EMHART

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: [email protected]
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
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

TUCKER ######### TUCKER #########
System software V ##.## System software V ##.##
Keypad/Display V ##.## Keypad/Display V ##.##

Central CPU V ##.## Central CPU V ##.##
SMPS V ##.## SMPS V ##.##
Interface ########### V ##.## Interface ########### V ##.##
Output 1 #### / #### V ##.## Output 1 #### / #### V##.## LM V ##.##

<F1..F5> <ESC> <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.
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 - 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
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.

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
Progr. Nr. 01 - 127 The parameters of the selected weld program will be
Weld part ident Display of the program ident for the weld part.
Autoplunge: Yes The deenergization time of the solenoid will be auto-

(tw = weld time) matically 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 Monitoring time in weld sequence was exceeded.
Timeout
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 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.
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 In standard operation (feeder - SKK/PK) the output no. must

operation 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 For each weld task a specific weld program should be
No. 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 Selection of sheet thickness of work surface: 0,8 mm, 1,2 mm,
Gauge 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 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".
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 and

keys as well as the and keys.
8
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 you

will return to the main menu.
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 . The individual menu lines of the
display signify the following:
WOP-Memory Record for all welds out of tolerance.

Weld part ident Display of the program ident for the weld part
O 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 .
Prog. Display of current weld program.
Page Display of current page.
Date Date when WOP occurred.

Time Time when WOP occurred.
Autoplunge: Yes The de-energization time of the solenoid will be auto-

(tw = weld time) matically adjusted to the reference stud drop time.
Autoplunge: No Automatic autoplunge was not activated.
Optimization: Yes An automatic adjustment of the weld current Is / weld
(up to max. 800A/60ms) time ts when welding through impurities on work
surface was performed.
Optimization: No No optimization of weld current lw and weld time tw
performed.
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 Monitoring time in weld sequence was exceeded.

Timeout
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 you

12
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
WOP auto
Number of Number of repeat Number rep.-
O WIP&WOP WOP lim act of faults feed
1 ####### ####### # # ###### #####
2 ####### ####### # # ###### #####
3 ####### ####### # # ###### #####
4 ####### ####### # # ###### #####
5 ####### ####### # # ###### #####
<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 Outlet:#
number number WOP auto.

of of repeat rep.
Prog WIP&WOP WOP lim  act feed
####### ####### # # #####
####### ####### # # #####
####### ####### # # #####
####### ####### # # #####
####### ####### # # #####
####### ####### # # #####
####### ####### # # #####
####### ####### # # #####
<↓↑> <F1..F5> <ESC>
Select output number and confirm with . The individual menu lines of the
display signify the following:
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 again you will
return to the sub-menu "Statistics".
By pressing you will return to the main menu.
14
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 3 4 5
Act. ###### ###### ###### ###### #####
Warn. ###### ###### ###### ###### #####
Fault ###### ###### ###### ###### #####
Monitor - drop time (ms)

Act. ###,# ###,# ###,# ###,# ###,#
Warn. +# -# +# -# +# -# +# -# +# -#
Fault +# -# +# -# +# -# +# -# +# -#
<F1..F5> <ESC>
Maintenance The wear of the collet as well as the drop time of the connected
weld tools will be displayed.
Collet Maint.- Weld statistics will begin with assembly of new collet.
No. of Welds Remark: After replacing the collet the maintenance meter must
be reset.
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 Monitoring of the mechanical parameter "stud drop time".

Time (ms) Remark: The difference refers to the established drop time of
the past 8 welds in relation to the programmed (!) drop time.
Act. Deviation of actual measured stud drop time from the pro-
grammed one will be displayed.
Warn. Programmed deviation with which, when exceeded, the corres-
ponding maintenance warning will become active.
Fault Programmed deviation with which, when exceeded, the corres-
ponding weld output will be set to fault condition.
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> <STUD>
<←↓↑→> <ENTER> <F1..F5> <ESC>
Select output and program number and confirm with . The individual menu lines
of the display signify the following:
Fault Output # 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 re-
displayed 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 over-

view on the weld circuit-related signals. Position the cursor on the corresponding
menu line of the main menu and press the key.

1 2 3 4 5
Weld cycle # # # # #
Feed cycle # # # # #
SOW # # # # #
Angularity switch PK # # # # #
Start weld # # # # #
Start feed # # # # #
SKK R-position # # # # #
I. Tolerance # # # # #
Program number ### ### ### ### ###
<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.
Feed cycle *: Stud feeding operation.

-: No stud feeding operation.
SOW *: SOW (stud on workpiece) signal is active.

-: No SOW signal.
Angularity *: Angultary signal is active.

switch PK -: No angultary signal.
Start weld *: Start weld signal is active.

-: No start weld signal.
Start feed *: Start feed signal is active.

-: No start feed signal.
20
SKK R-position *: SKK retracted signal is active.
-: No SKK retracted signal
I/O Tolerance *: Parameters are within the operating tolerance range.
-: Parameters are out of operating tolerance range
Program 1-127 : Display of program no under which the last weld was
number performed.
By pressing 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.

# # # # #
Operation mode #### #### #### #### ####
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 *: The signal "start weld " is set via the interface.
-: The "start weld" signal has not been set
Start Feed *: The signal "start feed" is given via the interface.
-: The signal "start feed" has not been set
Without weld *: The signal "without weld" has been set.

-: The signal "without weld" has not been set
Reset fault *: The signal “reset fault“ is set.

-: The signal “reset fault“ has not been set.
22
Restart *: The signal "restart" has been set.
-: The signal "restart" has not been set
Set WC *: The signal “Weld complete“ is set.

-: The signal “Weld complete“ has not been set.
Start SKK F-pos. *: 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.
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 ### ### ### ### ###
Piston retracted # # # # #
Pos. Stud divider # # # # #
Stud level low # # # # #
<F1..F5> <ESC>
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 retracted *: SKK is retracted.

-: No input signal “SKK retracted“.
Angularity switch *: Angultary signal is active.

PK -: No angultary signal.
Start weld *: Start weld signal is active.

-: No start weld signal.
Start feed *: Start feed signal is active.

-: No start feed signal.
Stud level low *: Stud level low signal is active.

-: No stud level low signal.
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. . . . . . . . . . . ##.##.## Time . . . . . . . ##.##.##
Software. . . . . . . V##.## Address. . . . . . . . . ###
Interface. ########### SMPS ready. . . . . ####
Operation stop. . . . #### Emergency . . . . . . ####
# # # # #
Connection ##### ##### ##### ##### #####
SF-Typ #### #### #### #### ####
SKK/PK ### ### ### ### ###
SF..A/D # # # #
Lift sensor #### #### #### #### ####
Maintenance # # # #
<F1..F5> <ESC>
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 Display of existing / not existing stop operation

Operation
Emergency Display of existing / not existing emergency stop
Connection norm: standard feeder configurated

SD2-M master feeder SD2 configurated
SD2-S: slave feeder SD2 configurated
SD5-Z: SD5 feeder configurated
SD5-W: SD5 divider configurated
PKE: 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> <F1..F5> <ESC>
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 V ##.##
Central CPU V ##.##
SMPS V ##.##
Interface ########### V ##.##

Outlet 1 #### / #### V ##.##
Outlet 2 #### / #### V ##.##
Outlet 3 #### / #### V ##.##
Outlet 4 #### / #### V ##.##
Outlet 5 #### / #### 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 3 4 5
Cyclus ##### ##### ##### ##### #####
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. . . . . . . . #, ## 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 “ “ - key must be pressed.
Attention: 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.
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 you
29
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

1 2 3 4 5
Operation mode #### #### #### #### ####
Ready # # # # #
SOW # # # # #
I.Tolerance # # # # #
Fault # # # # #
WC # # # # #
Maintenance # # # # #
Emergency stop # # # # #
Fault code ### ### ### ### ###
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 The following operation modes can be simulated: AUTO, TEST,

mode 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 pres-
sing 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
SOW # # # # #
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.
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 and .
• Confirm your entry with .
Test mode power supply
Output No. . . . . . . . . . . : #
Quantity of testcycles. : ###
Start . . . . . . . . . . . . . . . : #####
Actual weld current . . . . : #### A

Actual cycle count. . . . . : ###
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.
Output nr. Select the output for which the test mode is to be executed
Number of cycles Number of test cycles that are to be simulated.

(ref)
Start Press the keys and simultaneously to start the

function
32
Weld current act The measured weld current
Number of cycles Number of test cycles executed

(act.)
• 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
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 The number of welds exceeds the set limit value

clamping tongs
Maintenance weld The gun drop time established via 10 welds exceeds
head 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 “Program-
ming“ 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 System parameters

Address Interface . . . . . ### Address Interface . . . . . . ###
Network . . . . . .### Network . . . . . . .###
Language . . . . . . ########### Language . . . . . . . . . . . . . .###########
Parameter printout: . . . . . #######

###########
#############
##########
<↓↑> <+, -> <ENTER> <F1..F5> <ESC> <↓↑> <+, -> <ENTER> <F1..F5> <ESC>
Address Interface The unit address Interface serves to identify the TMP
when connecting it to the Pro-Bus customer interface.
Address Network 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 In standard operation (feeder - SKK/PK) the SKK/PK no. is to be

standard entered according to the TMP configuration. For example: "TMP
output 1 - feeder 1 - SKK/PK No. 1".
operation
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 When operating with a 5-way stud divider the SKK no. must be
operation with entered as it is at the "SD5-stud divider".
For example: "SD5-output 3 - SKK No. 3".
SD5
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.
SKK/PK active Yes : The output of the TMP-weld unit is activated.

No : The output of the TMP-weld unit is not activated.
Slide rail 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 Yes: If the SOW signal is not recognized when the weld tool
feed moves forward the feeding process will be repeated.
No: No auto-refeed requested.
Feed Yes: The feeding cycle is terminated upon arrival of the stud in
adjustment 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 Sequential welds out of tolerance can be limited by the customer

WOP 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 Yes : n.c.

switch No : 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.
Remark: Programming is to be effected via the and keys
Programmed parameters will be confirmed with or rejected with . You may

exit the input mode by pressing the key.
39
1.12.3 Function Menu "Weld Program"
This function menu will be selected by positioning the cursor on the third menu line
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 . . . . . . . .. ## A
Pilot current time. . . . . ## ms
Weld current . . . . . . . #### + ### - ### A
Weld current time . . . . ### + ## - ## ms
Varc pilot current. . . . . ## + ## - ## V
Varc weld current . . . . ## + ## - ## V
Optimization. . . . . . . . ####
Weld type . . . . . . . . . . ###########
Program continues <##>

<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 and .
Program The second menu page can be displayed by pressing the

continues direction key .
Having pressed the key the cursor will have moved to the second menu page.
Outlet : # Weld program: ###

Program continues . . . < ↑ >
Start delay . . . . . . . . . ### ms

Lift distance . . . . . . . . # ,## +, ## -, ## mm
Drop time . . . . . . . . . . ## ms
Autoplunge . . . . . . . . . ####
Air blow . . . . . . . . . . . ####
Detect stud . . . . . . . . . ####
Corresponding stud . . #########
Weld part ident. . . . . . ################
<1..5> <←↓↑→> <+,-> <ENT> 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.

stud Note: It will be verfied before the weld whether the last stud feed was
performed by the correct feeder.
None : Corresponding stud verification feature not requested
Remark: Verification of corresponding stud is only possible during operation with a 2-

way stud divider SD 2.
Weld part
Input of an alpanumeric text for identification of the weld part
identification
Remark: Programming is to be effected via the , , and keys.
Programmed parameters will be confirmed with or rejected with . You may

exit the input mode by pressing the key.
42
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
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 In selecting "Single Program" one copy of the weld program will
be made
Program Area In selecting "Program Area" several copies of the weld program
will be made
Programs per In selecting "Programs per Output" allweld programs of an
Output output will be copied
Select the requested copy function with the direction keys and and confirm
with .
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
Clear functions
1  2  3  4  5
Maintenance ####################
Statistic ####################
Fault memory ########################
WOP memory ########################
<←↓↑→> <ENTER>=Clear <F1..F5> <ESC>
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
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 The system test will indicate the measured battery voltage
By pressing the 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 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>
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.
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 .
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.
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

-------------------------------------- ----------------------------------------
Weld parameter monitor SKK/PK outlet: # Program.No ...:###
Programming Weld part ident : ################
Statistics Autoplunge...#### Optimization..####
Fault reset | Ref +tol -tol | Act | |
Status weld sequence ----+----------------+-------+---+--
Status customer interface Vp | ## ## ## | ## | V | #
Status Feeder/Stud-Divider Vw | ## ## ## | ## | V | #
Status TMP Iw | #### ### ### | #### | A | #
Functions tw | ### ## ## | ###,# | ms| #
Warnings td | ##,# | ##,# | ms| #
#Lift| #,## ,## ,## | #,## | mm| #
Fault :################################
-------------------------------------- ----------------------------------------
<↓↑> <ENTER> <F1..F5> <0..5> <ENTER> <F1..F5> <ESC>
Programming Programming weld parameters

---------------------------------------- ----------------------------------------
Weld parameters
Outlet/feeder 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 Fault No. ###
---------------------------------------- ----------------------------------------
fault memory O|Prg|Fault type |No.| Date | time
WOP memory -+---+-----------+---+--------+--------
Outlet statistics #|###|###########|###|##.##.##|##:##:##
Weld program statistics #|###|###########|###|##.##.##|##:##:##
Maintenance #|###|###########|###|##.##.##|##:##:##
#|###|###########|###|##.##.##|##:##:##
#|###|###########|###|##.##.##|##:##:##
#|###|###########|###|##.##.##|##:##:##
........................................
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
----------------------------------------
1 2 3 4 5
SOW # # # # #
I.Tolerance (WIP) # # # # #
Program number ### ### ### ### ###
----------------------------------------
<F1..F5> <ESC>

----------------------------------------
# # # # #
Operation mode #### #### #### #### ####
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 ### ### ### ### ###
Piston retracted # # # # #
Pos. Stud divider # # # # #
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 #### #### #### #### ####
----------------------------------------
<F1..F5> <ESC>
Functions E M H A R T T M P ####
---------------------------------------- ----------------------------------------
Display system configuration System software V##.##
test mode cycle function
test mode outputs interface Keypad/Display V##.##
test mode weld process Central CPU V##.##
test mode power supply SMPS V##.##
Interface ########### V##.##
Outlet 1 ####/##### V##.##
Outlet 2 ####/##### V##.##
Outlet 3 ####/##### V##.##
Outlet 4 ####/##### V##.##
Outlet 5 ####/##### V##.##
---------------------------------------- ----------------------------------------
<↓↑> <ENTER> <F1..F5> <ESC> <F1..F5> <ESC>
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
----------------------------------------
54
Test mode outputs interface
----------------------------------------
1 2 3 4 5
Operation mode #### #### #### #### ####
Ready # # # # #
SOW # # # # #
I.Tolerance (WIP) # # # # #
Fault # # # # #
WC # # # # #
Emergency stop # # # # #
Fault code ### ### ### ### ###
----------------------------------------
<←↓↑→> <+,-> <F1..F5> <ESC>
Test mode weld process

-----------------------------------------
1 2 3 4 5
Weld cycle us # # # # #
SOW # # # # #
Program number ### ### ### ### ###
Warning! The TMP-unit will work in test-
mode. 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
---------------------------------------- ----------------------------------------
<F1..F5> <ESC> <1..5> <+,-> <↓↑> <ENTER> <F1..F5> <ESC>
55
Sub-menu to EXTENDED FUNCTIONS (hidden)
Extended functions System parameters
--------------------------------------- ----------------------------------------
System parameters Address Interface.....###
Mechanical parameters Network.......###
Weld parameters
Copy programs Language.............###########
Clear functions
ZCPU System test Parameter printout.......#######
De/activate programs ###########
Stud length detection #############
Set date and time ##########
--------------------------------------- ----------------------------------------
<↓↑> <ENTER> <F1..F5> <ESC> <+,-> <ENTER> <F1..F5> <ESC>
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........#### +### -### A
Weld current time... ### + ## - ## ms
Varc pilot current.. ## + ## - ## V
Varc weld current... ## + ## - ## V
Optimization........####
Weld type...........###########
Program continues...<## >

----------------------------------------
<1..5> <←↓↑→> <+,-> <ENT> <F1..F5> <ESC>
56
Outlet:# Weld program:###
----------------------------------------
Program continues...<## >
Start delay......... ### ms

Lift distance....... #,## +,## -,## mm
Drop time........... ## ms
Autoplunge.......... ####
Air blow............ ####
Detect stud......... ####
Corresponding stud.. #########
Weld part ident..... ################
----------------------------------------
<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>

----------------------------------------
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 Clear functions Functions

--------------------------------------- ---------------------------------------- ----------------------------------------
F1 – display key functions | 1 | 2 | 3 | 4 | 5 display system configuration
F2 – main menu ---------------+----+----+----+----+---- test mode cycle functions
F3 - programming Maintenance |####|####|####|####|#### test mode outputs interface
F4 – weld parameter monitor Statistics |####|####|####|####|#### test mode weld process
F5 – fault reset Fault memory |######################## test moce power supply
F6 – approval for test mode WOP memory |########################
ESC – ESCAPE, abort

ENT – ENTER, confirmation -------------------------------------- --------------------------------------
| Activate clear function? | |Warning! Test mode will be activated |
0..9 – input SKK/PK, program No. | <ENTER>=YES <ESC>=NO | | Confirm <ENTER> Exit <ESC> |
+- - change, set/reset values -------------------------------------- --------------------------------------
<↓↑> - select menu, value ---------------------------------------- ----------------------------------------
<ENTER> <F1..F5> <ESC> <ENTER> <F1..F5> <ESC>
Fault outlet # Fault condition

--------------------------------------- ----------------------------------------
To continue operation clear

########## ########## ########## the fault condition
--------------------------------------- ----------------------------------------
<↓↑> <ENTER> <F1..F5> <ESC> <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: System reset, delete RAM-module.

DIP-Switch 7: Lock single programming.
DIP-Switch 8: 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: Fault Messages
When repairing the TMP 1000 on location operator safety must

be assured. Trouble-shooting is only to be performed by
Note 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: Display-Message:
1 slide rail remains in R-position

2 no SOW
3 slide rail not in R-position
4 SOW was not reset
5 weld procedure sequence fault
6 program not selectied
7 program not activated
8-12 Out of tolerance
13 no lift
14 short-circuit weld
15 drop time timeout
16 no arc, open circuit
17 measurement line broken
19 collet PM required
21 weld head PM required
23 handgun sequence not followed
25 wrong stud loaded
26 fault feed or stud divider function
32 SMPS regulation out of range
34 safety circuit fault
62
Fault: Display-Message:
35 system configuration fault

38 fiber optic connection feeder fault
39 fiber optic connection customer interface fault
40 fiber optic connection SMPS fault
43 feeder configuration fault
45 start weld not reset
46 missing stud feed
47 test conditions aren‘ t met
49 feeder not in automatic operation mode
62 ZCPU: RAM module fault or defective
100 feeder: no power to aux. supply
102 feeder: rail way not filled in time
103 feeder: air pressure too low
104 feeder: knife not in front position
106 feeder: feed tube monitor switch
109 feeder: feed cyle timeout
120 wrong corresponding stud
132 SD5: voltage fault
133 SD5: still in front position
134 SD5: front position not reached
135 SD5: R1-position not reached
140 SD5: front position and all R-pos.
141 SD5: at minimum 2 positions not OK
142 stud divider position not reached
143 SD5: not in home position
144 feeder: LM system fault
146 feeder: LM not ready
159 feeder: LM stud length faulty
160 feeder: colour mark not possible
202 SMPS: temperature exceeded
204 SMPS hardware fault
Operational faults of the TMP 1000 that can not be reset on

location by the listed remedial measures require unit replacement
Note
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
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: • 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
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
Fault 5: "weld procedure sequence fault"
Description: • Due to a misfunction the weld sequence is not ter-

minated correctly.
Cause: • Feeder or SMPS misfunction

• check weld (if necessary, reweld)
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
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
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

• verify tolerances
• check weld circuit and weld conditions
• check SMPS and weld tool
Fault 13: "Fault no lift"

Description: • Weld unit is unable to identify lift via measurement lines.
Cause: • weld conditions prohibit lift

• defective weld head
• internal process cycle fault
Remedial Measure: • check weld conditions

• check weld head
• check feeder
• feed studs
• check feeder connection
• repeat weld
• set WC
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
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

• check measurement line (if necessary, reduce weld
circuit resistance)
• check SKK / PK settings
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
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.
With reversed polarity and an uninterrupted measurement line-

ground 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
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

• 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

• check stud divider
• check feeder
• check feeding tube
This fault message will be displayed during divider operation at

the feeders which did not cause the fault. The remedial measures
Note 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
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
The safety symbol on the TMP door indicates dangerous electrical

voltage. Opening of the control cabinet is reserved for qualified
Warning 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
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

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

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
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
Fault 100: "feeder: no power to aux. supply"
Description: • The feeder identifies no voltage supply.
Cause: • defective feeder fuse

Remedial Measure: • replace feeder fuse

• check feeder
Detailed information on how to remove defects at the stud feeder can

be read from the corresponding operating manual
Note
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
Remedial Measure: • check feeder (if, necessary refill)

• remove blockage
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
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
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
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

Fault 120: "wrong corresponding stud"
Description: • The programmed corresponding stud is unacceptable
Cause: • stud divider without function

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

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

• bring stud divider back into initial position
• repeat feed cycle
75
Fault 134: "SD5: front position not reached"

function.
Cause: • insufficient compressed air supply

• stud divider got jammed

• remove blockage
Fault 135: "SD5: R1-position not reached"

function.


• remove blockage
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

• 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.


• remove blockage
76
Fault 142: "stud divider position not reached"
Description: • The stud divider did not reach the required position
within the monitoring time.


• 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.


• remove blockage
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

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
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Programming Manual

Control and Power Unit

Software version 1 Software version 2

Keypad/Display V ##.## Keypad/Display V ##.##

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

<F1..F5> <ESC> <F1..F5> <ESC>

Now please press the key to open the main menu.

Weld parameter monitor

<↓↑> <ENTER> <F1..F5>

• Function key : open main menu "Function Keys"

F1 - Display key functions

ESC - ESCAPE, abort

0..9 - input SKK/PK, program no.

Exit the menu by pressing any key.

Display- and Control Panel

Remark: Output "0" described below has a special function.

Weld parameter monitor

Autoplunge: Yes The deenergization time of the solenoid will be auto-

+ 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.

* Some voltage values are of particular importance (see Annex E).

Possible fault indications are:

None Weld cycle without fault.

Faults will be recorded under a fault number in the fault memory.

Selecting the function keys .. will open the corresponding sub-menu. By

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

The sub-menu "Programming" is to be selected for programming of the weld

<↓↑> <ENTER> <F1..F5> <ESC>

1.3.1 Function Menu "Programming Weld Parameters"

Programming weld parameters

Weld programm activ. . . ####

<1..9> <↓↑> <+,-> <ENTER> <F1..F5> <ESC>

Standard In standard operation (feeder - SKK/PK) the output no. must

Yes External program selection enabled.

Weld diameter Selection of weld flange diameter.

none Untreated work surface.

galvanized Galvanized work surface.

Energy adjustment Weld energy adjustment in a range from -50% - +50%

Programming is to be executed by the and keys. The selections of the

Programming output/feed time

Output active....... ####

<1..9> <↓↑> <+,-> <ENTER> <F1..F5> <ESC>

Yes The output of the TMP weld unit is activated.

No The output of the TMP weld unit is not activated.

Remark: Programming is to be performed via the numerical keys, the and

<↓↑> <ENTER> <F1..F5> <ESC>

1.4.1 Sub-Menu "Fault Memory"

Fault memory Fault no. ###

<↓↑> <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.

Fault Type Information at which component the fault occurred

No. No. of fault message.

Date Date of fault.