Programming Manual Control and Power Unit TMP

Programming Manual
Control and Power Unit
TMP
Emhart Teknologies
TUCKER GmbH, Max-Eyth-Straße 1, 35394 Gießen
Tel.: 0641/405-0; Fax.: 0641/405-383; Mail: Info@tucker.de
Table of Contents
1. Menu Access and Selection
1.1
Sub-Menu “Keyboard Functions“
1.2
Sub-Menu “Weld Parameter Monitor“
1.3
Sub-Menu “Programming“
1.3.1 Functions Menü “Programming Weld Parameters“
1.3.2 Functions Menü “Programming Output/Feeder“
1.4
Sub-Menu “Statistics“
1.4.1 “Fault Memory“
1.4.2 “WOP-Memory“
1.4.3 “Weld Output Statistics“
1.4.4 “Weld Program Statistics“
1.4.5 “Maintenance“
1.5
Sub-Menu “Clear Fault Condition“
1.6
Sub-Menu “Status Weld Sequence“
1.7
Sub-Menu “Status Customer Interface“
1.8
Sub-Menu “Status Feeder/Stud Divider“
1.9
Sub-Menu “Status TMP ....“
1.10 Sub-Menu “Functions“
1.10.1 Functions Menu “Display System Configuration“
1.10.2 Functions Menu “Test Mode Cycle Functions“
1.10.3 Functions Menu “Test Mode Outputs Interface“
1.10.4 Functions Menu “Test Mode Weld Process“
1.10.5 Functions Menu “TEST Mode Power Supply“
1.11 Sub-Menu “Warnings“
1.12 Sub-Menu “Extended Functions“
1.12.1 Functions Menu “System Parameters“
1.12.2 Functions Menu “Mechanical Parameter“
1.12.3 Functions Menu “Weld Program“
1.12.4 Functions Menu “Copy Programs“
1.12.5 Functions Menu “Clear Funktions“
1.12.6 Functions Menu “ZCPU System Test“
1.12.7 Functions Menu “De/Activate Program“
1.12.8 Functions Menu “Stud Length Detection“
1.12.9 Functions Menu “Set Date and Time“
Appendix A
Main Menu TMP Systemsoftware
Appendix B
DIP-Switch information
Appendix C
Fault Messages
Appendix D
Error Memory Messages
Appendix E
Messages regarding pilot arc voltage
1
2
3
5
5
8
9
9
11
13
14
15
17
20
22
24
25
27
27
28
30
31
32
34
35
36
37
40
42
44
45
46
47
49
50
61
62
79
80
1.
Menu Access and Selection
When switching the TMP weld unit on the screen display will be activated. The
TMP will identify itself by presenting unit and peripherals types as well as the
corresponding software versions.
Software version 1
TUCKER
System software
Software version 2
#########
V ##.##
Keypad/Display
Central CPU
SMPS
Interface ###########
V ##.##
V ##.##
V ##.##
V ##.##
Output 1
Output 2
Output 3
Output 4
Output 5
V ##.##
V ##.##
V ##.##
V ##.##
V ##.##
#### / ####
#### / ####
#### / ####
#### / ####
#### / ####
TUCKER
System software
Keypad/Display
Central CPU
SMPS
Interface ###########
Output 1
Output 2
Output 3
Output 4
Output 5
#### / ####
#### / ####
#### / ####
#### / ####
#### / ####
<F1..F5> <ESC>
Now please press the
#########
V ##.##
V ##.##
V ##.##
V ##.##
V ##.##
V##.##
V##.##
V##.##
V##.##
V##.##
LM V ##.##
LM V ##.##
LM V ##.##
LM V ##.##
LM V ##.##
<F1..F5> <ESC>
key to open the main menu.
OPERATION
Weld parameter monitor
Programming
Statistics
Fault reset
Status weld sequence
Status customer interface
Status Feeder/Stud-Divider
Status TMP
Functions
Warnings
<↓↑> <ENTER>
<F1..F5>
As soon as the main menu appears on the screen the sub-menues listed can be
selected.
1. Position the cursor with the direction keys
submenu and confirm your selection with
and
on the corresponding
.
2. Sub-menus with alterable contents may also be selected by pressing one of the
function keys listed below directly.
•
•
•
•
•
•
Function key
Function key
Function key
Function key
Function key
Function key
: open main menu "Function Keys"
: open main menu "OPERATION"
: open main menu "Programming"
: open main menu "Monitor Parameters"
: open main menu "Reset Fault"
and
open changing over languages.
1
1.1
Sub-Menu “Keyboard Functions“
The sub-menu “Keyboard Functions“ is selected via the
key. This menu informs
the user about the configuration of the operation control keys.
Key Functions
F1
F2
F3
F4
F5
F6
- Display key functions
- Main menu
- Programming
- weld parameter monitoring
- fault reset
- Release Manual Functions
ESC
ENT
- ESCAPE, abort
- ENTER, confirmation
0..9
+<↓↑>
- input SKK/PK, program no.
- change, set/reset values
- select menu, value
Exit the menu by pressing any key.
Display- and Control Panel
2
1.2
Sub-Menu “Weld Parameter Monitor“
Having selected the sub-menu "Weld Parameter Monitor" using
or through the
direction keys the cursor will move to the first menu line requesting selection of the
TMP output (1-5) to be monitored as well as the program no. (1-27) of the weld
program to be monitored.
Remark: Output "0" described below has a special function.
Weld parameter monitor
SKK/PK outlet : #
Program.No.:. . . . ###
Weld part ident : ################
Autoplunge : ####
Optimization. . . . .####
Vp
Vw
Iw
tw
td
#Lift
Ref
##
##
####
###
##,#
#,##
+tol
##
##
###
##
-tol
##
##
###
##
,##
,##
Act
##
##
####
###,#
##,#
#,##
V
V
A
ms
ms
mm
#
#
#
#
#
#
Fault : ####################################
< 0..5> <ENTER>
<F1..F5> <ESC>
Select output and program number and confirm with
of the display signify the following:
. The individual menu lines
SKK/PK Output 0
The parameters of the weld tool that welded last will be
displayed in the table.
SKK/PK Output 1-5
The parameters of the last weld of the selected weld
tool will be listed.
Progr.-Nr. 0
The parameters of the last weld program will be
displayed in the table.
Progr. Nr. 01 - 127
The parameters of the selected weld program will be
displayed in the table.
Weld part ident
Display of the program ident for the weld part.
Autoplunge:
(tw = weld time)
Yes The deenergization time of the solenoid will be automatically adjusted to the reference stud drop time.
Autoplunge
No
Automatic autoplunge is not activated.
Optimization:
Yes Automatic adjustment of the weld current Iw / weld time
(Up to max. 800A/60ms) tw when welding through impurities on work surfaces.
Optimization:
No
No optimization of weld current (Iw) and weld time (tw).
3
Ref
Preset value set according to weld program.
+ tol
Positive tolerance. "0" selections will not be monitored.
- tol
Negative tolerance. "0" selections will not be monitored.
Act
Actually measured weld parameters of last weld.
Vp [V]
Arc voltage in pilot current phase. *
Vw [V]
Arc voltage in weld current phase.
Iw [A]
Weld current.
tw [ms]
Weld time.
td [ms]
Stud drop time.
Lift [mm]
Lift distance.
An exclamation mark before the text Lift signifies that the
stud length measurement function for SD2 has been
deactivated in terms of position.
* Some voltage values are of particular importance (see Annex E).
Fault
The fault will be displayed that has occured during welding.
Possible fault indications are:
None
Weld cycle without fault.
SMPS
Defect within SMPS, welding was stopped.
Lift Cycle On
Fault when enabling the solenoid.
No arc Voltage
Defective lift; short circuit in weld circuit.
Short circuit weld The last weld performed was a short circuit operation.
Lift Cycle Off
Fault when disabling the solenoid.
Drop Time
Timeout
Monitoring time in weld sequence was exceeded.
No Weld Current
The last weld performed was an open circuit operation.
Faults will be recorded under a fault number in the fault memory.
Selecting the function keys
..
will open the corresponding sub-menu. By
pressing
or
you will access the main menu.
4
1.3
Sub-Menu "Programming"
Please note that opening of the sub-menu "Programming" is
exclusively reserved for authorized and qualified personnel.
Note
The sub-menu "Programming" is to be selected for programming of the weld
parameters as well as the weld outputs and the specific feed times.
Direct access will be accomplished via the function key
cursor on the second line of the main menu and pressing
or by positioning the
.
Programming
Weld parameters
Output/feeder
<↓↑> <ENTER>
<F1..F5> <ESC>
1.3.1 Function Menu "Programming Weld Parameters"
The function menu "Programming Weld Parameters" is selected via the
keys and confirmed via
.
and
Programming weld parameters
Output No . . . . . . . . . . . :
#
Weld programm no . . . . : ###
Weld programm activ. . .
Weld diameter. . . . . . . . .
Workpiece gauge . . . . . .
Workpiece coating . . . . .
Energy adjustment . . . . .
####
#####
#####
########
### %
<1..9> <↓↑> <+,-> <ENTER>
<F1..F5> <ESC>
The significance of the individual menu lines is described on the following pages.
5
Output No.:
The output number defines the weld tool which will be
addressed based on the TMP connector configuration.
When indicating the output the following operation modes are to be differentiated:
Standard
operation
In standard operation (feeder - SKK/PK) the output no. must
be entered corresponding to the TMP connector configuration.
For example: "TMP-pin 1 - feeder 1 - SKK/PK no. 1".
SD2 operation
When using a 2-way stud divider "SD2" only output no. 1 is to
be addressed.
SD5 operation
When using a 5-way stud divider the output no. is to be
entered corresponding to the "SD5" configuration. For
example: "SD5 connector configuration 3 - SKK no. 3".
SD5 operation
When using a 5-way stud divider the output no. is to be
entered corresponding to the "SD5" configuration. For
example: "SD5 connector configuration 3 - SKK no. 3".
Weld Program
No.
For each weld task a specific weld program should be
available which is to be addressed via the corresponding
program no. (1 - 127).
Enter a number between 1 and 5 for the weld output as well as between 1 and 127
for a weld program via the numerical keypad and confirm with
or press
to exit the input mode.
Yes
External program selection enabled.
No
External program selection disabled.
Remark: if no external program selection is requested only
weld program 1 may be activated for the corresponding
output.
Weld diameter
Selection of weld flange diameter.
Flange diameter
Selection of flange diameter in a range from 2 mm - 8 mm
(step size: 1 mm).
SWB10
When welding T-studs with a length of 3,8 mm and a flange
diameter of 3 mm the TUCKER-name SWB10 is to be entered.
Workpiece
Gauge
Selection of sheet thickness of work surface: 0,8 mm, 1,2 mm,
2 mm or >2 mm.
6
Coating
Selection of work surface coating.
none
Untreated work surface.
galvanized
Galvanized work surface.
Energy adjustment
Weld energy adjustment in a range from -50% - +50%
(step size: 5%).
Programming is to be executed by the
and
individual parameters can be either confirmed with
keys. The selections of the
or rejected with
.
By pressing the
or the
key the cursor will move to the field "output no." and
enables further programming. By pressing
you will return to the sub-menu
"programming".
7
1.3.2 Function Menu "Programming Output / Feeder"
The function menu "Programming Output / Feeder" will be selected via the
and
keys in the sub-menu "Programming" and confirmed with
.
Programming output/feed time
Weld output No . : #
Output active....... ####
Feed time............. #### ms
<1..9> <↓↑> <+,-> <ENTER>
<F1..F5> <ESC>
Weld output no. The weld output no. will define the weld tool which will be
addressed based on the TMP connector configuration.
Yes
The output of the TMP weld unit is activated.
No
The output of the TMP weld unit is not activated.
Feed time
The time between feeding signal and arrival of the stud in the
stud receiver is to be selected in a range from 50ms - 1600ms.
Remark: Programming is to be performed via the numerical keys, the
keys as well as the
and
keys.
8
and
1.4
Sub-Menu "Statistics"
The sub-menu "Statistics" will be selected by positioning of the cursor on the third
line of the main menu and by presing the
key. The sub-menu "Statistics"
contains sub menus in which information on faults, welds and maintenance are
recorded.
Statistics
Fault memory
WOPs memory
Weld output statistics
Weld program statistics
Maintenance
<↓↑> <ENTER>
<F1..F5> <ESC>
1.4.1 Sub-Menu "Fault Memory"
By positioning the cursor on the first line of the sub-menu "Statistics" and then
pressing the
key you can access the "Fault Memory" screen.
Fault memory
Fault no.
###
O Prg
Fault type
No.
Date
Time
#
#
#
#
#
#
###########
###########
###########
###########
###########
###########
###
###
###
###
###
###
##.##.##
##.##.##
##.##.##
##.##.##
##.##.##
##.##.##
##:##:##
##:##:##
##:##:##
##:##:##
##:##:##
##:##:##
###
###
###
###
###
###
Fault description:
<↓↑>
<F1..F5> <ESC>
The individual menu lines will be described on the following page:
Fault Memory
All faults of the equipment will be recorded.
Fault No.
Number of fault on which the cursor is positioned.
9
A
Display of output 1 - 5.
Prg
If faults occur during the weld sequence the weld program
will be displayed.
Fault Type
Information at which component the fault occurred
(unit / SKK/PK / feeder / stud divider).
No.
No. of fault message.
Date
Date of fault.
Time
Time of fault.
Fault Description Short fault description (according to current cursor position).
With the keys
and
you can alternately display the fault memory.
By pressing
you will return to the sub-menu "Statistics". By pressing
will return to the main menu.
you
Trouble Shooting Information:
• Faults can be reset based on the information "Fault Messages".
• Faults which can not be reset on location through the listed remedial measures
require the replacement of the weld unit.
• Faults occurred at a peripheral unit are to be remedied based on the information
given in the corresponding operating manual.
• Faults will be reset in the menu "Clear Fault Condition".
10
1.4.2
"WOP- Memory"
The "WOP-Memory" contains messages and information about welds out of
tolerance (Weld Outside Parameter = WOP)
The "WOP-Memory" screen can be accessed by positioning of the cursor on the
second line of the sub-menu "Statistics" and by pressing
.
WOP-mem Outlet:# Prog:###
Page:###
Weld part ident : ################
Date........ ##.##.##
Time .......... .##:##:##
Autoplunge. ..####
Optimization.... ...####
Ref
+tol -tol
Act
Vp
##
##
##
## V
#
Vw
##
##
##
## V
#
Iw
#### ### ###
#### A
#
tw
###
##
## ###,# ms #
td
##,#
##,# ms #
#Lift
#,##
,##
,##
#,## mm #
Fault : #################################
<0..5>
<↓↑> <ENTER> <F1..F5> <ESC>
Select output number and confirm with
display signify the following:
WOP-Memory
Weld part ident
O
. The individual menu lines of the
Prog.
Page
Record for all welds out of tolerance.
Display of the program ident for the weld part
Those outputs for which WOP‘ s are to be displayed
can be entered with the numerical keys 1 - 5.
With the key 0 all WOP‘ s will be displayed in
sequence of their occurrence.
The selection must be confirmed with
.
Display of current weld program.
Display of current page.
Date
Time
Date when WOP occurred.
Time when WOP occurred.
Autoplunge:
Yes
The de-energization time of the solenoid will be automatically adjusted to the reference stud drop time.
No
Automatic autoplunge was not activated.
(tw = weld time)
Autoplunge:
Optimization:
Yes
(up to max. 800A/60ms)
An automatic adjustment of the weld current Is / weld
time ts when welding through impurities on work
surface was performed.
Optimization:
No optimization of weld current lw and weld time tw
performed.
No
11
Ref
Preset value set according to weld program.
+ tol
Positive tolerance. "0" selections will not be measured.
- tol
Negative tolerance. "0" selections will not be measured.
Act
Actually measured weld parameters of the last weld
performed.
Vp [V]
Arc voltage in pilot current phase.
Vw [V]
Arc voltage in weld current phase.
lw [A]
Weld current.
tw [ms]
Weld time.
td [ms]
Stud drop time.
Lift [mm]
Lift distance.
Fault
The fault will be displayed that has occured during welding.
• Possible fault messages are:
None
Weld sequence without fault.
SMPS
Defect within SMPS, welding was stopped.
Lift Cycle On
Fault when enabling the solenoid.
No arc voltage
Defective lift; short circuit in weld circuit.
Short circuit weld
The last weld performed was an short circuit operation.
Lift Cycle Off
Fault when disabling the solenoid.
Drop Time
Timeout
Monitoring time in weld sequence was exceeded.
No weld currentt
The last weld performed was an open circuit operation.
The WOPs can be alternately displayed with the keys
and
.
By pressing
you will return to the sub-menu "Statistics". By pressing
will return to the main menu.
12
you
1.4.3
"Weld Output Statistics"
By positioning the cursor on the third line of the sub-menu "Statistics" and then
pressing the
key you can access the memory menu "Weld Output Statistics"
screen.
Weld outlet statistics
Number of
O WIP&WOP
1 #######
2 #######
3 #######
4 #######
5 #######
WOP
Number of repeat
lim act
WOP
#######
#
#
#######
#
#
#######
#
#
#######
#
#
#######
#
#
Number
of faults
######
######
######
######
######
auto
rep.feed
#####
#####
#####
#####
#####
<F1..F5> <ESC>
The individual menu lines signify the following:
Output
Display of the output the statistics are related to.
Number of WIP & WOP Total number of welds.
Number of WOPs
Total number of welds out of tolerance.
WOP repeat limit
Display of programmed acceptable sequential welds
that may be out of tolerance.
Actual WOP repeat
Actual number of sequential welds out of tolerance.
Number of faults
Total number of faults occurred.
Auto refeed
No. of studs automatically supplied due to missing
SOW-signal during internal slide rail control.
The information for the individual weld programs can be alternately displayed with
the keys
and
.
By pressing
you will return to the sub-menu "Statistics".
By pressing
you will return to the main menu.
13
1.4.4
"Weld Program Statistics"
By positioning the cursor on the fourth line of the sub-menu "Statistics" and then
pressing the
key you can access the memory menu "Weld Program Statistics"
screen.
Weld program statistics
number
of
WIP&WOP
#######
#######
#######
#######
#######
#######
#######
#######
Prog
Outlet:#
number
of
WOP
#######
#######
#######
#######
#######
#######
#######
#######
<↓↑>
WOP
repeat
lim  act
#
#
#
#
#
#
#
#
#
#
#
#
#
#
#
#
auto.
rep.
feed
#####
#####
#####
#####
#####
#####
#####
#####
<F1..F5> <ESC>
Select output number and confirm with
display signify the following:
. The individual menu lines of the
Weld Program Statistics Statistics of welds within and out of tolerance for the
individual outputs.
Output
Selection of the ouput for which statistical information
is to be displayed.
Prog
Display of the program the statistics are related to.
Number of WIP & WOP Total number of welds.
Number of WOPs
Total number of welds out of tolerance.
WOP repeat limit
Display of programmed acceptable sequential welds
that may be out of tolerance.
Actual WOP repeat
Actual number of sequential welds out of tolerance.
Auto refeed
No. of studs automatically supplied due to missing
SOW-signal during internal slide rail control.
The information for the individual weld programs WOP‘ s can be alternately
displayed with the keys
and
.
By pressing
you can select another output, by pressing
return to the sub-menu "Statistics".
By pressing
you will return to the main menu.
14
again you will
1.4.5 "Maintenance"
The "Maintenance" screen contains information about the condition of the
connected weld tools due to wear.
By positioning the cursor on the fifth line of the sub-menu "Statistics" and then
pressing the
key you can access the "Maintenance" screen.
Maintenance
Collet maint. – No. welds
1
2
Act.
###### ######
Warn. ###### ######
Fault
###### ######
3
######
######
######
4
######
######
######
###,#
+# -#
+# -#
###,#
+# -#
+# -#
5
#####
#####
#####
Monitor - drop time (ms)
Act.
Warn.
Fault
###,#
+# -#
+# -#
###,#
+# -#
+# -#
###,#
+# -#
+# -#
<F1..F5> <ESC>
The individual menu lines signify the following:
Maintenance
The wear of the collet as well as the drop time of the connected
weld tools will be displayed.
Collet Maint.No. of Welds
Weld statistics will begin with assembly of new collet.
Act.
Actual number of welds performed with a collet.
Warn.
Programmed number of welds with which, when exceeded, the
corresponding maintenance warning will become active.
Fault
Programmed number of welds with which, when exceeded, the
weld output will be set into fault condition.
Monitor Drop
Time (ms)
Monitoring of the mechanical parameter "stud drop time".
Act.
Deviation of actual measured stud drop time from the programmed one will be displayed.
Warn.
Programmed deviation with which, when exceeded, the corresponding maintenance warning will become active.
Fault
Programmed deviation with which, when exceeded, the corresponding weld output will be set to fault condition.
Remark: After replacing the collet the maintenance meter must
be reset.
Remark: The difference refers to the established drop time of
the past 8 welds in relation to the programmed (!) drop time.
15
Maintenance Information:
• The maintenance warning will be transmitted to the customer interface and will
appear as " ! " in the corresponding field of the sub-menu " Status TMP . . . . ".
• Irrespective of the TMP unit maintenance warnings the prescribed maintenance
intervals of the unit components must be maintained.
• Information on the specific maintenance works can be read from the
corresponding operating manuals.
• Having repaired the unit components the maintenance statistics in the menu "
Clear Functions" must be reset to " 0 ".
16
1.5
Sub-Menu "Clear Fault Condition"
The sub-menu "Clear Fault Condition" can be selected directly with the function
key
or by positioning the cursor on the fourth line of the main menu
"OPERATION" and then pressing
.
In case of no fault condition the following will be displayed on the monitor when the
sub-menu "Clear Fault Condition" is selected:
OPERATION
Weld parameter monitoring
Programming
Statistics
Fault reset
No fault exist
Status TMP
Functions
Warnings
<↓↑> <ENTER>
<F1..F5>
In case of a TMP system fault all fault sources will be displayed
Fault condition
To continue operation clear
the fault condition.
<F1..F5> <ESC>
If system faults requires the opening of the weld unit it is exclusively
reserved for authorized and qualified personnel. All fault messages
will be cleared when the TMP unit is switched on again, following
the remedy of the fault condition.
17
In case there are simultaneous faults at other TMP outputs apart from the unit
faults (flashing of one, of several or of all "operation/error"-LED‘ s) these can be
represented as follows after the system fault has been remedied.
Fault output #
<RESTART>
<SET WC>
<←↓↑→> <ENTER>
<STUD>
<F1..F5> <ESC>
Select output and program number and confirm with
of the display signify the following:
Fault Output #
. The individual menu lines
The fault is only related to the TMP output displayed. All faults
of this output will be listed.
The fault occurred will cause a defective weld cycle.
In case there are simultaneous faults at other TMP outputs these can be
represented alternately with the direction keys
and
.
The sub-menu "Clear Fault Condition" offers the user several possibilities how to
deal with fault messages
The below mentioned operations can be selected with the two cursor keys
and activated by pressing the
key.
,
RESTART
By selecting RESTART the fault will be reset and the weld will
be performed if there is a start weld signal, if possible.
SET WC
With the command SET WC the fault will be reset, if possible
and the signal "Welding complete" will be issued.
STUD
With the command STUD a stud feeding cycle will be initiated,
if possible.The screen display remains the same; the fault
message will not be reset.
Remark: In case the fault message will not reset after having performed the
corresponding operation the following message will be displayed:
"Function cannot be performed"
18
Please note the remedial measures in the corresponding operating manuals for
the reseting of faults at unit peripherals.
Having reset the fault the menu selected before the fault occurred will be redisplayed automatically.
Irrespective of the removal of faults you can exit the sub-menu "Fault Reset" by
pressing
and return to the main menu.
Remark: If the fault can not be cleared by either RESET, RESTART or SET WC
reseting of faults is limited to the remedial measures listed in section "Fault
Messages".
Operational defects of the weld equipment which can not be
cleared through the listed remedial measures are to be fixed by
qualified service personnel.
19
1.6
Sub-Menu "Status Weld Sequence"
The sub-menu "Status Weld Sequence" is to be selected for obtaining an overview on the weld circuit-related signals. Position the cursor on the corresponding
menu line of the main menu and press the
key.
Status weld sequence
Weld cycle
Feed cycle
SOW
Angularity switch PK
Start weld
Start feed
SKK R-position
I. Tolerance
Program number
1
#
#
#
#
#
#
#
#
###
2
#
#
#
#
#
#
#
#
###
3
#
#
#
#
#
#
#
#
###
4
#
#
#
#
#
#
#
#
###
5
#
#
#
#
#
#
#
#
###
<F1..F5> <ESC>
The individual menu lines of the dispay signify the following:
The status information is related to output 1 ... 5 of the TMP-weld unit.
Weld cycle
*:
Weld cycle operation.
-:
No weld cycle operation.
*:
Stud feeding operation.
-:
No stud feeding operation.
*:
SOW (stud on workpiece) signal is active.
-:
No SOW signal.
Angularity
switch PK
*:
Angultary signal is active.
-:
No angultary signal.
Start weld
*:
Start weld signal is active.
-:
No start weld signal.
*:
Start feed signal is active.
-:
No start feed signal.
Feed cycle
SOW
Start feed
20
SKK R-position
I/O Tolerance
Program
SKK retracted signal is active.
-:
No SKK retracted signal
*:
Parameters are within the operating tolerance range.
-:
Parameters are out of operating tolerance range
1-127 : Display of program no under which the last weld was
number
By pressing
*:
performed.
or
you will return to the main menu.
21
1.7
Sub-menu "Status Customer Interface"
The sub-menu "Status Customer Interface" is to be selected for obtaining an
overview on interface signals given. Position the cursor on the sixth menu line of
the main menu and press the
key.
Status customer interface
Operation mode
Start weld
Start feed
Without weld
Reset fault
Restart
Set WC
Start SKK F-pos.
Start SKK R-pos.
Program number
#
#
#
#
#
#### #### #### #### ####
#
#
#
#
#
#
#
#
#
#
#
#
#
#
#
#
#
#
#
#
#
#
#
#
#
#
#
#
#
#
#
#
#
#
#
#
#
#
#
#
###
###
### ### ###
<F1..F5> <ESC>
The individual menu lines of the display signify the following:
Status information is related to output 1 ... 5 of the TMP - weld unit.
AUT
Selected operation mode: "automatic".
MAN
Selected operation mode: "manual".
STOP
Selected operation mode: "operation stop".
The following menu lines represent through “ * “ whether a signal has been given
or through“ - “ that a signal has not been given.
Start Weld
Start Feed
Without weld
Reset fault
*:
The signal "start weld " is set via the interface.
-:
The "start weld" signal has not been set
*:
The signal "start feed" is given via the interface.
-:
The signal "start feed" has not been set
*:
The signal "without weld" has been set.
-:
The signal "without weld" has not been set
*:
The signal “reset fault“ is set.
-:
The signal “reset fault“ has not been set.
22
Restart
Set WC
Start SKK F-pos.
*:
The signal "restart" has been set.
-:
The signal "restart" has not been set
*:
The signal “Weld complete“ is set.
-:
The signal “Weld complete“ has not been set.
*:
The signal for advancing the weld head slide rail is set.
-:
The signal "start SKK extend" has not been set
Start SKK R-pos. *:
-:
The signal for retracting the weld head slide rail is set.
The signal “start SKK retract“ has not been set.
Program number 1...127: Number of the weld program selected via the
customer interface.
Remark: If a signal is set the corresponding command is given via the customer
interface.
By pressing
or
you will return to the main menu.
23
1.8
Sub-menu "Status Feeder / Stud Divider"
The sub-menu "Status Feeder / Stud divider" is to be selected for obtaining an
overview on the feeder and stud divider signals. Position the cursor on the seventh
menu line of the main menu and press the
key.
Status feeder / stud divider
#
Operation mode
###
Feed cycle
#
Piston retracted
#
Pos. Stud divider
#
SKK R-position
#
Angularity switch PK
#
Start weld
#
Start feed
#
Stud level low
#
#
###
#
#
#
#
#
#
#
#
#
###
#
#
#
#
#
#
#
#
#
###
#
#
#
#
#
#
#
#
#
###
#
#
#
#
#
#
#
#
<F1..F5> <ESC>
The individual menu lines of the display signify the following:
Status information is related to output 1 ... 5 of the TMP - weld unit.
Operation Mode
Feeder is in operation mode "Automatic","Manual" or "Test".
Feed cycle
*:
Display that a feeding cycle is performed.
-:
No feeding cycle performed.
Piston retracted
*:
-:
SKK/PK piston is retracted.
Piston is not retracted.
Position Stud Div.
*:
Display of current stud divider position.
-:
No stud divider position recognized.
*:
SKK is retracted.
-:
No input signal “SKK retracted“.
Angularity switch
PK
*:
-:
Angultary signal is active.
No angultary signal.
Start weld
*:
Start weld signal is active.
-:
No start weld signal.
*:
Start feed signal is active.
-:
No start feed signal.
*:
-:
Stud level low signal is active.
No stud level low signal.
SKK retracted
Start feed
Stud level low
By pressing
or
you will return to the main menu.
24
1.9
Sub-menu "Status TMP . . . . "
This sub-menu contains specific messages and information on the peripheral
units. Position the cursor on the eighth menu line of the main menu and press the
key.
Status TMP
Date. . . . . . . . . . . ##.##.##
Software. . . . . . .
V##.##
Interface.
###########
Operation stop. . . .
####
#
#
Connection
##### #####
SF-Typ
####
####
SKK/PK
###
###
SF..A/D
#
#
Lift sensor
####
####
Maintenance
#
#
Time . . . . . . . ##.##.##
Address. . . . . . . . . ###
SMPS ready. . . . . ####
Emergency . . . . . . ####
#
#
#
##### ##### #####
####
####
####
###
###
###
#
#
####
####
####
#
#
<F1..F5> <ESC>
By pressing
or
you will return to the main menu.
The individual menu lines of the display signify the following:
Date
Shows the date in the sequence of "day.month.year".
Time
Shows the time in the sequence of "hour:minutes:seconds".
Software
The version no. (V ##.##) informs about the present software
version of the TMP weld unit.
Address
When connecting several TMP weld units to a central personal
computer each TMP must be attributed a customer-specific address
Interface
The following customer interface are possible: parallel, Interbus-S,
Profibus DP or no interface.
SMPS ready The weld energy source SMPS is ready / not ready
Stop
Operation
Emergency
Connection
Display of existing / not existing stop operation
Display of existing / not existing emergency stop
norm:
SD2-M
SD2-S:
SD5-Z:
SD5-W:
PKE:
standard feeder configurated
master feeder SD2 configurated
slave feeder SD2 configurated
SD5 feeder configurated
SD5 divider configurated
manual gun extension configurated
25
SF-Typ
Represents the connected feeder type, i.e. SF 12, SF 50, SF 52,
SF 53, SF 54, SF 56. If no feeder is connected,“ - “ is displayed.
SKK/PK
If a weld head is connected, SKK is displayed, otherwise PK or
“ - “ is displayed.
SF..A/D
If the feeder is equipped for slide rail control, “ D “ is displayed,
otherwise “ A “ or “ - “ is displayed.
Lift sensor
If the weld head is equipped for lift measuring, “ yes “ is displayed,
otherwise “ no “ or “ - “ is displayed.
Maintenance
If the weld tool exceeded the programmed limit value, “ ! “ is
displayed, otherwise “ - “ is displayed.
26
1.10 Sub-menu "Functions"
This sub-menu contains a command mode for the manual control of the TMP as
well as the possibility to display the software levels.
The sub-menu "Functions" will be opened by positioning the cursor on the last
menu line of the main menu and by pressing the
key.
The individual functions are to be selected via the keys
,
and
.
.Functions
display system configuration
test mode cycle functions
test mode outputs interface
test mode weld process
test mode power supply
<↓↑> <ENTER>
By pressing
or
<F1..F5> <ESC>
you will return to the main menu.
1.10.1 Function Menu "Display System Configuration"
This sub-menu will be selected by positioning the cursor on the first menu line of
the sub- menu "Functions" and by pressing the
key.
EMHART
TMP
####
System software
V ##.##
Keypad/Display
Central CPU
SMPS
V ##.##
V ##.##
V ##.##
Interface
Outlet 1
Outlet 2
Outlet 3
Outlet 4
Outlet 5
V ##.##
V ##.##
V ##.##
V ##.##
V ##.##
V ##.##
###########
#### / ####
#### / ####
#### / ####
#### / ####
#### / ####
<F1..F5> <ESC>
The TMP will identify itself by displaying unit and peripherals as well as the
corresponding software versions.
By pressing
you will return to the sub-menu "Functions".
27
1.10.2 Function Menu "Test Mode Cycle Functions"
In test mode important control commands can be given directly at the control
panel. These control commands supersede external customer control and will be
executed immediately.
This sub-menu will be selected by positioning the cursor on the second menu line
of the sub- menu "Functions" and by pressing the key
Test mode cycle functions
1
2
Cyclus
##### #####
SKK F-pos. ##### #####
SKK R-pos. ##### #####
Start feed
##### #####
Lift
##### #####
Set WC
##### #####
Color mark ##### #####
Reference outlet :
#
SKK ext. . . #### ms
SKK ret. . . #### ms
3
4
#####
#####
#####
#####
#####
#####
#####
#####
#####
#####
#####
#####
#####
#####
5
#####
#####
#####
#####
#####
#####
#####
Drop time. . . ##, # ms
Lift. . . . . . . . #, ## ms
<←↓↑→> <ENTER>=Start
<F1..F5> <ESC>
To execute a certain function the corresponding menu line as well as the TMP
output number is to be selected with the cursor keys. The start command will be
given by operating the
key.
Remark:
Test mode will be automatically cancelled if no key is operated within 60s.
- As a precaution additionally the “
Attention:
“ - key must be pressed.
With certain software levels (f.i. System V1.30, OPEL carline) these
test functions may still be performed despite the system being in stop
operation mode.
The individual menu lines of the display signify the following:
Cycle
The command for executing a weld sequence test without
performing an actual weld can be given.
SKK ext.
The command for advancing the weld head can be given.
SKK ret.
The command for retracting the weld head can be given.
Start feed
The command for “stud feeding“ can be given.
Lift
The command for executing a lift can be given.
28
Set WC
A WC-signal is generated for the selected output
Color mark
A color mark is generated for the selected output
The readings of the selected TMP output will be displayed in menu lines 10
and 11. If the connected SKK is equipped with a lift measuring system
(option) the measured lift will be displayed in menu line 11.
By pressing
you will exit the "test mode cycle functions". By pressing
will return to the main menu.
29
you
1.10.3
Function Menu "Test Mode Outputs Interface"
In the function menu "Test Mode Outputs Interface" the customer interface
signals may be set and tested.
This sub-menu will be selected by positioning the cursor on the third menu line
of the sub- menu "Functions" and by pressing the
key.
Test mode outputs interface
Operation mode
Ready
SOW
SKK R-position
I.Tolerance
Fault
WC
Maintenance
Emergency stop
Fault code
1
2
3
4
5
#### #### #### #### ####
#
#
#
#
#
#
#
#
#
#
#
#
#
#
#
#
#
#
#
#
#
#
#
#
#
#
#
#
#
#
#
#
#
#
#
#
#
#
#
#
### ### ### ### ###
<←↓↑→> <ENTER>=Start
<F1..F5> <ESC>
The cursor can be moved within the table with the direction keys. Signals will be
set or cancelled by pressing
or
.
The individual menu lines of the dispay signify the following:
Operation
mode
The following operation modes can be simulated: AUTO, TEST,
PROG, ERR, STOP, NO
Outputs
The following outputs can be connected: ready, SOW, SKK back,
i. tolerance, fault, WC, maintenance, emergency stop.
Fault code
An fault code no. from 1 - 255 can be set.
The test mode can only be performed if the signal for stop
operation has been set by customer control.
By pressing
you will exit the "Test Mode Outputs Interface" mode. By pressing
you will return immediately to the main menu.
30
1.10.4 Function Menu "Test Mode Weld Process"
During test mode all signals at the customer interface will be processed as in
standard operation. Control commands will be executed without the weld cur-rent
being enabled.
This function will be selected by positioning the cursor on the fourth menu line of
the sub- menu "Functions" and by pressing the
key.
Test mode weld process
1
2
3
4
5
Weld cycle
#
#
#
#
#
Feed cycle
#
#
#
#
#
SOW
#
#
#
#
#
Angularity switch PK
#
#
#
#
#
Start weld
#
#
#
#
#
Start feed
#
#
#
#
#
SKK R-position
#
#
#
#
#
I.Tolerance
#
#
#
#
#
Program number
### ### ### ### ###
Warning ! The TMP-unit will work in test mode
However the unit will not weld !
<F1..F5> <ESC>
Regarding the function, this menu isidentical with the menu “Status Weld
Process“. It displays various process data.
The test mode can only be performed if the signal for “Without
welding“ has been set by customer control.
By pressing
or
you will return to the main menu.
31
1.10.5 Functions Menu “Test Mode Power Supply“
In the Function Menu "Test Mode Power Supply" the function of the SMPS can be
tested in a short circuit
•
Select the requested function menu with the direction keys
•
Confirm your entry with
and
.
.
Test mode power supply
Output No. . . . . . . . . . . :
Quantity of testcycles. :
#
###
Start . . . . . . . . . . . . . . . :
#####
Actual weld current . . . . :
Actual cycle count. . . . . :
#### A
###
The short circuit test can be stopped
with the <ESC> key
<←↓↑→> <+, -> <ENTER>
<F1..F5> <ESC>
• Select the output that is to be tested.
• Position the cursor on the menu line "Start".
•
Confirm your entry with
• Press
.
to start the test cycle.
Remark: Test mode will be automatically cancelled if no key is operated within 60 s.
•
Press
and
simultaneously to start the function.
Remark: With some software versions it is possible to execute these test functions
even with an active Operation stop.
The individual menu lines of the display signify the following:
Output nr.
Select the output for which the test mode is to be executed
Number of cycles
(ref)
Number of test cycles that are to be simulated.
Start
Press the keys
function
and
32
simultaneously to start the
Weld current act
The measured weld current
Number of cycles
(act.)
Number of test cycles executed
•
By pressing
you will return to the function menu.
•
By pressing
you will return to the main menu.
33
1.11
Function Menu "Warnings"
The sub-menu “Warnings“ can be accessed by positioning the cursor on the tenth
line of the main menu “OPERATION“ and by pressing the key
If there is no warning message available when selecting the sub-menu “Warnings “
the following screen message will be displayed:
OPERATION
Weld parameter monitor
Programming
Statistics
Fault reset
No warning message available
Status TMP
Functions
Warnings
<↓↑> <ENTER>
<F1..F5>
Warnings will be marked by “ slow “ flashing of the corresponding output LED. If
there are warnings available they will be displayed in the sub-menu “Warnings“.
Warnings
<F1..F5> <ESC>
The following warnings can be displayed:
Maintenance
clamping tongs
The number of welds exceeds the set limit value
Maintenance weld
head
The gun drop time established via 10 welds exceeds
the programmed limit values (the differences to the
programmed drop time are evaluated).
Level to low
The proximity switch for monitoring the filling level in the
stud feeder is not covered.
C-CPU: empty
The battery in the RAM-module on the central CPU is
battery RAM-module run down. Before replacing the RAM-module a backup
via PC should be performed.
C-CPU: empty
The battery for securing the real-time clock is run down
battery clock
and must be replaced.
34
1.12
Sub-Menu "Extended Functions"
Access to the sub-menu "Extended Functions" is secured by a
code and is exclusively reserved for the service personnel.
Extended functions
System parameters
Mechanical parameters
Weld parameters
Copy programs
Clear functions
ZCPU system test
De / activate programs
Stud length detection
Set date and time
<↓↑> <ENTER>
<F1..F5> <ESC>
This menu gives access to all data which are related to the weld process.
The menu “Extended Functions“ can be accessed via the sub-menu “Programming“ by pressing first the < + > key and then the < 0 > key.
There is also the possibility to access the individual sub-menues directly through
the following codes.
<+>
<1> :
System parameters
<+>
<2> :
Mechanical parameters
<+>
<3> :
Weld parameters
<->
<99> :
Clear functions
35
1.12.1 Function Menu "System Parameters"
This function menu will be selected by positioning the cursor on the first menu line
of the "Extended Functions" menu and by pressing the
key.
TMP version1
TMP version 2
System parameters
Address
System parameters
Interface . . . . . ###
Network . . . . . .###
Language . . . .
. . ###########
Parameter printout:
. . . . . #######
###########
#############
##########
<↓↑> <+, -> <ENTER>
Address Interface
Address Network
Address
Interface . . . . . . ###
Network . . . . . . .###
Language . . . . . . . . . . . . . .###########
<F1..F5> <ESC>
<↓↑> <+, -> <ENTER>
<F1..F5> <ESC>
The unit address Interface serves to identify the TMP
when connecting it to the Pro-Bus customer interface.
The unit address Network serves to identify the TMP
when connecting several weld units to a central PC.
Select a number between 1 and 255 to identify the unit.
Language
There are two country-specific languages available to the
user for the communication between the TMP weld unit
and the operating personnel.
Parameter printout The printer output can be activated and adapted here
- Printing of WOP or WIP and WOP
- Individual or all weld outputs
- Bautrate
36
1.12.2 Function Menu "Mechanical Parameters"
This function menu will be selected by positioning the cursor on the second menu
line of the "Extended Functions" menu and by pressing the
key.
Mechanical parameters outlet : #
Outlet active . . . .####
Slide rail . . . .
######
Start feed . . . . ##################
Feedtime . . . . . . ####
Loadtime . . . . . ####
Repeat feed . . . .####
Feed adj . . . . . .
Permitted WOP .
#
Color mark . . . . .
Protect. gas . . . .####
Air blow . . . . . . .
Pre-gas (ms) . . . ####
Angularity . . . . . .
Post-gas (ms) . . ####
Stud monitor. . . .
Maint. at . . . . ######
tp-Maint . . . . . . +
Fault at . . . . ######
tp-Fault . . . . . . +
<1..5> <←↓↑→> <+,-> <ENT>
####
####
####
####
####
#-#
#-#
<F1..F5> <ESC>
When the menu "mechanical parameters" has been opened the cursor will move
into the heading requesting the input of the selected SKK/PK outlet no. (1 - 5).
SKK/PK: No. in
standard
operation
In standard operation (feeder - SKK/PK) the SKK/PK no. is to be
entered according to the TMP configuration. For example: "TMP
output 1 - feeder 1 - SKK/PK No. 1".
SKK/PK: No in
For programming the weld head parameters as well as for
operation with SD2 programming the parameters of the "master" feeder select only the
SKK/PK output no. 1.
Information: In order to program the feeding time of the second
stud feeder select SKK/PK output no. 2 while the menu line
"SKK/PK active" displays "yes".
SKK/PK: No. in
operation with
SD5
When operating with a 5-way stud divider the SKK no. must be
entered as it is at the "SD5-stud divider".
For example: "SD5-output 3 - SKK No. 3".
Enter the respective SKK/PK output no. with the numerical keys and confirm with
The cursor is now positioned in the first menu line requesting input. With the
direction keys you can access the various menu lines directly.
The individual menu lines of the display signify the following:
SKK/PK active
Yes : The output of the TMP-weld unit is activated.
No :
Slide rail
The output of the TMP-weld unit is not activated.
Internal: The SKK slide rail will be controlled by the TMP-weld unit.
External: The SKK slide rail will be under customer-specified control.
37
Start feed
Extern after SOW: The customer may execute a start signal for
"stud feeding" after the collet has disengaged from the welded
stud.
Intern after SOW: The TMP weld unit will execute the "stud feeding"
cycle after the collet has disengaged from the welded stud.
Extern after WC: The customer may execute a start signal for
"stud feeding" after the end of each welding process.
Internal after WC: The TMP weld unit will execute the "stud feeding"
cycle after the end of each welding process.
Feedtime
The time between executing the stud feeding signal and arrival of
the stud in the receiver can be adjusted in a range from of 50 ms 1600 ms.
Loadtime
T-Studs SWB 10 with SF 54: The time between piston retract
signal and the end of feedtime can be adjusted in a range from
50 ms - 1600 ms.
Other Studs with SF ..: The time between piston retract signal and
enabling of the blow air can be adjusted in a range from
50 ms - 1600 ms.
Repeat
feed
Yes: If the SOW signal is not recognized when the weld tool
moves forward the feeding process will be repeated.
No:
No auto-refeed requested.
Feed
adjustment
Yes: The feeding cycle is terminated upon arrival of the stud in
the weld tool disregarding the feeding time.
(Condition: SKK/PK is equipped with a sensor for weld stud
detection).
No: No automatic feed adjustment.
Permitted
WOP
Sequential welds out of tolerance can be limited by the customer
by selecting a number between 1 - 9. When this number has been
reached the welding operation will be interrupted.
Color mark
Yes:
When connecting color marking units SMB 128 (option) welds
out of tolerance will be marked by color.
No:
Welds out of tolerance will not be marked by color.
Protec. gas Yes: Shielded arc welding operation with gas (option) is activated
No:
Shielded arc welding operation with gas is not activated.
38
Air blow
Yes: If the weld tool is optionally equipped with an air nozzle
for clearing the work surface, it will be activated
No:
Air nozzle for clearing the work surface will not be activated.
Pre-gas
The time of protect. gas flow before weld begin can be adjusted
in a range from 0 ms - 1000 ms.
Post-gas
The time of protect. gas flow after the weld has been performed
can be adjusted in a range from 0 ms - 1000 ms.
Angularity
switch
Yes : n.c.
Stud monitor
Yes: Stud length detection will be activated.
Special case SD2: Additionally testing of the feeder
allocated by the programm is activated.
No: Stud length detection will not be activated.
Maint. at
0...950.000 : Number of welds with a collet after which the
maintenance warning will be activated (step size: 5000).
" 0 " selections will not be monitored.
tp-Maint.
0 - ±8 : Tolerance value for testing the drop time. If it is exceeded
the maintenance warning will be activated.
" 0 " selections will not be monitored.
Fault at
0...950.000 :. Number of welds with a collet after which the output
will be set into fault condition (step size: 5000).
“ 0 “ selections will not be monitored.
tp-Fault
0 - ± 8 : Tolerance value for testing the drop time. If it is exceeded
the output will be set into fault condition.
“ 0 “.selections will not be monitored.
No :
n.c.
Remark: Programming is to be effected via the
Programmed parameters will be confirmed with
exit the input mode by pressing the
key.
39
and
keys
or rejected with
. You may
1.12.3 Function Menu "Weld Program"
This function menu will be selected by positioning the cursor on the third menu line
of the "Extended Functions" menu and by pressing the
key.
This menu consists of two monitor pages. You can alternately display them by
pressing the keys
and
in the corresponding menu line.
Outlet: #
Weld program: ###
Program active . . . . . .
####
Pilot current . . . . . . . ..
Pilot current time. . . . .
Weld current . . . . . . .
Weld current time . . . .
Varc pilot current. . . . .
Varc weld current . . . .
Optimization. . . . . . . .
Weld type . . . . . . . . . .
Program continues
## A
## ms
#### + ###
### + ##
## + ##
## + ##
####
###########
- ###
- ##
- ##
- ##
A
ms
V
V
<##>
<1..5> <←↓↑→> <+,-> <ENT>
<F1..F5> <ESC>
When the menu "Weld Program" has been opened the cursor will move into the
heading requesting the input of the selected outlet no. (1 - 5).
Enter the outlet no. as well as the number of the weld program with the numerical
keys and confirm each with
.
Now the cursor is positioned in the first menu line. You can access the various
menu lines with the direction keys
and
directly.
Program active
Yes : External program selection enabled
No : External Program selection disabled.
Remark: if no external program selection is requested only weld
program 1 may be activated for the corresponding output.
Pilot current
Selection of pilot current in a range from 20A - 30A.
Pilot current time Selection of pilot current time 30 ms - 60 ms.
Weld current
Selection of weld current in a range from 100A - 1000A.*
+ tolerance
Positive tolerance from 0 - 100A (Selection of “0“ will cancel monitoring)
- tolerance
Negative tolerance from 0 - 100A (Selection of “0“ will cancel monitoring)
* depending on the unit type!
Weld current time Selection of weld time in a range from 6 ms - 1000 ms.
+ tolerance
Positive tolerance from 0 - 8 ms (Selection of “0“ will cancel
monitoring)
- tolerance
Negative tolerance from 0 - 8 ms (Selection of “0“ will cancel monitoring)
40
Varc pilot current Input of arc voltage value (pilot current phase) for parameter monitoring
(range: 16V - 36V).
+ tolerance
Positive tolerance from 0V-10V (Selection of “0“ will cancel monitoring)
- tolerance
Negative tolerance from 0V-10V (Selection of “0“ will cancel monitoring)
Varc weld current Input of arc voltage value (in main current phase) in a range from
16V - 36V.
+ tolerance
Positive tolerance from 0V–10V (Selection of “0“ will cancel monitoring)
- tolerance
Negative tolerance from 0V–10V (Selection of “0“ will cancel monitoring)
Optimization
No :
Optimization of weld parameters not requested.
Current : Automatic adjustment of the weld current when welding
through impurities on work surfaces.
Time :
Automatic adjustment of the weld time ts when welding
through impurities on work surfaces.
Weld type
DC :
Welding with constant current
Pulse :
Welding with pulse wave form current
Remark: Programming is to be performed with the keys
Program
continues
and
.
The second menu page can be displayed by pressing the
direction key
.
Having pressed the
key the cursor will have moved to the second menu page.
Outlet : #
Weld program: ###
Program continues . . . < ↑ >
Start delay . . . . . . . . .
Lift distance . . . . . . . .
Drop time . . . . . . . . . .
Autoplunge . . . . . . . . .
Air blow . . . . . . . . . . .
Detect stud . . . . . . . . .
Corresponding stud . .
Weld part ident. . . . . .
### ms
# ,## +, ##
-, ##
## ms
####
####
####
#########
################
<1..5> <←↓↑→> <+,-> <ENT>
mm
F1..F5> <ESC>
Program continues The first menu page can be displayed by pressing the direction key
Start Delay
If the weld location is not sufficiently stable the time between SOW and
lift can be adjusted in a range between 0 ms - 500 ms.
41
Lift distance
Input of lift value in a range from 0,6mm-3,0mm for parameter monitoring
(step size: 0,1 mm).
Note: Input only necessary when the connected weld tool is equipped with an
integrated lift measurement system to detect distance.
+ tolerance
Positive tolerance from 0-0,6mm (Selection of “0“ will cancel monitoring)
- tolerance
Negative tolerance from 0-0,6mm (Selection of “0“ will cancel monitoring)
Drop time
Input of the time between de-energizing of the solenoid and the plunging
of the stud into the melted work surface.
Note: Input serves to adapt weld time to stud plunge time and also
serves as reference value for maintenance monitoring
Autoplunge
Yes : Autoplunge is activated to keep weld time constant.
No : No autoplunge requested.
Air blow
Yes: If the weld tool is optionally equipped with an air nozzle
for clearing the work surface, it will be activated
No: Air nozzle for clearing the work surface will not be activated.
Detect stud
Yes : Stud detection via the length measurement function of the lift
measuring system is activated.
No : No autoplunge requested
Attention: Stud detection function is only performed if the stud detection
function in the mechanical parameters has been activated as well.
Remark: If "Detect Stud" is activated it will be verified before each weld whether the
stud length of the supplied stud is according to the programmed reference value. In
case of an deviation the corresponding fault message will be initiated.
Corresponding Feeder 1 - 5 : The weld program will be attributed a feeder.
Note: It will be verfied before the weld whether the last stud feed was
stud
performed by the correct feeder.
None : Corresponding stud verification feature not requested
Remark: Verification of corresponding stud is only possible during operation with a 2way stud divider SD 2.
Weld part
identification
Input of an alpanumeric text for identification of the weld part
Remark: Programming is to be effected via the
,
Programmed parameters will be confirmed with
exit the input mode by pressing the
key.
or rejected with
42
,
and
keys.
. You may
1.12.4 Function Menu "Copy Programs"
The function menu "Copy Programs" serves to transfer weld programs.
This function menu will be selected by positioning the cursor on the fourth menu
line of the "Extended Functions" menu and by pressing the
key.
Copy programs
Single program
Program area
Programs per output
Copy
Outlet
#
#######
###
To
Outlet
#
#######
###
#######
###
####
<1..9> <↓↑> <ENTER>
<F1..F5> <ESC>
The user has the following possibilities to copy weld programs:
Single Program
Program Area
Programs per
Output
In selecting "Single Program" one copy of the weld program will
be made
In selecting "Program Area" several copies of the weld program
will be made
In selecting "Programs per Output" allweld programs of an
output will be copied
Select the requested copy function with the direction keys
with
.
and
and confirm
Select a number between 1 and 5 for the weld output as well as a number
between 1 and 127 for the weld program and confirm your input with
.
By pressing
the cursor will move to the function selection and by pressing
again you will exit the menu.
Information on copying programs:
Weld programs will need to be copied when in a robot unit studs are to be welded
at different weld locations with identical programs. The stud detection is not
copied.
If a weld program is copied to an address under which a program is
already stored the existing program will be overwritten by the new
program.
43
1.12.5
Function Menu "Clear Functions"
The function menu "Clear Functions" serves to Clear and thus to reset counters
and memories of the statistics menu.
This function menu will be selected by positioning the cursor on the fifth menu line
of the "Extended Functions" menu and by pressing the
key.
Clear functions
Maintenance
Statistic
Fault memory
WOP memory
1  2  3  4  5
####################
####################
########################
########################
<←↓↑→> <ENTER>=Clear
<F1..F5> <ESC>
The individual menu lines signify the following:
Maintenance
By clearing "Maintenance" the statistics in "Maintenance"
menu information will be reset to "0" . Any existing
maintenance warning will be automatically reset
Statistic
By clearing the "Statistics" the information in the two statistics
menus "Weld Output" and "Weld Program Statistics" will be
reset to "0"
Fault Memory
By clearing the "Fault Memory" all information will be deleted
in the "Fault Memory"
WOP Memory
By clearing the "WOP Memory" all information will be deleted
in the "WOP Memory"
For selecting statistics or a memory position the cursor with the direction keys
And
and confirm with the
key. The message "Activate Clear Function"
will appear on the display.
By pressing the
key the selected memory will be cleared, by pressing
the
selection will be cancelled. By pressing
again you will exit the menu "Clear
Functions".
44
1.12.6
Function Menu "ZCPU System Test"
This function menu will be selected by positioning the cursor on the sixth menu
line of the "Extended Functions" menu and by pressing the
key.
ZCPU System test
RAM-Module:
- existent . . . . . . . . . . . . . . . . . . . . . . #
RAM-Module Battery:
- within operating tolerance. . . . . . . . #
- voltage level (Volts) . . . . . . . . . . .#, #
ZCPU Battery:
- within operating tolerance. . . . . . . . #
- voltage level (Volts) . . . . . . . . . . .#, #
<F1..F5> <ESC>
The individual menu lines will be described on the following pages:
RAM-Module : The system test checks whether the RAM-module is responsive.
Existent
*:
A RAM-Module is existent.
-:
No RAM-Module.
RAM-Module battery : The system checks the battery in the RAM-Module
Tolerance
*:
The battery voltage is within the operating tolerance.
-:
The battery voltage is out of the operating tolerance
Voltage level
The system test will indicate the measured battery voltage
ZCPU-Module battery : The system checks the battery on the ZCPU (real-time
clock)
Tolerance
*:
The battery voltage is within the operating tolerance.
-:
The battery voltage is out of the operating tolerance
Voltage level
By pressing the
The system test will indicate the measured battery voltage
key you will exit the function menu "ZCPU System Test“.
45
1.12.7
Function Menu "De/Activate Program"
The function menu “De/Activate Program“ displays a clearly arranged overview on
the active/inactive weld programs in terms of output. Individual programs may be
de/activated.
The function menu is selected by positioning the cursor on the seventh line of the
“Extended Functions“ menu and then pressing the
key.
Overview active programs
1
2
11 12
21 22
31 32
41 42
51 52
61 62
71 72
81 82
91 92
101 102
111 112
121 122
<1..5>
3
13
23
33
43
53
63
73
83
93
103
113
123
4
14
24
34
44
54
64
74
84
94
104
114
124
<←↓↑→>
5
15
25
35
45
55
65
75
85
95
105
115
125
O: #
6
16
26
36
46
56
66
76
86
96
106
116
126
< + >=active
7
17
27
37
47
57
67
77
87
97
107
117
127
8
18
28
38
48
58
68
78
88
98
108
118
< - >=inactive
9
19
29
39
49
59
69
79
89
99
109
119
10
20
30
40
50
60
70
80
90
100
110
120
<ESC>
An overview on all programs nos. is displayed. Program numbers displayed in
italic are activated.
In order to alter a de/activation the cursor must be positioned on the requested
program number via the arrow keys
,
,
or
and then the keys
or
must be pressed.
The status of the program will be altered correspondingly and the cursor moves
automatically to the next position.
Exit the menu with
.
46
1.12.8 Function Menu "Stud Length Detection"
From the function menu“Stud Length Detection“ a reference value for the stud
length can be stored in memory if a lift measuring system is available. This value is
then considered for checking the supplied stud, if the stud detection function (see
“Mechanical Parameters“ as well as “Weld Parameters“) has been activated.
This function menu will be selected by positioning the cursor on the fifth menu line
of the sub-menu "Functions" and by pressing the
key.
Stud length detection
Feeder number :
#
Stud load . . . . . : #########
Process . . . . . . : #########
Value (ref) . . . . : ### mm
Checkup . . . . . : ########
Difference . . . . : ####
The length of the stud
selected will be stored in mem.
<1..5>
<↓↑>
<ENTER>
<F1..F5> <ESC>
Select a number between 1 and 5 for the feeder and confirm your input with
.
The individual menu lines signify the following:
Feeder number Input of feeder no. 1 to 5
Note: In a SD2-application both feeders/studs must be measured for
the master output.
Stud load
....?.... :
Press
and
simultaneously, to load a stud on
the selected feeder.
started:
The stud feed cycle has begun.
Note: If you are not sure whether the right stud has been supplied, you
should always perform this function before a reference measurement.
Process
....?.... :
Press
and
simultaneously to start the
reference measurement process (stud length)..
During internal slide rail control the head will be
advanced automatically to the front position.
started:
The reference measurement process has begun.
Note: If you are not sure whether the right stud has been supplied, you
should always perform this function before a reference measurement
47
Value (ref.)
The stud length is displayed.
Test
The stud length will be tested.
Difference
The difference of the displayed stud length to the measured
value will be displayed.
• Press
to get to the menu line "Feeder number".
• Press
again, to return to the Sub-Menu "Extended Functions".
48
1.12.9 Function Menu "Set Date and Time"
The date and time can be changed in the function menu “Set Date and Time“.
This function menu will be selected by positioning the cursor on the ninth line of
the “Extended Functions“ menu and by pressing the
key.
Set date and time
Date :
Time :
<0..9>
<←↓↑→>
##.##.##
##:##:##
<ENTER>
<F1..F5> <ESC>
In order to change the date or the time, move to the number to be changed with
the arrow keys
,
,
or . The selected number is represented in italic.
Then enter a new number via the numerical keys. Confirm this number with the
key
thereby exiting the menu. Only meaningful numbers will be accepted.
By pressing
changes will be rejected and the menu is also exited.
The individual menu lines signify the following:
Date
The current date will be displayed.
Time
The current time will be displayed.
Note: If the date changes after the TMP has been switched off or nonsense
numbers are displayed, probably the battery jumper for the real-time clock has not
been set.
49
Appendix A:TMP Software Main-Menu OPERATION
OPERATION
-------------------------------------Weld parameter monitor
Programming
Statistics
Fault reset
Status weld sequence
Status customer interface
Status Feeder/Stud-Divider
Status TMP
Functions
Warnings
-------------------------------------<↓↑> <ENTER>
<F1..F5>
Weld parameter monitor
---------------------------------------SKK/PK outlet: #
Program.No ...:###
Weld part ident :
################
Autoplunge...####
Optimization..####
| Ref +tol -tol | Act |
|
----+----------------+-------+---+-Vp |
##
##
## |
## | V | #
Vw |
##
##
## |
## | V | #
Iw | #### ### ### | #### | A | #
tw | ###
##
## | ###,# | ms| #
td | ##,#
| ##,# | ms| #
#Lift| #,## ,## ,## | #,## | mm| #
Fault :################################
---------------------------------------<0..5> <ENTER>
<F1..F5> <ESC>
Programming
---------------------------------------Weld parameters
Outlet/feeder
Programming weld parameters
---------------------------------------Outlet No.
........: #
Weld position No......:###
Weld position aktive...
####
Weld diameter..........
#####
Workpiece gauge........
#####
Workpiece coating......########
Energy adjustment......
### %
---------------------------------------<↓↑> <ENTER>
<F1..F5> <ESC>
---------------------------------------<1..9> <↓↑> <+,-> <ENTER> <F1..F5> <ESC>
Programming outlet/feed time
---------------------------------------Weld outlet no....:#
Outlet active......####
Feede time.........#### ms
---------------------------------------<1..9> <↓↑> <+,-> <ENTER> <F1..F5> <ESC>
50
Statistics
---------------------------------------fault memory
WOP memory
Outlet statistics
Weld program statistics
Maintenance
Fault memory
Fault No. ###
---------------------------------------O|Prg|Fault type |No.| Date
| time
-+---+-----------+---+--------+-------#|###|###########|###|##.##.##|##:##:##
#|###|###########|###|##.##.##|##:##:##
#|###|###########|###|##.##.##|##:##:##
#|###|###########|###|##.##.##|##:##:##
#|###|###########|###|##.##.##|##:##:##
#|###|###########|###|##.##.##|##:##:##
........................................
Fault description:
---------------------------------------<↓↑> <ENTER>
<F1..F5> <ESC>
---------------------------------------<↓↑>
<F1..F5> <ESC>
WOP-mem. outlet:# Prog:### Page:###
---------------------------------------.Weld part ident :
################
Date.......##.##.## Time......##:##:##
Autoplunge....#### Opt...........####
| Ref +tol -tol | Act |
|
----+----------------+-------+---+-Vp |
##
##
## |
## | V | #
Vw |
##
##
## |
## | V | #
Iw | #### ### ### | #### | A | #
tw | ###
##
## | ###,# | ms| #
td | ##,#
| ##,# | ms| #
#Lift| #,## ,## ,## | #,## | mm| #
Fault :################################
---------------------------------------<0..5> <↓↑> <ENTER>
<F1..F5> <ESC>
Weld outlet statistics
---------------------------------------|Number |Number|WOP
|Number |auto.
| of
| of |repeat | of
|rep.
O |WIP&WOP| WOP |lim|act|Faults |feed
---+-------+------+---+---+-------+----1 |#######|######| # | # | ######|#####
2 |#######|######| # | # | ######|#####
3 |#######|######| # | # | ######|#####
4 |#######|######| # | # | ######|#####
5 |#######|######| # | # | ######|#####
---------------------------------------<F1..F5> <ESC>
51
Weld program statistics
Outlet:#
---------------------------------------| number|number|WOP
|auto.
|
of | of |repeat |rep.
Prog|WIP&WOP| WOP |lim|act|feed
----+-------+------+---+---+----|#######|######| # | # |#####
|#######|######| # | # |#####
|#######|######| # | # |#####
|#######|######| # | # |#####
|#######|######| # | # |#####
|#######|######| # | # |#####
|#######|######| # | # |#####
|#######|######| # | # |#####
---------------------------------------<↓↑>
<F1..F5> <ESC>
Maintenance
---------------------------------------Collet maint.- No. welds
| 1
| 2
| 3
| 4
| 5
-----+------+------+------+------+-----Act |######|######|######|######|######
Warn.|######|######|######|######|######
Fault|######|######|######|######|######
Monitor – drop time (ms)
-----+------+------+------+------+-----Act | ###,#| ###,#| ###,#| ###,#| ###,#
Warn.| +# -#| +# -#| +# -#| +# -#| +# -#
Fault| +# -#| +# -#| +# -#| +# -#| +# -#
---------------------------------------<F1..F5> <ESC>
Fault outlet #
----------------------------------------
##########
##########
##########
---------------------------------------<←↓↑→>> <ENTER>
<F1..F5> <ESC>
52
Status weld sequence
---------------------------------------1
2
3
4
5
Weld cycle
#
#
#
#
#
Feed cycle
#
#
#
#
#
SOW
#
#
#
#
#
Angularity switch PK #
#
#
#
#
Start weld
#
#
#
#
#
Start feed
#
#
#
#
#
SKK R-position
#
#
#
#
#
I.Tolerance (WIP)
#
#
#
#
#
Program number
### ### ### ### ###
---------------------------------------<F1..F5> <ESC>
Status customer interface
---------------------------------------#
#
#
#
#
Operation mode #### #### #### #### ####
Start weld
#
#
#
#
#
Start feed
#
#
#
#
#
Without weld
#
#
#
#
#
Reset fault
#
#
#
#
#
Restart
#
#
#
#
#
Set WC
#
#
#
#
#
Start SKK F-pos.
#
#
#
#
#
Start SKK R-pos.
#
#
#
#
#
Program number
### ### ### ### ###
---------------------------------------<F1..F5> <ESC>
Status feeder/stud divider
---------------------------------------#
#
#
#
#
Operation mode
### ### ### ### ###
Feed cycle
#
#
#
#
#
Piston retracted
#
#
#
#
#
Pos. Stud divider
#
#
#
#
#
SKK R-position
#
#
#
#
#
Angularity switch PK #
#
#
#
#
Start weld
#
#
#
#
#
Start feed
#
#
#
#
#
Stud level low
#
#
#
#
#
---------------------------------------<F1..F5> <ESC>
53
Status TMP ####
---------------------------------------Date.........##.##.## Time......##:##:##
Software.......V##.## Address........###
Interface.########### SMPS ready....####
Operation stop...#### Emergency.....####
#
#
#
#
#
Connection ##### ##### ##### ##### #####
SF-Typ
#### #### #### #### ####
SKK/PK
###
###
###
###
###
SF.. A/D
#
#
#
#
#
Lift sensor #### #### #### #### ####
Maintenance
#
#
#
#
#
---------------------------------------<F1..F5> <ESC>
Functions
---------------------------------------Display system configuration
test mode cycle function
test mode outputs interface
test mode weld process
test mode power supply
E M H A R T
T M P
####
---------------------------------------System software
V##.##
---------------------------------------<↓↑> <ENTER>
<F1..F5> <ESC>
---------------------------------------<F1..F5> <ESC>
Keypad/Display
Central CPU
SMPS
Interface ###########
Outlet 1
####/#####
Outlet 2
####/#####
Outlet 3
####/#####
Outlet 4
####/#####
Outlet 5
####/#####
V##.##
V##.##
V##.##
V##.##
V##.##
V##.##
V##.##
V##.##
V##.##
Test mode cycle function
---------------------------------------| 1 | 2 | 3 | 4 | 5
----------+-----+-----+-----+-----+----Cycle
|#####|#####|#####|#####|#####
SKK F-pos.|#####|#####|#####|#####|#####
SKK R-pos.|#####|#####|#####|#####|#####
Start feed|#####|#####|#####|#####|#####
Lift
|#####|#####|#####|#####|#####
Set WC
|#####|#####|#####|#####|#####
Color mark|#####|#####|#####|#####|#####
Reference outlet :#
SKK ext...#### ms
Drop time...##,# ms
SKK ret...#### ms
Lift........#,## mm
---------------------------------------<←↓↑→> <ENTER>=Start
<F1..F5> <ESC>
54
Test mode outputs interface
---------------------------------------1
2
3
4
5
Operation mode #### #### #### #### ####
Ready
#
#
#
#
#
SOW
#
#
#
#
#
SKK R-position
#
#
#
#
#
I.Tolerance (WIP) #
#
#
#
#
Fault
#
#
#
#
#
WC
#
#
#
#
#
Maintenance
#
#
#
#
#
Emergency stop
#
#
#
#
#
Fault code
### ### ### ### ###
---------------------------------------<←↓↑→> <+,->
<F1..F5> <ESC>
Test mode weld process
----------------------------------------1
2
3
4
5
Weld cycle us
#
#
#
#
#
Feed cycle
#
#
#
#
#
SOW
#
#
#
#
#
Angularity switch PK
#
#
#
#
#
Start weld
#
#
#
#
#
Start feed
#
#
#
#
#
SKK R-position
#
#
#
#
#
I.Tolerance
#
#
#
#
#
Program number
### ### ### ### ###
Warning! The TMP-unit will work in testmode. However the unit will not weld!
----------------------------------------<F1..F5> <ESC>
Warnings:
----------------------------------------
Test mode power supply
---------------------------------------Outlet No. . . . . . . :
Quantity of testcycles .:
#
###
Start . . . . . . . . . : #####
Actual weld curent. . . :
Actual cycle count. . . :
####
###
The short circuit test can be stopped
With the <ESC> key
---------------------------------------<1..5> <+,-> <↓↑> <ENTER> <F1..F5> <ESC>
---------------------------------------<F1..F5> <ESC>
55
Sub-menu to EXTENDED FUNCTIONS (hidden)
Extended functions
--------------------------------------System parameters
Mechanical parameters
Weld parameters
Copy programs
Clear functions
ZCPU System test
De/activate programs
Stud length detection
Set date and time
System parameters
---------------------------------------Address
Interface.....###
Network.......###
--------------------------------------<↓↑> <ENTER>
<F1..F5> <ESC>
---------------------------------------<+,-> <ENTER>
<F1..F5> <ESC>
Language.............###########
Parameter printout.......#######
###########
#############
##########
Mechanical parameters outlet:#
---------------------------------------Outlet active.####
Slide rail....######
Start feed....##################
Feedtime(ms)..####
Loadtime(ms)..####
Repeat feed...#### Feed adj......####
Permitted WOP.
# Color marke...####
Protect. Gas..#### Air blow......####
Pre-gas.(ms)..#### Angularity....####
Post-gas.(ms).#### Stud monitor..####
Maint. at...###### tp-Maint.....+# -#
Fault at....###### tp-Fault.....+# -#
---------------------------------------<1..5> <←↓↑→> <+,-> <ENT> <F1..F5> <ESC>
Outlet:#
Weld program:###
---------------------------------------Program active .....####
Pilot current....... ## A
Pilot current time.. ## ms
Weld current........#### +### -###
Weld current time... ### + ## - ##
Varc pilot current.. ## + ## - ##
Varc weld current... ## + ## - ##
Optimization........####
Weld type...........###########
A
ms
V
V
Program continues...<## >
---------------------------------------<1..5> <←↓↑→> <+,-> <ENT> <F1..F5> <ESC>
56
Outlet:#
Weld program:###
---------------------------------------Program continues...<## >
Start delay.........
Lift distance.......
Drop time...........
Autoplunge..........
Air blow............
Detect stud.........
Corresponding stud..
Weld part ident.....
### ms
#,## +,## -,## mm
## ms
####
####
####
#########
################
---------------------------------------<1..5> <←↓↑→> <+,-> <ENT> <F1..F5> <ESC>
Copy prorams
---------------------------------------#####################
#####################
#####################
Copy
Outlet
#
####### ###
To
Outlet
#
####### ###
####
####### ###
---------------------------------------<1..9> <↓↑> <ENTER>
<F1..F5> <ESC>
Clear functions
---------------------------------------| 1 | 2 | 3 | 4 | 5
---------------+----+----+----+----+---Maintenance
|####|####|####|####|####
Statistics
|####|####|####|####|####
Fault memory
|########################
WOP memory
|########################
---------------------------------------<←↓↑→> <ENTER>=Clear
<F1..F5> <ESC>
57
ZCPU System test
---------------------------------------RAM-Module:
- existent...........................#
RAM-Module Battery:
- within operating tolerance.........#
- voltage level (Volts)............#,#
ZCPU Battery:
- within operating tolerance.........#
- voltage level(Volts).............#,#
---------------------------------------<F1..F5> <ESC>
Overview active programs
O:#
1
2
3
4
5
6
7
8
9 10
11 12 13 14 15 16 17 18 19 20
21 22 23 24 25 26 27 28 29 30
31 32 33 34 35 36 37 38 39 40
41 42 43 44 45 46 47 48 49 50
51 52 53 54 55 56 57 58 59 60
61 62 63 64 65 66 67 68 69 70
71 72 73 74 75 76 77 78 79 80
81 82 83 84 85 86 87 88 89 90
91 92 93 94 95 96 97 98 99 100
101 102 103 104 105 106 107 108 109 110
111 112 113 114 115 116 117 118 119 120
121 122 123 124 125 126 127
<1..5><←↓↑→> <+>=active<->=inactive<ESC>
Stud length detection
---------------------------------------Feeder number: #
Stud load....: #########
Process......: #########
Value (ref)..: #########
Checkup......: #########
Difference...: ####
The length of the stud
selected will be stored in mem.
<1..5> <↓↑> <ENTER>
<F1..F5> <ESC>
58
Set date and time
----------------------------------------
Date: ##.##.##
Time: ##:##:##
---------------------------------------<0..9> <←↓↑→> <ENTER>
<F1..F5> <ESC>
59
Special menus (Function keys, confirmations)
Key functions
--------------------------------------F1 – display key functions
F2 – main menu
F3 - programming
F4 – weld parameter monitor
F5 – fault reset
F6 – approval for test mode
ESC – ESCAPE, abort
ENT – ENTER, confirmation
0..9 – input SKK/PK, program No.
+- change, set/reset values
<↓↑> - select menu, value
Clear functions
---------------------------------------| 1 | 2 | 3 | 4 | 5
---------------+----+----+----+----+---Maintenance
|####|####|####|####|####
Statistics
|####|####|####|####|####
Fault memory
|########################
WOP memory
|########################
Functions
---------------------------------------display system configuration
test mode cycle functions
test mode outputs interface
test mode weld process
test moce power supply
-------------------------------------|
Activate clear function?
|
| <ENTER>=YES
<ESC>=NO
|
----------------------------------------------------------------------------<ENTER>
<F1..F5> <ESC>
-------------------------------------|Warning! Test mode will be activated |
| Confirm <ENTER>
Exit <ESC> |
----------------------------------------------------------------------------<ENTER>
<F1..F5> <ESC>
Fault outlet
#
---------------------------------------
Fault condition
----------------------------------------
##########
##########
##########
--------------------------------------<↓↑> <ENTER>
<F1..F5> <ESC>
To continue operation clear
the fault condition
---------------------------------------<F1..F5> <ESC>
60
Appendix B:
DIP-Switch Information.
The DIP-switches are located in the unit interior. Please note
that only electrotechnically trained personnel may open the unit
Warning
ZCPU DIP-Switches
DIP-Switch 2:
DIP-Switch 7:
DIP-Switch 8:
System reset, delete RAM-module.
Lock single programming.
Lock extended programming.
Customer Interfcace DIP-Switches
Due to the differing interface cards along with their software levels the DIP-switch
configuration differs and therefore must be looked up based on these factors.
Some examples:
TSG-emulation (FK-generation in case of error)
TSG-emulation (FK-generation during slide rail control)
Output “I/O-TOL“ or “Feedback BU“
No. of heads (IBS for BMW)
Display of I/O`s on the LED`(IBS for BMW)
Feeder DIP-switches:
The DIP-switches in the feeder are configurated differently depending on the
software. Therefore the feeder service manual must be consulted for details.
Some examples:
Key-operated switch removable in position Auto/All
Proximity switch escapement blade active/deactivated
Internal/external slide rail control
With / without protection gas
With / without lift (LM-Box)
Proximity switch escapement chamber active/deactivated
SKK DIP-Switches:
The DIP-switches in the weld head may differ depending on the pcb type and
therefore the corresponding service manual must be consulted for details.
Some examples:
Pcb B 289 (SKK 240 / 310)l
Pcb B 89 (SKK 160)
LM-Head
61
Appendix C:
Note
Fault Messages
When repairing the TMP 1000 on location operator safety must
be assured. Trouble-shooting is only to be performed by
qualified personnel
In the sub-menu "Clear Fault Condition" the user will find help in the form of
fault messages indicating clearly the trouble source.
• Trouble-shooting by operating personnel is limited to the "remedial"
measures of the respective fault message.
• During repair the general rules and regulations for the prevention of
accidents and industrial safety must be observed.
Fault:
1
2
3
4
5
6
7
8-12
13
14
15
16
17
19
21
23
25
26
32
34
Display-Message:
slide rail remains in R-position
no SOW
slide rail not in R-position
SOW was not reset
weld procedure sequence fault
program not selectied
program not activated
Out of tolerance
no lift
short-circuit weld
drop time timeout
no arc, open circuit
measurement line broken
collet PM required
weld head PM required
handgun sequence not followed
wrong stud loaded
fault feed or stud divider function
SMPS regulation out of range
safety circuit fault
62
Fault:
Note
Display-Message:
35
38
39
40
43
45
46
47
49
62
100
102
system configuration fault
fiber optic connection feeder fault
fiber optic connection customer interface fault
fiber optic connection SMPS fault
feeder configuration fault
start weld not reset
missing stud feed
test conditions aren‘ t met
feeder not in automatic operation mode
ZCPU: RAM module fault or defective
feeder: no power to aux. supply
feeder: rail way not filled in time
103
104
106
109
120
132
133
134
135
140
141
142
143
144
146
159
160
202
204
feeder: air pressure too low
feeder: knife not in front position
feeder: feed tube monitor switch
feeder: feed cyle timeout
wrong corresponding stud
SD5: voltage fault
SD5: still in front position
SD5: front position not reached
SD5: R1-position not reached
SD5: front position and all R-pos.
SD5: at minimum 2 positions not OK
stud divider position not reached
SD5: not in home position
feeder: LM system fault
feeder: LM not ready
feeder: LM stud length faulty
feeder: colour mark not possible
SMPS: temperature exceeded
SMPS hardware fault
Operational faults of the TMP 1000 that can not be reset on
location by the listed remedial measures require unit replacement
63
Fault 1:
"Slide rail remains in R-position"
Description:
•
After a successful weld start the weld head slide rail
remains in R-position (internal slide rail control).
Cause:
•
•
•
compressed-air supply interrupted
feeder fault (i.e. defective magnetic solenoid valve)
weld head fault (i.e weld head got jammed)
Remedial Measure:
•
•
•
•
•
reset fault
check compressed air supply
check feeder fuses
replace feeder or weld head
inform TUCKER service !
Fault 2:
"No SOW"
Description:
•
After a successful weld start SOW was not detected.
Therefore welding is not permitted.
Cause:
•
•
•
•
•
•
no stud in collet
no studs left in feeder
feed tube incorrectly set or contaminated
weld circuit interrupted
weld head fault (i.e. weld head got jammed)
defective collet
Remedial Measure:
•
•
•
•
•
•
•
remove feeding problem
check feed tube setting and feeder
check weld circuit
feed studs
repeat weld
replace collet
inform TUCKER service !
Fault 3:
"Slide rail not in R-position"
Description:
•
Proximity switch for R-position not configured,
defective or power supply missing.
Cause:
•
•
•
•
•
•
drop in compressed-air supply
defective cable package
monitoring time after welding was exceeded
defective weld head
defective feeder
collet welded to work surface
64
Remedial Measure:
•
•
•
•
•
•
•
•
•
Fault 4:
" SOW was not reset"
Description:
•
After a weld performed on internal slide rail control
SOW signal remains.
Cause:
•
•
collet and stud welded together
connection between weld cable and work surface
ground
Remedial Measure:
•
•
•
replace collet
search for short-circuit and remove
inform TUCKER service !
Fault 5:
"weld procedure sequence fault"
Description:
•
Due to a misfunction the weld sequence is not terminated correctly.
Cause:
•
Feeder or SMPS misfunction
Remedial Measure:
•
•
•
reset fault
check weld (if necessary, reweld)
inform TUCKER service !
Fault 6:
"program not selected"
Description:
•
The weld unit does not detect any program number.
Cause:
•
•
•
program no. is 0
transfer signal has not been set
defective data line
Remedial Measure:
•
customer interface (or interface program) must be
verified
inform TUCKER service !
•
check compressed-air
check tube package
check weld head - slide rail motion
check or replace weld head
check feeder
check feeder fuses F1 - F3
reset fault
replace collet
inform TUCKER service !
65
Fault 7:
"program not activated"
Description:
•
The selected weld program is not active and therefore
cannot be executed.
Cause:
•
•
•
weld unit incorrectly programmed
customer control fault
defective data line
Remedial Measure:
•
check weld program and activate or select an active weld
program
inform TUCKER service !
•
Fault 8 - 12:
"out of tolerance"
Description:
•
The maximum number of defective welds in sequence
was reached.
Cause:
•
•
•
tolerances programmed too tightly
weld circuit resistance too high
defective SMPS or weld tool
Remedial Measure:
•
•
•
•
•
reset fault
verify tolerances
check weld circuit and weld conditions
check SMPS and weld tool
inform TUCKER service !
Fault 13:
"Fault no lift"
Description:
•
Weld unit is unable to identify lift via measurement lines.
Cause:
•
•
•
•
•
weld conditions prohibit lift
defective cable package
defective weld head
defective feeder
internal process cycle fault
Remedial Measure:
•
•
•
•
•
•
•
•
check weld conditions
check weld head
check feeder
feed studs
check feeder connection
repeat weld
set WC
inform TUCKER service !
If the weld unit can not identify lift this fault will be displayed in the
reference data line via a coded pilot current arc voltage (V = 99V).
Note
66
Fault 14:
"short-circuit weld"
Description:
•
During main current phase (except no lift) shortcircuit was
detected.
Cause:
•
•
weld gap too small
weld parameters too strict
Remedial Measure:
•
•
•
•
•
•
set WC
repeat weld
feed studs
check weld program
check weld head lift
inform TUCKER service !
Fault 15:
"Drop time timeout"
Description:
•
Max. drop time was exceeded and welding was stopped.
Cause:
•
•
•
•
air gap incorrectly adjusted
weld circuit resistance too high
measurement line-ground missing
defective SKK / PK
Remedial Measure:
•
•
reset fault
check measurement line (if necessary, reduce weld
circuit resistance)
check SKK / PK settings
inform TUCKER service !
•
•
Fault 16:
"no arc, open circuit"
Description:
•
Extinguishing of the arc during weld, resp. the weld
current is below I = 80A.
Cause:
•
•
•
•
air gap too large
gun was removed at the beginning of the weld
extremely impure work surface
SMPS fault
Remedial Measure:
•
•
•
•
•
•
repeat weld
feed studs
check gun settings
check weld conditions
check workpiece conditions
inform TUCKER service !
67
Fault 17:
"measurement line broken"
Description:
•
Measurement line signal not any longer detected.
Cause:
•
•
•
•
measurement line broken or incorrectly connected
reversed measurement line-ground and measurement line
SOW power failure
weld line interrupted
Remedial Measure:
•
•
•
•
•
•
•
check fuses on front panel.
reset fault.
check weld line.
check instrument lead.
check instrument lead ground.
check feeder fuses.
inform TUCKER service !
With reversed polarity and an uninterrupted measurement lineground the measurement line signal can not be detected
Note
Fault 19:
"collet PM required"
Description:
•
The collet is worn out and should be replaced.
Cause:
•
the limit value of preventive maintenance statistics was
exceeded.
Remedial Measure:
•
•
•
replace collet.
reset fault.
clear maintenance statistics.
Fault 21:
"weld head PM required"
Description:
•
The weld head is contaminated and thus does not keep
the required drop time.
Cause:
•
the limit value of the drop time tolerance for preventive
maintenance was exceeded.
Remedial Measure:
•
•
•
replace weld head and perform maintenance.
reset fault.
clear maintenance statistics.
68
Fault 23:
"handgun sequence not followed"
Description:
•
Correct sequence when welding with a gun (PK) was not
observed.
Cause:
•
•
•
angularity by-passed or incorrectly adjusted
trigger start by-passed
correct sequence "SOW-ANG-START" not observed
Remedial Measure:
•
•
•
•
observe sequence "SOW-WS-START"
check PK for correct setting of angularity
release trigger and restart
inform TUCKER service !
Fault 25:
"wrong stud loaded"
Description:
•
The supplied stud is not the specified stud required by
unit control.
Cause:
•
the weld unit identified an incorrect stud in the weld head
via the lift measuring system or the stud verification test
Remedial Measure:
•
•
•
•
reset fault
repeat feed process
verify correct stud length in the feeder
verify programming
Fault 26:
"Fault feed or stud divider function
Description:
•
During stud feed a fault occurred.
Cause:
•
when using a 2-way stud divider a fault occurred at a
peripheral unit
Remedial Measure:
•
•
•
•
•
reset fault
check stud divider
check feeder
check feeding tube
inform TUCKER service !
Note
This fault message will be displayed during divider operation at
the feeders which did not cause the fault. The remedial measures
are to be taken at the concerned unit
69
Fault 32:
"SMPS regulation out of range"
Description:
•
The programmed weld current is not reached.
Cause:
•
•
external circuit resistance too high
defective SMPS
Remedial Measure:
•
•
•
•
check external circuit
increase energy cross-section in the external circuit
check SMPS
inform TUCKER service !
Fault 34:
"safety circuit fault"
Description:
•
During welding the voltage in the external circuit is too
high.
Cause:
•
•
other source of current
defective SMPS
Remedial Measure:
•
•
•
check equipment for other source of current
check SMPS
inform TUCKER service !
Warning
The safety symbol on the TMP door indicates dangerous electrical
voltage. Opening of the control cabinet is reserved for qualified
electricians
Fault 35:
"system configuration fault"
Description:
•
The weld unit identified an unacceptable system
configuration.
Cause:
•
•
incorrect connection of stud divider (SD2 or SD5)
defective peripheral unit
Remedial Measure:
•
•
•
•
check peripherals
verify system configuration
check connections
inform TUCKER service !
70
Fault 38:
"fiber optic connection feeder fault"
Description:
•
Connection between the ZCPU and the feeder failed.
Cause:
•
•
line interruption
defective hardware
Remedial Measures:
•
•
check fibre optic line to the feeder
inform TUCKER service !
Fault 39:
"fiber optic connection to customer inter. fault"
Description:
•
Connection between the ZCPU and the customer
interface failed.
Cause:
•
•
•
external power supply failed
line interruption
defective hardware
Remedial Measures:
•
•
verify power supply to customer interface
inform TUCKER service !
Fault 40:
"fibre optic connection to SMPS fault "
Description:
•
The central CPU cannot connect wíth the SMPS.
Cause:
•
•
line interruption
hardware fault
Remedial Measure:
•
inform TUCKER service !
Fault 43:
"feeder configuration fault"
Description:
•
The weld unit identified an unacceptable system
configuration.
Cause:
•
when using a stud divider (SD2 / SD5) the feeder will
indicate an external slide rail control or connection of a
manual weld gun
Remedial Measure:
•
•
•
verify system configuration
check feeder
inform TUCKER service !
71
Fault 45:
"start weld not reset"
Description:
•
The pending weld start is invalid.
Cause:
•
•
when switching the weld unit on a start signal is pending
after an emergency stop a start signal is pending
Remedial Measure:
•
•
cancel start signal
reset fault
Fault 46:
"missing stud feed "
Description:
•
A weld start signal was given without a stud having been
supplied.
Cause:
•
no refeed performed after last weld
Remedial Measure:
•
•
perform refeed
reset fault
Fault 47:
"test conditions aren‘t met"
Description:
•
"Test mode weld sequence" was activated at the weld
unit, the signals at the customer interface, however, do
not meet the conditions for a test mode.
Cause:
•
test mode access is unauthorized
•
reset fault
For performing the "test mode weld sequence" the signal "without
weld" must be set at the customer interface
Note
Fault 49:
"Feeder not in Automatic Operation Mode"
Description:
•
The key-operated switch at the feeder is not locked in
position “Automatic“.
Remedial Measure:
•
Switch the key-operated switch to “Automatic“ in case it
should be locked in any other position unintentionally.
72
Fault 62:
"ZCPU: RAM module fault or defective"
Description:
•
The central CPU does not identify or identifies a defective
RAM module.
Cause:
•
the RAM module is not correctly connected or defective
Remedial Measure:
•
•
•
connect RAM module correctly (if necessary replace)
check central CPU
inform TUCKER service !
Fault 100:
"feeder: no power to aux. supply"
Description:
•
The feeder identifies no voltage supply.
Cause:
•
•
defective feeder fuse
defective feeder
Remedial Measure:
•
•
•
replace feeder fuse
check feeder
inform TUCKER service !
Note
Detailed information on how to remove defects at the stud feeder can
be read from the corresponding operating manual
Fault 102:
"feeder: rail way not filled in time"
Description:
•
The stud feeder identifies a stud escapement fault.
Cause:
•
•
•
•
•
stud got jammed in escapement rails
mechanical defect of the escapement rails
defective proximity switch "Min" or "Max"
escapement bowl empty
defective feeder
Remedial Measure:
•
•
•
check feeder (if, necessary refill)
remove blockage
inform TUCKER service !
73
Fault 103:
"feeder: air pressure too low"
Description:
•
The stud feeder indicates insufficient input air pressure.
Cause:
•
•
no or too little air pressure at feeder
defective PE-transformer in the feeder
Remedial Measure:
•
•
•
check compressed air supply
check PE-transformer
inform TUCKER service !
Fault 104:
"feeder: shuttle not in front position"
Description:
•
The stud feeder indicates a defective shuttle function.
Cause:
•
•
stud got jammed between blade and rail
defective proximity switch for blade initial position
Remedial Measure:
•
•
•
remove blockage
check proximity switch
inform TUCKER service !
Fault 106:
"feeder: feed tube monitor switch open"
Description:
•
The signal for feed tube locking at the stud feeder is
not configured.
Cause:
•
•
feed tube not connected (gun)
no bridge for feed tube locking (head)
Remedial Measure:
•
•
•
•
•
connect feed tube
verify locking switch
check cable package
check feeder
inform TUCKER service !
Detailed information on how to remove defects at the stud feeder
can be read from the corresponding operating manual
Note
74
Fault 109:
"feeder: feed cycle timeout"
Description:
•
the weld tool indicates an incorrectly performed feed cycle.
Cause:
•
the feeder does not terminate a feed cycle in the maximum
monitoring time
Remedial Measure:
•
•
check feeder
inform TUCKER service !
Fault 120:
"wrong corresponding stud"
Description:
•
The programmed corresponding stud is unacceptable
Cause:
•
•
stud divider without function
defective cable package
Remedial Measure:
•
•
•
check weld program
check cable package
set WC
Fault 132:
"SD5: voltage fault"
Description:
•
The stud divider SD5 identifies no supply voltage.
Cause:
•
•
defective SD5 fuse
defective stud divider
Remedial Measure:
•
•
•
replace defective fuse
check stud divider
inform TUCKER service !
Fault 133:
"SD5: still in front position"
Description:
•
The stud divider indicates a defective detaching slide
function.
Cause:
•
the detaching slide has already been moved to front
position
Remedial Measure:
•
•
•
•
reset fault
bring stud divider back into initial position
repeat feed cycle
inform TUCKER service !
75
Fault 134:
"SD5: front position not reached"
Description:
•
The stud divider indicates a defective detaching slide
function.
Cause:
•
•
insufficient compressed air supply
stud divider got jammed
Remedial Measure:
•
•
•
check compressed air supply
remove blockage
inform TUCKER service !
Fault 135:
"SD5: R1-position not reached"
Description:
•
The stud divider indicates a defective detaching slide
function.
Cause:
•
•
insufficient compressed air supply
stud divider got jammed
Remedial Measure:
•
•
•
check compressed air supply
remove blockage
inform TUCKER service !
Fault 140:
"SD5: front position AND all R-positions
Description:
•
The stud divider indicates that all rear positions as well
as the front position are covered.
Cause:
•
•
SD5 connection line divider - control interrupted
defective stud divider
Remedial Measure:
•
•
•
check connection line
check stud divider
inform TUCKER service 1
Fault 141:
"SD5: at minimum 2 positions not OK"
Description:
•
The stud divider indicates that there are at least 2
uncovered positions.
Cause:
•
•
insufficient compressed air supply
stud divider got jammed
Remedial Measure:
•
•
•
check compressed air supply
remove blockage
inform TUCKER service !
76
Fault 142:
"stud divider position not reached"
Description:
•
The stud divider did not reach the required position
within the monitoring time.
Cause:
•
•
insufficient compressed air supply
stud divider got jammed
Remedial Measure:
•
•
•
check compressed air supply
remove blockage
inform TUCKER service
Fault 143:
"SD5: not in home position"
Description:
•
The stud divider did not reach the home position
within the monitoring time.
Cause:
•
•
insufficient compressed air supply
stud divider got jammed
Remedial Measure:
•
•
•
check compressed air supply
remove blockage
inform TUCKER service !
Fault 144:
"feeder: LM system error"
Description:
•
The linar motor is not ready for welding
Cause:
•
•
•
defective Servo-Controller-Card
defective Servo-Amplifier-Card
defective fuse F8 (Backplane)
Remedial Measure:
•
•
if necessary replace all components successively
inform TUCKER service !
Fault 145:
"feeder: LM not ready"
Description:
•
The SF LM-Feeder is not ready for the next weld
Cause:
•
the Linear-Motor is heated up and needs a cooling
phase before the next weld
Remedial Measure:
•
if possible reduce weld cycles
77
Fault 159:
"feeder: - LM stud length faulty "
Description:
•
The stud length, measured at the sustainer is too small
Cause:
•
wrong stud fed (into the weld head
Remedial Measure:
•
feed stud with the correct length or with the exact
measured length
Fault 160:
"feeder: colour mark not possible "
Description:
•
No colour mark box connected
Cause:
•
a color marking was actuated without a color
marking box being connected
Remedial Measure:
•
connect a colour marking box
Detailed information on how to remove defects at the stud feeder
can be read from the corresponding operating manual
Note
Fault 202:
"SMPS : Temperature Exceeded"
Description:
•
The SMPS in the TMP is overheated
Cause:
•
the environmental temperature is too high for the
requested weld energy
Remedial Measure:
•
•
improve cooling system
reduce weld energy
Fault 204:
"SMPS hardware fault"
Description:
•
One defective SMPS component.
Cause:
•
SMPS defect
Remedial Measure:
•
•
check SMPS
inform TUCKER service
78
Appendix D:
Error Memory Messages
The messages listed in the table below are registered in the error memory for
documentation reasons. They will, however, not cause an error.
Code:
Display Message:
69
RAM-Module deleted
70
Maintenance deleted
71
Statistics deleted
72
Error memory deleted
73
WOP memory deleted
79
Appendix E:
Messages regarding pilot arc voltage
Various pilot arc voltages are used to display particular conditions:
Code:
Message:
96V
Weld discontinued due to overshooting the safety circuit
threshold voltage.
97V
Reserved.
98V
Short circuit test flagged.
(is not needed in normal welding mode)
99V
No gun lift detected.
An attempt is made to successfully bring the process to
a close.
Revision: March 2001
80
Notizen/Notes:
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