Emhart Teknologies Tucker TMP Series Betriebsanleitung

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Emhart Teknologies

TUCKER GmbH, Max-Eyth-Straße 1, 35394 Gießen

Tel.: 0641/405-0; Fax.: 0641/405-383; Mail: Info@tucker.de

Programming Manual

Control and Power Unit

TMP

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Table of Contents

1. Menu Access and Selection 1

1.1 Sub-Menu “Keyboard Functions“2

1.2 Sub-Menu “Weld Parameter Monitor“3

1.3 Sub-Menu “Programming“5

1.3.1 Functions Menü“Programming Weld Parameters“5

1.3.2 Functions Menü“Programming Output/Feeder“8

1.4 Sub-Menu “Statistics“9

1.4.1 “Fault Memory“9

1.4.2 “WOP-Memory“11

1.4.3 “Weld Output Statistics“13

1.4.4 “Weld Program Statistics“14

1.4.5 “Maintenance“15

1.5 Sub-Menu “Clear Fault Condition“17

1.6 Sub-Menu “Status Weld Sequence“20

1.7 Sub-Menu “Status Customer Interface“22

1.8 Sub-Menu “Status Feeder/Stud Divider“24

1.9 Sub-Menu “Status TMP ....“25

1.10 Sub-Menu “Functions“27

1.10.1 Functions Menu “Display System Configuration“27

1.10.2 Functions Menu “Test Mode Cycle Functions“28

1.10.3 Functions Menu “Test Mode Outputs Interface“30

1.10.4 Functions Menu “Test Mode Weld Process“31

1.10.5 Functions Menu “TEST Mode Power Supply“32

1.11 Sub-Menu “Warnings“34

1.12 Sub-Menu “Extended Functions“35

1.12.1 Functions Menu “System Parameters“36

1.12.2 Functions Menu “Mechanical Parameter“37

1.12.3 Functions Menu “Weld Program“40

1.12.4 Functions Menu “Copy Programs“42

1.12.5 Functions Menu “Clear Funktions“44

1.12.6 Functions Menu “ZCPU System Test“45

1.12.7 Functions Menu “De/Activate Program“46

1.12.8 Functions Menu “Stud Length Detection“47

1.12.9 Functions Menu “Set Date and Time“49

Appendix A Main Menu TMP Systemsoftware 50

Appendix B DIP-Switch information 61

Appendix C Fault Messages 62

Appendix D Error Memory Messages 79

Appendix E Messages regarding pilot arc voltage 80

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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 Software version 2

T U C K E R #########

System software V ##.##

Keypad/Display V ##.##

Central CPU V ##.##

SMPS V ##.##

Interface ########### V ##.##

Output 1 #### / #### V ##.##

Output 2 #### / #### V ##.##

Output 3 #### / #### V ##.##

Output 4 #### / #### V ##.##

Output 5 #### / #### V ##.##

<F1..F5> <ESC>

Now please press the 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 and on the corresponding

submenu and confirm your selection with .

2. Sub-menus with alterable contents may also be selected by pressing one of the

function keys listed below directly.

•Function key : open main menu "Function Keys"

•Function key : open main menu "OPERATION"

•Function key : open main menu "Programming"

•Function key : open main menu "Monitor Parameters"

•Function key : open main menu "Reset Fault"

•Function key and open changing over languages.

T U C K E R #########

System software V ##.##

Keypad/Display V ##.##

Central CPU V ##.##

SMPS V ##.##

Interface ########### V ##.##

Output 1 #### / #### V##.## LM V ##.##

Output 2 #### / #### V##.## LM V ##.##

Output 3 #### / #### V##.## LM V ##.##

Output 4 #### / #### V##.## LM V ##.##

Output 5 #### / #### V##.## LM V ##.##

<F1..F5> <ESC>

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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 - Display key functions

F2 - Main menu

F3 - Programming

F4 - weld parameter monitoring

F5 - fault reset

F6 - Release Manual Functions

ESC - ESCAPE, abort

ENT - 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

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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. . . . .####

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 and program number and confirm with . The individual menu lines

of the display signify the following:

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: Yes

(tw = weld time) The deenergization time of the solenoid will be auto-

matically adjusted to the reference stud drop time.

Autoplunge No Automatic autoplunge is not activated.

Optimization: Yes

(Up to max. 800A/60ms) Automatic adjustment of the weld current Iw / weld time

tw when welding through impurities on work surfaces.

Optimization: No No optimization of weld current (Iw) and weld time (tw).

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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.

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1.3 Sub-Menu "Programming"

Please note that opening of the sub-menu "Programming" is

exclusively reserved for authorized and qualified personnel.

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 or by positioning the

cursor on the second line of the main menu and pressing .

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 and

keys and confirmed via .

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.

Note

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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.

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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 keys. The selections of the

individual parameters can be either confirmed with 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".

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