Emhart DCE Appendix A

APPENDIX A
TABLE OF CONTENTS
CHANGING THE DCE POWER SUPPLY................................................................... 1
CHANGING THE GLOBAL DCE POWER SUPPLY ................................................. 6
CHANGING THE AC WELDER POWER SUPPLY ................................................. 16
PROCEDURE FOR POWER VERIFICATION .......................................................... 19
PROGRAMMING STUD LENGTH DETECTION (WELD HEADS) ....................... 20
PROGRAMMING ANGULARITY (WELD GUNS) .................................................. 22
ADJUSTING STUD STICKOUT (WELD HEAD) ..................................................... 23
ADJUSTING STUD STICKOUT (WELD GUN) ....................................................... 24
CLEAR RAM PROCEDURE....................................................................................... 25
PK560 HANDGUN SET-UP (3 STEPS) .................................................................... 27
PISTON LUBRICATION PROCEDURE .................................................................... 30
PISTON TIP AIR FLOW PROCEDURE FOR NUT WELD HEADS ........................ 36
PROPER ETF20 FEEDER SETUP PROCEDURE ..................................................... 44
CHANGING THE DCE POWER SUPPLY
IMPORTANT SAFETY NOTE:
HAZARDOUS VOLTAGES ARE
PRESENT INSIDE THE DCE
CONTROL. TURN OFF AND LOCK
OUT ALL 480VAC INPUT POWER TO
DCE WELDER CONTROL CABINET
BEFORE CONTINUING WITH THIS
PROCEDURE
VERIFY WITH VOLTMETER THAT
 After securing and locking out the input power to the DCE cabinet, open the
480VAC
INPUT POWER HAS BEEN
front door of the DCE and remove the top cover. Continue with the
procedure on the next
page.
TURNED
OFF
CONTINUE TO NEXT PAGE
1
Loosen three Philips
screws and remove
the wires
Dismount Relay K1
Flat head screw driver
You may need to push the DIN bracket
back in order to access the release tab on the
K1 relay
CONTINUED NEXT PAGE
2
Loosen the flat head screw
on the terminal block and
pull ground wire out
Remove wire-run strip
covers as necessary
X-20
Remove the brown and white
wires on X-20. These wires are
going to the Safety Module Pcb.
CONTINUED NEXT PAGE
3
Remove Fiber Optic connection
Remove X-14 connector
Fan +24v power
su p p l y
X-20 wires
X-6
X-14
Remove X-6 connector
SOW +15v power supply
connector
Remove two 13mm hex bolts
CONTINUED NEXT PAGE
4
Lift power supply
by the support
bars and remove
The K-1 relay is left
inside the controller
Filter
END OF PROCEDURE
5
CHANGING THE GLOBAL DCE POWER SUPPLY
Remove welder cover
by removing these 4
bolts.
Note: There is a
ground cable attached
to cover. It is OK to
let the cover hang on
this cable
6
With power turned off,
open the cabinet door.
Note the Plexi-glass
inner door.
Open Plexi-glass inner
door by first removing
the top screw.
7
Next, remove the
bottom 2 screws
Remove the ground
cable under the bottom
Plexi-glass door hinge.
8
Open the Plexi-glass
door then remove it by
removing the upper
and lower door hinges.
Remove the upper
ground wire from the
terminal strip next to
the Relay K1
9
NOTE: Unless there is
something wrong with
Relay K1 it will be used on
the new power supply
Relay K1
To remove K1, push
down on the top of the
relay and swing the
bottom out
10
Remove the three
wires on the bottom of
Relay K1
Lift K1 off of the
mounting rail
Remove the Wire
Harness Cover
adjacent to the PWM
(Pulse Width
Modulator) board.
Locate small white
floating terminal strip
X20 inside the harness
run
11
Remove the brown
and white wires from
the bottom of X20
Remove Wire Harness
Cover that runs along
the top of the power
supply.
12
X14
(2-pin)
X6
(3-pin)
Remove connectors
X14 and X6 from the
PWM board.
Remove Fiber-Optic
cable from upper left
hand side of PWM
board
13
The bundle of cables
disconnected from the
SMPS Power Supply.
Fiber optic cable
X14
X6
X20
Remove the
ASSIST Box cable
connection from
the Ethernet Board
(If applicable)
ZCPU board
Ethernet board
14
Remove the 2 hex
bolts at the bottom
of the SMPS Power
Supply
Slide SMPS Power
Supply out front of
Welder Control.
Reverse this procedure to re-install the new
SMPS Power Supply.
15
CHANGING THE AC WELDER POWER SUPPLY
1.
Remove wires from top of Power Supply
Grounding wire
(not shown in this
picture)
X5-1
Brown
F10
Brown
F11**
White
X6-1
White
X3-2
Brown
X3-1
White
Yellow
Green
Always label all wires disconnected from Power Supply
**Note: The schematics call this F12 and not F11. This may or may not be labeled F11 on your control;
always consider this slot and Fuse as F12.
A. When this fuse is bad
1. “Measurement Line Broken” all active outlets
2. “Common Measurement Line Broken”
3. No power LED’s on Head 1 Driver board and Weld Common Driver Board
SEE PICTURE BELOW
Weld Common Driver Bd.
Head 1 Driver Bd.
Head 1 Weld
Power Cable
Weld Common Weld Power
Cable
16
2. Remove wires from Relay K1 and dismount relay from bracket
Remove these
three wires
Remove these
four wires
Green
Brown
White
Yellow
3. Remove Fiber Optic cable and indicated wire connections from PWM Board
Wire Run
Cover
X4
Fiber Optic
Cable
X6
X19
17
4. Remove bolts from bracing bracket at top of Power Supply.
Bolts
5. Remove mounting bolts at bottom of Power Supply
Bolts
6. Remove all cabling that exit the bottom of the Control Cabinet (weld power cables, etc.)
7. Slide Power Supply out the front of the cabinet. Reverse procedure to reinstall.
18
PROCEDURE FOR POWER VERIFICATION
Examine the Green LED H1 on the outside of the front door of the DCE Control.

If Green LED is on, continue troubleshooting with your ORIGINAL fault.

If Green LED is off, perform the following steps
H1
1.
Verify that there is 480VAC +/- 10%, 60 cycle, 3-phase) to the controller, and (should be
277VAC +/- 10% in reference to ground). If not, repair plant power. If power is OK continue
with step 2.
2.
Open the cabinet door and power up the control. On the inside of the front door near the top is the
Auxiliary Power Supply Board (see the figure below). Verify that the Red LED’s (D1 through
D5, and D10) on the board are lit. If any of the Red LED’s are out proceed to step 3. If not,
proceed to step 2 A.
F5 under cover
D5
D10
CAUTION
480VAC and
230VAC are
present under this
cover.
D4
F3
F4
F2
F1
D3
D2
D1
X9
A)
B)
C)
If all LED’s are lit, disconnect X9 on the door power supply and carefully check for
24vdc between pins 1 & 2 on the board itself.
If 24vdc is present, the green LED is defective. Continue troubleshooting your original
fault. Replace the green LED at the earliest opportunity.
If 24vdc is not present, continue troubleshooting your original fault and replace the
Auxiliary Power Supply Board at the earliest opportunity.
3.
If any of the red LED’s are out.
A)
Secure power to the control and remove the corresponding fuse to the LED that is out and
check it (Note: The fuse for D3 is F4 and the fuse for D4 is F3; also, do not forget about
the fuse under the cover). Replace defective fuse and power up control checking for
green led H1 on front door of DCE Cabinet.
B)
Secure power to the control and remove F1 through F6 on the Fuse Bank and check fuses
(See Appendix B Fig. 7). If any are defective replace fuse(s) and power up control
checking for green led. If the fuses are ok, replace the door power supply.
4.
Once you have the Green LED lit, reset faults if possible and proceed with troubleshooting any
remaining faults.
19
PROGRAMMING STUD LENGTH DETECTION (WELD HEADS)
This program will prevent welding if there are deviations of stud preload or stick-out.
**You must have a part present, clamped, in a weld position, and stick-out properly adjusted
(SEE “ADJUSTING STUD STICKOUT” IN APPENDIX A) to perform this setup**
Activate Stud Length Detection for Single Weld Applications.
1.
2.
3.
4.
5.
At the keypad and from the Main Menu scroll down to Programming and press <Enter>.
With Outlet Programming Highlighted press <Enter>.
Outlet _ will be flashing; Enter the outlet # and press <Enter>.
Scroll down to Check Stud Length and press + to change from no to yes.
Use the right arrow and move to <Teach> Press <Enter>.
When the keypad shows the “Warning Entering Test Mode” press <Enter>.
6. At Teach Length - Press F6 and <Enter> at the same time.
When the keypad shows “Function Complete” press <Enter>.
There will now be a Value (Ref) listed. This is the measured preload and your
programmed penetration can never exceed this value.
7. Scroll Down to Check Length - Press F6 and <Enter> at the same time.
When the keypad shows “Function Complete” press <Enter>.
This will show any measured deviation in the difference line which you will need to
consider when programming a tolerance.
8. Scroll down to Tolerance – Select a tolerance from .300mm to 2.000mm by using the + or –
on the keypad.
9. Scroll down to <> this will take you back to Check Stud Length, press <Enter> to save the
values.
10. Test to see if program is working correctly.
Activate Stud Length Detection for Multiple Welding Applications.
1. At the keypad and from the Main Menu scroll down to Programming and press <Enter>.
2. With Outlet Programming highlighted press <Enter>.
3. Outlet _ will be flashing; Enter the outlet # and press <Enter>.
4. Scroll down to Check Stud Length and press + to change from no to yes and press <Enter>.
5. Press <Esc>
6. Scroll down to Weld Programming and press <Enter>.
7. Outlet _ will be highlighted; enter the outlet # and press <Enter>.
8. Weld Program _ will be highlighted; enter the program # and press <Enter>.
9. Scroll down to Check Stud Length and press + to change from Outlet to Program.
10. Use the right arrow and move to <Teach> Press <Enter>.
When the keypad shows the “Warning Entering Test Mode” press <Enter>.
11. At Teach Length - Press F6 and <Enter> at the same time.
When the keypad shows “Function Complete” press <Enter>.
There will now be a Value (Ref) listed. This is the measured preload and your
programmed penetration can never exceed this value.
12. Scroll Down to Check Length - Press F6 and <Enter> at the same time.
When the keypad shows “Function Complete” press <Enter>.
This will show any measured deviation in the difference line which you will need to
consider when programming a tolerance.
20
13. Scroll down to Tolerance – Select a tolerance from .300mm to 2.000mm by using the + or –
on the keypad.
14. Scroll down to <> this will take you back to Weld Program Standard. Scroll up to
Graphical Monitoring and press <Enter> to save the values.
15. Test to see if program is working correctly.
16. Advance the robot to the next weld point and repeat steps 7 thru 16 to the remaining points.
21
PROGRAMMING ANGULARITY (WELD GUNS)
This program will prevent welding if the gun is not in proper position with regard to the
programmed angularity.
**You must have a part present, clamped and stick-out properly adjusted (SEE “ADJUSTING
STUD STICKOUT” IN APPENDIX A) to perform this setup**
1.
2.
3.
4.
5.
At the keypad and from the Main Menu scroll down to Programming and press <Enter>.
With Outlet Programming Highlighted press <Enter>.
Outlet _ will be flashing; Enter the outlet # and press <Enter>.
Scroll down to Angularity and press + to change from no to yes.
Use the right arrow and move to <Teach> Press <Enter>.
When the keypad shows the “Warning Entering Test Mode” press <Enter>.
6. The Teach Position Value (Ref) will be highlighted and the green LED on the rear of the
gun will be flashing.
a. Press the gun on the part firmly seating the flash shield.
b. Pull the trigger and release. Note: It will not weld at this point
When the keypad shows “Function Complete” press <Enter>.
There will now be a Value (Ref) listed. This is the measured preload and your
programmed penetration can never exceed this value.
7. Scroll Down to Check Position Difference. The green LED on the rear of the gun will be
flashing.
a. Press the gun on the part firmly seating the flash shield.
b. Pull the trigger and release.
When the keypad shows “Function Complete” press <Enter>.
This will show any measured deviation in the difference line which you will need to
consider when programming a tolerance.
8. Scroll down to Tolerance – Select a tolerance from .050mm to 2.000mm by using the + or –
on the keypad.
9. Scroll down to <> this will take you back to Angularity, press <Enter> to save the values.
10. Test to see if program is working correctly.
22
ADJUSTING STUD STICKOUT (WELD HEAD)
***Weld Head must be plugged into an ETF feeder and Air Supply should be on and at the
proper pressure.***
Loosen Collar
Stabilizer
Loosen Adjustment
Screws
Stick-Out
Gauge
2mm
1.
2.
3.
Loosen the adjustment screws and collar screws as needed.
Adjust stabilizer as needed to achieve stud stickout per drawing above.
Tighten all screws and recheck with gauge.
23
ADJUSTING STUD STICKOUT (WELD GUN)
Flash Shield
Loosen Adjustment
Screws
On each side
Stick-Out
Gauge
2mm
1.
2.
3.
Loosen the adjustment screws and collar screws as needed.
Adjust flash shield as needed to achieve stud stickout per drawing above.
Tighten all screws and recheck with gauge.
24
CLEAR RAM PROCEDURE
IMPORTANT: Write down all of the “Outlet Programming” and “Weld Programming”
values as these values will be lost after performing this procedure.
1.
Turn off main power switch to DCE Control. Wait 30 seconds. Open the door of DCE Control.
2.
Locate the DCE ZCPU Board on right wall inside the DCE Control.
3.
Locate the Dip Switches on the DCE ZCPU Board. SEE PICTURE ON THE FOLLOWING
PAGE.
4.
Turn Dip Switch 2 “on”. Dip Switches on the DCE ZCPU Board are looked at ONLY during
“power up” of the DCE Control.
5.
Close door to cabinet and power up the DCE Control.
The RAM should now be cleared. You must now reprogram the “Outlet Programming” and “Weld
Programming” under the “Main Menu” “Programming”.
IMPORTANT: After reprogramming the DCE Control, it is STRONGLY recommended that you
turn the DCE Control off, wait 30 seconds, then open the door of the DCE Control and turn Dip
Switch 2 “off”. Normal position for all Dip Switches is “off”.
If this is not done, the next time you cycle power on the DCE Control with Dip Switch 2 still “on”,
you will again clear the RAM.
SEE NEXT PAGE FOR PICTURE OF DCE ZCPU BOARD
25
DCE ZCPU Board
OFF
ON
8
1
DIP
SWITCHES
NOTE: DIP
SWITCHES ARE
“OFF” FOR
NORMAL
OPERATION.
ALL DIP SWITCH
POSITIONS ARE
REGISTERED
ONLY AT DCE
CONTROL
POWER-UP
26
PK560 HANDGUN SET-UP (3 STEPS)
1. SETTING LIFT
Flash Shield
.045” lift gauge
BACK
direction
Loosen Flash
Shield setscrew
-Loosen Flash Shield setscrew, pull flash
shield fully back (this may require force).
-Push on stud with .045” tooth of lift gauge
as far back as it will go; hold gauge at that
position.
-Carefully pull Flash Shield forward to
gauge. Hold Flash Shield at that position
and tighten Flash Shield set screw.
-With stud in collet,
push down on gun
until flash shield sits
squarely on a flat
surface. Hold at this
position for the
remainder of
Angularity
adjustment.
2. SETTING ANGULARITY
-Turn 1.5mm allen wrench clockwise
until “” LED turns off, then turn
counter-clockwise until the “” LED
just barely turns on.
-This is perfect Angularity. Adjust
more counter-clockwise for less
Angularity sensitivity.
Flash Shield
PKE BOX
CONTINUED
NEXT PAGE
27
PK560 HANDGUN SET-UP (continued)
At the DCE Keypad, press “ESC” key until “Main Menu” is displayed at the top of the screen.
1. Use the <> arrow key to select the line “System Configuration”; press “Enter” key.
2. Use the <> arrow key to select the line “System Parameters”; press “Enter” key.
3. Use the <> arrow key to select the line “Outlet 1…PKE”; press “Enter” key.
You should now see the following screen:
Outlet 1 Configuration
PKE
--------------------------------------Program Select Switch.........no
Program Select Sensor.........no
Mechanical Angularity Switch..yes
Mechanical Counter............no
Slide Rail Valves.............Intern
Stud Arrival Sensor...........no
Air Pressure Monitor..........no
Gas Pressure Monitor..........no
Color Mark....................no
Airblow.......................no
Page 2.<>
--------------------------------------Help Message Area
4. Use the <> arrow key to select the line “Mechanical Angularity Switch”. Use the <+> or
<-> keys to ensure that this line reads “yes”; press “Enter” key.
3. SETTING DROP DOWN TIME FOR PK560 HANDGUN
At the DCE Keypad, press “ESC” key until “Main Menu” is displayed at the top of the screen.
1. Use the <> arrow key to select the line “Service Functions”; press “Enter” key.
2. Use the <> arrow key to select the line “Cycle Functions”; press “Enter” key.
You should now see the following screen:
Cycle Functions
---------------------------------------| 1 | 2 | 3 | 4 | 5
----------+-----+-----+-----+-----+----Cycle
|..?..|..?..|..?..|..?..|..?..
SKK ext. |..?..|..?..|..?..|..?..|..?..
SKK ret. |..?..|..?..|..?..|..?..|..?..
Start feed|..?..|..?..|..?..|..?..|..?..
Lift
|..?..|..?..|..?..|..?..|..?..
Set WC
|..?..|..?..|..?..|..?..|..?..
Color mark|..?..|..?..|..?..|..?..|..?..
Reference output: 1
SKK ext. .
0 ms
Drop time...11,5 ms
SKK ret. .
0 ms
Lift dist. . 0,0 mm
---------------------------------------Help Message Area
3. Loosen (slightly unscrew) the black cap on the back of the PK560 handgun.
4. With a stud in the collet, hold the PK560 handgun firmly onto a grounded piece of metal.
Ensure that the Flash Shield is completely seated on the metal.
(CONTINUED ON NEXT PAGE)
28
PK560 HANDGUN SET-UP (continued)
5. Pull the Trigger on the PK560 handgun. The stud will lift and drop without welding. On the
lower right side of the keypad, read the “Drop Time” in ms- mille seconds.
a. The desired “Drop Time” time reading is between 11.0ms and 11.5ms.
b. To adjust this time proceed to step 6.
6. Using a flat standard screwdriver, adjust the Plunge Spring tension by turning the adjustment
screw just inside the center of black cap that you loosened earlier.
NOTE: After each adjustment of the Plunge Spring tension, repeat
a. Turn adjustment clockwise to decrease “Drop Time”.
b. Turn adjustment counter-clockwise to increase “Drop Time”.
Repeat Steps 4 through 6 until the “Drop Time” reads between 11.0ms and 11.5ms.
7. Once you have adjusted the “Drop Time” to a value between 11.0ms and 11.5ms, carefully
tighten the black cap on the back of the PK560 without moving the adjustment screw. It
might be helpful to keep the screwdriver in place while tightening the black cap.
29
PISTON LUBRICATION PROCEDURE
1. You’re Weld Head, Piston and Front end Components will differ depending on the
style and fastener being welded.
2. This procedure applies to all Weld Guns also.
Boots not shown were
removed for clarity.
Remove front end components to gain access
to the piston assembly.
30
Remove Piston Assembly
Clean Piston Head and O-Ring
31
Clean the inside of the Load Tube
thoroughly with a clean cloth.
Carefully remove the O-Ring
and clean the groove.
Clean and inspect the O-Ring for
wear and replace if necessary.
32
Place the O-Ring in
the groove.
With your finger spread the O Lube that was
expelled by the O-Ring, around the O-Ring.
33
Apply the remaining Parker O Lube on your
finger inside the Load Tube, and spread evenly
Insert the piston and move it back and forth a
few times to help spread the O Lube.
The piston should
move freely.
34
Wipe excess Parker O Lube off the face
of the Load Tube with a clean rag.
Reassemble the front
end of the weld tool.
Install new boots if they are missing or
damaged. (not shown)
35
PISTON TIP AIR FLOW PROCEDURE FOR NUT WELD HEADS
STEP 1
Feeder Input
Air
Regulator
First check the air
regulator settings on the
feeder. These regulators
provide air to the piston
air flow –control.
(the flow-control itself is
mounted on the side
of the weld head)
Head
Forward Air
Regulator
STEP 2
Feeder Input
Air
Regulator
Adjust Feeder Input Air Regulator to the
standard setting for your production plant.
NOTE: No less than 80psi. 90psi is preferable.
WARNING: All subsequent adjustments in this
procedure flow from this setting. Changing this
adjustment during normal operation will affect
the piston air flow.
36
STEP 3
Head
Forward Air
Regulator
Adjust Head Forward Air Regulator to 40psi.
WARNING: Changing this adjustment during
normal operation will affect the piston air flow.
NOTE: You will only have a reading on this dial
when the weld head extends pneumatically to
the forward position. (See steps 5 through 9 if
you want to manually extend the head to make
this adjustment).
STEP 4
Ensure accessibility to the front of the weld
head. Remove Nut from the collet.
37
STEP 5
At Control Keypad, select “Service Functions”
from the “Main Menu”. Press the “Enter” key.
STEP 6
At Control Keypad, select “Cycle Functions”
from the “Service Functions” menu. Press the
“Enter” key.
STEP 7
38
STEP 8
Select the line “SKK F-pos.” under the
appropriate column number for the specific
head you are adjusting.
See next page.
39
STEP 9
While holding down the “F6” key, press the
“Enter” key.
The weld head should pneumatically extend to
the forward position.
STEP 10
With the head extended forward, you should
now hear and feel air coming out the end of the
collet.
Insert the tube of the Flow Meter into the empty
collet. Ensure that the tube covers the tip of the
Piston.
SEE NEXT PAGE
40
Flow Meter tube
Piston tip
This is what should be happening when you
insert the Flow Meter tube into the empty collet.
Piston tip should be inserted in the Flow Meter
Tube.
Collet shown removed here for clarification.
STEP 11
Adjust the piston Flow Control mounted on the
side of the Nut Weld Head so that the registered
flow on the Flow Meter reads 40 l/min.
SEE NEXT PAGE.
41
Top of the ball hits the 40 l/min. mark.
STEP 12
Select the line “SKK R-pos.” under the column
number for the specific head you are adjusting.
See next page.
42
STEP 13
While holding down the “F6” key, press the
“Enter” key.
The weld head should pneumatically move to the
rear position. Now hit the “Esc” key repeatedly
until you exit the “Cycle Functions” mode.
Return to normal operation.
43
PROPER ETF20 FEEDER SETUP PROCEDURE
The following settings are required for proper operation of the ETF20 Feeder:
Go to main menu on Emhart key pad.
Scroll down to
“Programming” press “Enter”.
“Outlet Programming” press “Enter”.
44
Input the outlet # to which ETF 20 feeder is connected to:
“#” press “Enter”.
(Note: There are 3 pages of parameters for this step)
Scroll down to next page.
The following are the required settings for this feeder:
Set these parameters on this page:
Container Up time ……
2200 ms
Container Down time ….
1200 ms
45
Scroll down to next page and set these parameters
Maximum hopper steps……………………………………. 30
Bowl Delay………………………………………………… 0 studs
Press Enter after you have completed with your settings to save them.
46




Important Feeder Hardware Adjustments
Feeder / Hopper door opening for 27mm and 25.5mm Large Flange studs Emhart
Number 29933 and 29646 needs to be set at 43mm (Easiest way to set this adjustment
is by using some type of a space (gauge) block ).
Feeder / Hopper door opening for T5 x 14mm long Xmas tree stud Emhart number
SWB 236 or 29631 needs to be set at 33mm.
Feeder / Hopper door opening for Grounding stud-nut assembly needs to be set at
30mm.
Air flow controls on the lift mechanism need to be set in such a way that the stud
lifting mechanism moves up and down freely and with-in set time. Air flow controls
also need to be adjusted so that the air cylinder creates no impact at the top or the
bottom position.
o This can be accomplished by setting its air flow controls to the following
settings.
 Set the air flow control at the top (upper) of the air cylinder 6 and 1/4
turns from fully closed.
 Set the air flow control at the bottom (lower) of the cylinder to 6 turns
from fully closed.
Upper air flow control
Lower air flow control
47


Air flow control on the kicker cylinder needs to be set in such a way that it does not
start moving toward its extended position (forward) until the lifting mechanism is at
least one half way down to its down (retracted) position.
Kicker cylinder needs to be adjusted so that when it is in its extended position its tip
rides right on top of the fully lowered lift mechanism stud channel.
Air flow control
Kicker cylinder
Lower air flow valve
48

Connecting rod between air cylinder and lift channel needs to be connected
to the bolt hole on the back of the lift channel.
Rear mounting hole
Connecting rod
49