies are disconnected!

It is recommended that the TC 2013 should be cleaned prior to the conversion.

3.6.2 Disassembly of clamping cylinder

Slight reconstructions are to be carried out in order to be able to install the wire cutter on
the TC 2013. Existing components are partly replaced by new ones.
The following steps are to be performed:

Figure 3-2 Disassembly of clamping cylinder

8
7

Assembly instructions
6

3
1

1. Make system pressureless and secure against switching back on.

2. Detach air hose from push-in fitting (1) and unscrew push-in fitting. This is needed
again for the wire cutter.
3. Unscrew sensors (2) together with the clamping holders and protect against uninten-
tional tearing-off.
4. Detach and remove 4 cheese-head screws M6x130 (3). These are needed again for the
wire cutter.
5. Pull off lid (4) including O-ring. These parts are no longer needed.

3-4 3HDA000057A8519-001 Wire cutter

 Assembly of the wire cutter on the TC 2013

6. Push/pull out cushion disc (5) and combined piston (6) with piston rod (7) from the cyl-
inder tube (8).
7. Remove socket screw M6x30 (9) from the piston and instead attach the combined pis-
ton (6) with shaft (10) on the piston rod.

3.6.3 Assembly of wire cutter

NOTICE
Before installing the wire cutter, the threads of the
shaft (10a) must always be coated with a thread
locker, e.g. "LOCTITE 243" or "PETEC thread locker
Supersolid" (article no. 930250)!

Figure 3-3 Assembly of wire cutter

6
10a
Assembly instructions

10

11
12
2

5 13

1
14
3 15

8. Guide piston rod (6) and shaft (10) lightly oiled into the cylinder tube (8) and through
the adapter with wiper and O-ring.
9. Push cushion disc (5) and lid (11) into the cylinder tube. It should be ensured that the O-
rings (12x3 and 60x3) are assembled.
10. Screw blade carrier (12) together with the cutting plate at the bottom onto the shaft.
11. Screw housing (13), cover and cutting plate at the top. Then push the blade carrier (12)
and rotate the piston so that the blade carrier is upright.

Wire cutter 3HDA000057A8519-001 3-5

Corrective and preventive maintenance

12. Screw casing and cover with screws (3) and dowel pins (14) on the lid (11) of the wire
cutter.
13. Attach sensors (2) together with the clamping holders at the lower screws and position
using the setting aid on the cylinder tube.

Figure 3-4 Setting aid for sensors (view from below)

Sensors fastened in this orientation

Setting aid

Assembly instructions
14. Assemble push-in fitting (1) and insert air hose.
15. Screw in screws M5x10 (15) into the housing of the wire cutter but tighten only such
that the wire capture container can be suspended.
16. Carry out function test. In doing so, ensure in particular that compressed air is blown
out and the sensors switch correctly (piston away, clamping / piston back, wire cut-
ting). As a test, also let a piece of welding wire be cut.

3.7 Corrective and preventive maintenance

Regular corrective and preventive maintenance should be performed to guarantee opera-
tion of the wire cutter. The following activities are recommended:

Maintenance table

Interval Activity

daily Visual inspection

Empty wire collecting tank

weekly Clean unit of dirt and chips in the area of the blades with a brush. Do not
use compressed air.

Replace blunt cutting plates at the right time.

Regularly check the level of oil in the oiler of the TC 2013 torch cleaner
and top up.

monthly Test emergency stopping devices for function.

3-6 3HDA000057A8519-001 Wire cutter

 General

4 TCP gauging (BullsEye®)

4.1 General
You obtain TCP gauging as
– individual device (for ceiling assembly or as option for retrofitting on TC 2013),
– as individual device with stand (standalone version),
– integrated in the TC 2013 or
– integrated in the TSC 2013.

4.1.1 Designated use

The TCP gauging unit is intended solely to measure and adjust the robot tool center point
(TCP)

4.1.2 TCP (tool center point)

The tool position of an industrial robot is described through what is known as its TCP (tool
center point). This is the imagined reference point located at a suitable place on the tool,
Assembly instructions

precisely where the tip of the welding wire would touch the workpiece if a predefined dis-
tance (stick-out length of the welding wire) from the base surface of the gas nozzle is used.
All programmed positions of the robot relate to the TCP.

Figure 4-1 The welding torch is oriented around the entered TCP.

Robot tool flange

TCP Reference

TCP gauging (BullsEye®) 3HDA000057A8519-001 4-1

Technical data

4.2 Technical data

4.2.1 Dimensions

Protective sleeve
Adjusting tip

Assembly instructions

4.2.2 Connection data electrics

Electrical connection 40mA, at 24VDC

Connection of robot digital sensor input

4-2 3HDA000057A8519-001 TCP gauging (BullsEye®)

 Safety

4.2.3 System requirements

TCP software from BullsEye 10

RobotWare from version 5.06
Digital input at least 1 free input
RobotWare options Arc, BullsEye®

4.3 Safety

WARNING
Observe the safety instructions in Chapter 1 Torch
Service Center - TSC 2013.

CAUTION
Danger due to piercing!

The protective sleeve must always be placed on the

Assembly instructions

adjusting tip in work on TCP gauging.

4.4 Features of TCP gauging

The robot checks the TCP at fixed intervals of time. Seam displacement due to torch mis-
alignments etc. can consequently be minimised.
Further advantages of regular TCP gauging are:
– reduction of costs in manufacturing,
– greater reproducibility,
– minimisation of time-consuming and expensive re-programming of components,
– monitoring of the robot, error message appears if the calibration of the robot is no lon-
ger correct or the TCP gauging has lost its original position.

TCP gauging (BullsEye®) 3HDA000057A8519-001 4-3

Structure and function

4.5 Structure and function

4.5.1 TCP gauging as standalone device

Standalone TCP gauging can be installed either on the ceiling of a robot cell or retrofitted
as an addition to the TC 2013.
TCP gauging consists of the following components:

1. adjusting tip
1 2 4
2. protective sleeve for adjusting syringe
3. fibre-optic sensor
4. fibre-optic
5
5. housing

Assembly instructions
4.5.2 TCP gauging with stand
TCP gauging (1) is mounted on a stand (3), available as a standalone version. A holding
angle (2) is provided to attach the TCP gauging unit on the stand. The TCP gauging unit is
screwed and pinned with the baseplate (4) on the workshop floor or on the floor of the
robot cell.

1. TCP gauging (complete)

2. holding angle
3. height-adjustable stand 1
4. baseplate

4-4 3HDA000057A8519-001 TCP gauging (BullsEye®)

 Functional description

4.6 Functional description

TCP gauging with BullsEye® version 10 allows completely automatic definition of the tool
center point (TCP) for IRC robot control.

4.6.1 Examples of operation

When a robot receives the command to rotate about the TCP all the robot axes are moved
such that the TCP remains stationary.
If the torch is damaged and the program is executed again, the robot performs the same
movements, but the TCP no longer moves on the same trajectory because of the incorrect
alignment.
You then have 2 options:
1. physical moving of the torch in order to align it correctly (a difficult, if not impossible
task!) or
2. automatic correction of the incorrect alignment, the TCP being redefined according to
the new torch position with BullsEye®. After BullsEye® has updated the TCP position,
the torch rotates about the TCP as previously, because the trajectory of the robot arm
was adapted in order to offset the incorrect alignment of the torch.
After a point has been programmed the angles of the robot joints are not stored in the
robot but the data of the position of the tool center point.
Assembly instructions

If the robot repeats the programmed trajectory, it calculates the joint angles necessary so
that the TCP is back in the position it was at in the original programming of the trajectory.
As long as the robot control has information on the position of the tool center point it
ensures proper alignment of the trajectories.

Figure 4-2 Movement of robot arm and torch with correct TCP

Figure 4-3 Robot arm moves on the same trajectory, however the torch trajectory has
changed

TCP gauging (BullsEye®) 3HDA000057A8519-001 4-5

Functional description

4.6.2 TCP deviation

Component programming is normally undertaken with an adjusted TCP. The adjusted TCP
may deviate from the actual TCP due to faults in operating sequence.
TCP deviations may have the following causes:
– collision with a component clamp,
– no wire free-burn at the seam end
– adjustable torch holder,
– contact tube wear or highly modified pre-dressing of the welding wire.
The consequence is seam displacements in the components. To correct the seam positions
the TCP must be re-adjusted.
There are various options for this:

4.6.2.1 Manual TCP adjusting method

• Manual alignment in a mechanical torch gauge.
• Manual alignment via two adjusting tips.
• Manual gauging, using programming device.
Further information on manual gauging can be found in the user manual on robot control.

Assembly instructions
4.6.2.2 Program correct by TCP calibration
• Automatic re-adjustment of the welding wire in a measuring beam.
• Motion program for the robot as software module.

Figure 4-4 Robot and torch motion with correct TCP

Path of the welding torch

(trjectory correct)

Path of the robot

Workpiece
Robot arm

If a position is saved, this is always done using the current tool and taking account of the
current axial angle. These angles are always run in the program sequence.
If the tool center point (TCP) is no longer in the defined position due to a change, the
welded seam is away by the dimensional deviation of the write electrode tip from the
defined TCP. This is shown by Figure 4-5.

4-6 3HDA000057A8519-001 TCP gauging (BullsEye®)

 Functional description

Figure 4-5 Deviation from the programmed trajectory

New path of the welding torch

Same path
of th robot

Workpiece
Robot arm

The tool is re-measured by the automatic TCP gauging. The welding gun then runs the cor-
rect trajectory on the component.

Figure 4-6 The TCP was corrected

Assembly instructions

Path of the welding torch

(once again correctly on he trajectory)

Path of the robot

has shifted

Workpiece
Robot arm

The welding gun runs the correct path again (the axial configuration of the robot has
changed).

TCP gauging (BullsEye®) 3HDA000057A8519-001 4-7

Assembly

4.7 Assembly

4.7.1 Subsequent assembly on the TC 2013

The TCP gauging can be retrofitted on the TC 2013 at any time.

WARNING
Before assembly and installation work the system
must be electrically dead and pressureless and pro-
tected against being switched back on.

1. It should be verified before starting 2

assembly that the protective sleeve 1
(3) is in position on the adjusting tip!
(5) . If not, put the protective sleeve 2
on (danger of piercing).
2. Place the TCP gauging unit on the TC
2013 so that the two pins (4) rest in the
holes provided (2).

Assembly instructions
3. Then secure with 1 screw M6x12 (1)

4. Then attach the two pins (4).

1 3

4 4

CAUTION
The electrical connection must be carried out accord-
ing to the connection diagram (Fig. 4-7).

4-8 3HDA000057A8519-001 TCP gauging (BullsEye®)

 Assembly

4.7.2 Assembly of TCP gauging with stand

NOTICE
In assembling the TCP gauging unit with stand (stand-
alone version), proceed as described in Section 2.4
Assembly and disassembly of the TC 2013.

4.7.3 Assembly site and alignment

Assemble the welding gun on the robot so that the torch axis points in the X-direction of
the wrist.
The installation site of the TCP gauging unit must be in the working range of the robot so
that no singularity and end positions of the robot are reached.
Place the TCP gauging unit at the desired place in front or alongside the robot. Do not yet
fasten, but secure against tipping over!
Assembly instructions

It is optionally possible to install the TCP gauging unit suspended (e.g. from the cell ceiling).
The direction of the sensor should be aligned parallel to the robot base coordinates system
in the x- or y-direction. The y-axis of the write coordinates system on the robot should
always be parallel to the direction of the light barrier. This specification also results in align-
ment of the TCP gauging unit to the robot base coordinates system.
The assembly site in the robot working range must be selected so that rotation about the
torch axis of at least 30° is possible. Greater accuracy is provided by 45° rotation, which
should preferably be selected in the setup.

TCP gauging (BullsEye®) 3HDA000057A8519-001 4-9

Assembly

4.7.3.1 Electrical installation

WARNING
Electrical installation must only be performed by qual-
ified personnel!

To simplify assembly, the TCP gauging unit is supplied pre-assembled and with a connect-
ing cable. Connect the cable supplied from the robot control with the connection on the
TCP gauging unit (BullsEye®). The position of the device alongside or in front of the robot
depends among other things on the assembly of the welding gun on the wrist and is only
fixed after a test run.
Carry out the connection according to the following connection diagram.

Figure 4-7 Connection diagram: TCP gauging unit

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Assembly instructions

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4-10 3HDA000057A8519-001 TCP gauging (BullsEye®)

 Using for the first time

4.8 Using for the first time

4.8.1 General
Before operating for the first time it should be checked that
• all components are correctly assembled and attached,
• all electrical connections are correctly made,
• the functioning of all safety devices has been ensured.

WARNING
Danger from incorrect connections/settings and non-
functioning/missing safety devices!

4.8.2 Installation of Software BullsEye®10

The software option BullsEye®10 is automatically made available to all welding robots when
the baseware (robot operating system) is installed. This is conditional on the option "Bull-
sEye®" in the keystring being present for the control module. BullsEye®10 is not available
available as a standalone option on CD.
Assembly instructions

Further information on use of BullsEye® software can be found in the BullsEye® user manual.

4.8.3 EIO Configuration

For DeviceNet or EtherNet/IP Local IO, the configuration of system parameters for the I/O
is set up automatically when loading the software. If a manual configuration is done, make
sure the parameter Connection Type is set to Change-Of-State (COS) connection to get the
most accurate measurement.

How do I set up a non-ABB supplied I/O device?

Only ABB I/O devices are guaranteed to work with BullsEye. Many I/O devices from other
vendors are too slow or too unrepeatable to allow BullsEye to work correctly. When using
non-ABB devices, you may need to slow the scan speed substantially to improve accuracy.
A DeviceNet device from WAGO, for example, may be used in the COS (Change of State)
mode, but the PIT (Production Inhibit Time) should be reduced as much as possible, prefer-
ably to zero. Both is done in the system parameters in the topic I/O, of type DeviceNet
Device.

TCP gauging (BullsEye®) 3HDA000057A8519-001 4-11

Operation

4.9 Operation
TCP gauging is controlled by the robot. The program sequence for TCP gauging is con-
tained in the robot program.

4.9.1 Switching on
When robot control is switched on, the TCP gauging unit is also ready for operation.

CAUTION
Danger of electric shock!

Make sure that all live components are properly cov-

ered.

4.9.2 Function test

A function test is to be performed before using the TCP gauging unit for the first time. The
function test is to be performed in manual mode.

Assembly instructions
CAUTION
Tests must only be performed by qualified personnel.

1. Check that the digital input, which is connected to the TCP gauging unit,
responds properly. To do so, check that the signal is defined on an I/O card as
input.
2. Place your hand through the beam of the TCP control unit, to interrupt the beam. The
LED for the input on the I/A card must light up if the beam is interrupted. If this is not
the case, check that the E/A card and the connections are properly configured.

4.10 Maintenance
TCP gauging is supplied ready for use and apart from cleaning of the device requires
extremely little maintenance work.

Maintenance table

Interval Activity

daily Visual inspection

as needed Clean light entry/exist surfaces with a clean cloth.

as needed Replacement of the fibre-optic sensor if this is defective

4-12 3HDA000057A8519-001 TCP gauging (BullsEye®)

 Maintenance

Replacement of the sensor

If the fibre-optic sensor of TCP gauging is to be replaced due to a defect, it should be
ensured that the 3 switches on the senor are in the illustrated position.

Pos. Switch position

1 Standard
2 T.Off
3 LO

3
Assembly instructions

TCP gauging (BullsEye®) 3HDA000057A8519-001 4-13

Spare parts

4.11 Spare parts

Assembly instructions
Pos. Quantity Name ABB article number

TCP gauging (BullsEye®) 3HDA000000A9324

1 1 Adjusting tip for reference points 0.746.335.025

2 1 Protective sleeve 0.746.335.026
3 1 Fibre-optic sensor SU18-40A/110/115/126A 3HDA000057A5166
Pepperl+Fuchs GmbH
4 1 Fibre-optic KLE-C01-2,2-2,0-K103 3HDA000057A5175
Pepperl+Fuchs GmbH
Optional:
1 TCP gauging 3HDA000057A5435
complete with stand

4-14 3HDA000057A8519-001 TCP gauging (BullsEye®)

 Dimension sheet Gas nozzle

5 Appendix

5.1 Dimension sheet Gas nozzle

Assembly instructions

Appendix 3HDA000057A8519-001 5-1

Dimension sheet Gas nozzle

Assembly instructions

5-2 3HDA000057A8519-001 Appendix

 Safety Data Sheet Release Agent AS 72-K

5.2 Safety Data Sheet Release Agent AS 72-K

After cleaning, the gas nozzle should be sprayed with the release agent AS 72K.

NOTICE
No safety data sheet is required for this product in
accordance with article 31 of the REACH ordinance
(EC) No 1907/2006.

The release agent AS 72-K is not dangerous goods

according to the transport regulations.

The safety data sheet is provided to the information arrangement for the simplification.
Assembly instructions

Appendix 3HDA000057A8519-001 5-3

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5-6 3HDA000057A8519-001 Appendix

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