Operating Manual

Safety modul E485A for

DCE-welding equipment

Emhart TUCKER GmbH, Max-Eyth-Str. 1. 35394 Gießen

Tel: 0641-405 0; Fax: 0641-405 383; Mail: [email protected]
Table of contents
1 General remarks............................................................................................. 1

2 Safety circuits ................................................................................................. 2

2.1 Operator protection ................................................................................ 2

2.2 Stop operation........................................................................................ 2

2.3 Release for maintenance operation ....................................................... 2

3 Function.......................................................................................................... 3

3.1 Operating elements................................................................................ 3

3.2 Switching-on conditions ......................................................................... 4

3.3 Operator protection ................................................................................ 4

3.4 Stop operation........................................................................................ 4

3.5 Maintenance operation........................................................................... 4

4 Installation ...................................................................................................... 5

4.1 Connector pin assignment X2 ................................................................ 5

4.2 Example configuration 1......................................................................... 6

4.3 Example configuration 2......................................................................... 6

4.4 Example configuration 3......................................................................... 7

4.5 Example configuration 4......................................................................... 7

4.6 Example configuration 5......................................................................... 8

5 Certain fault situations .................................................................................... 9

5.1 Protection against switching back on ..................................................... 9

5.2 Single-channel cases of error ................................................................ 9

6 Diagrams ...................................................................................................... 10

6.1 Operator Protection.............................................................................. 10

6.2 Stop- and maintenance operations ...................................................... 11

Safety module E485A

1 General remarks

The E485A safety module is a component of the DCE 1500 stud welding
equipment. As a central unit it controls the safe stopping of the stud welding
equipment by means of external signals supplied by the user. In addition, it
controls the release of some maintenance functions for authorised operating
personnel and prevents the equipment from being reactivated in the event of
certain faults.
The safety-relevant functions of the DCE 1500 stud welding equipment have
dual channels and have been designed using safe technology. Depending on
the model of the safety circuit connected to the safety module, the DCE 1500
can be operated in accordance with various safety requirements. The maximum
achieved is safety category 4.

The safety module controls the following switching tasks within the DCE 1500:

• Disconnection from mains supply - power circuit

The safety module controls the separation of the power circuit (SMPS) of
the DCE 1500 from the mains supply via the Protection K1. The proper
switching process is reported to the safety module via the signalling
contacts.

• Disconnection of the mains supply - feeder

The safety module controls the separation of all feeders (SFLM) connected
to the DCE 1500 via the Protection K2. The proper switching process is
reported to the safety module via the signalling contacts.

• Impulse inhibitor - power circuit

The current transformation can be controlled via the impulse inhibitor of the
power circuit independent of other circumstances.

Activating the different safety circuits is reported from the safety module to the
central CPU which then transfers the signal to all other components of the plant.

The E485A safety module is located on the mounting plate in the control cabinet
of the DCE 1500.

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Safety module E485A

2 Safety circuits

2.1 Operator protection

The power circuit (SMPS) of the welding equipment and all connected feeders
are disconnected completely and safety from the mains supply on a time-delay
basis. The central CPU and operating equipment remain under protective extra
low voltage. The customer interfaces continue to supplied with voltage from the
operator of the stud welding equipment and therefore are not disconnected. An
automatic start-up is not possible.
Once the operator protection (OP) has been deactivated, the DCE is
operational again after 30 s.
The operator protection (OP) has been wired on a dual channel basis and has
been designed using safe technology.

2.2 Stop operation

The power generation of the power circuit (SMPS) is stopped by the impulse
inhibitor and all connected feeders are completely and safety disconnected from
the mains supply on a time-delay basis. The central CPU and the operating
equipment remain in operation. The customer interfaces continue to be supplied
with voltage from outside the equipment and are therefore not disconnected.
Stop of operation is wired on a dual channel basis and is designed using safe
technology.

2.3 Release for maintenance operation

A certain group of operating personnel can be allowed access to the
maintenance operation1 by setting a key switch to “ON“. This procedure in
conjunction with the agree key of the robot operating device permits the
following functions to be carried out:

Carriage forwards/backward

Stud feeding

Teach-Mode: The distance between the stud and the workpiece is
measured, checked and stored for reference purposes by activating a lifting
motion of the welding tool.

This function is merely required for maintenance work. The key cannot be
removed if it is in the “ON“ position.

1
Is also denoted as “E2-closure” or” partial removal of operational interruption“ (PRM)

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Safety module E485A

3 Function

3.1 Operating elements

The switching state of the safety module can be determined by means of the six
light diodes on the safety module. The LEDs H1-H6 are arranged on the safety
module in the following way:

The LEDs have the following designations:

LED State

H1 OFF → ERROR: “safety circuit“ activated

H2 OFF → “Operator protection channel 1“ (E2) activated

H3 OFF → “Operator protection channel 2“ (E6) activated

H4 OFF → “Operator protection“ activated

H5 OFF → “Stop operation channel 1“ (E7)

H6 OFF → “Stop operation channel 2“ (E11)

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Safety module E485A

3.2 Switching-on conditions

The device possesses full functionality only after the “Operator protection“ and
”Stop operation“ have been deactivated. In addition, switching-on is prevented if
safety components are defective; (see 5.1).

3.3 Operator protection

The safety circuit “Operator protection“ is connected by the two input channels
E2 and E6 (see 4.1)

The “Operator protection” is activated by opening at least one, normally,

however, both of the input circuits E2 and E6.

The operator protection can only be deactivated by simultaneous closing of both

input channels E2 and E6, if both input channels were previously open; see 5.1.

If “Operator protection” is activated, the “maintenance operation” cannot be

switched on.

3.4 Stop operation

The safety circuit “Stop operation“ is connected by both input channels E7 and
E11 (see 4.1).
The stop of operation is activated if the input circuits E7 and E11 are opened.
Stop operation is deactivated if the input circuits E7 and E11 are closed.

3.5 Maintenance operation

Maintenance operation is released by switching the key switch (Door DCE)

“Maintenance operation“ and initiated by closing the input circuits E10 (see 4.1).

Maintenance operation can only be activated during stop operation.

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Safety module E485A

4 Installation

4.1 Connector pin assignment X2

Covered by the door, the plug-in connector X2 (Han-10-modular) is located in

the control cabinet of the DCE 1500. The user will find located here the
connection possibilities for the signals of the safety circuits listed in chapter 2.

Pin Signal name Name Function

B2 Agree button E10 Input
External agree button for maintenance
B8 Agree button
operation
B9 RM BS M3 Feedback contact for external circuiting
A9 RM BS Contact only closes if operator protection is
definitely activated
B11 RM BU M2 Signalling contact
Contact open during stop operation
A11 RM BU
B10 BS Channel 11 E2 Input
Operator protection channel 1, contact-
A10 BS Channel 12
controlled
B12 BS Channel 21 E6 Input
Operator protection channel 2, contact-
A12 BS Channel 22
controlled
A5 BU Channel 11 / SP E7 Input
Stop operation
B5 BU Channel 12
Channel 1 & 2,
B6 BU Channel 21 E11 contact-controlled or voltage-controlled
(SP/SN)
A6 BU Channel 22 / SN
A2 +24V SI-Module Input
Supply voltage of the safety module for the
A8 024V SI-Module
contact-controlled operation
A3 BS Channel SP Input
Operator protection voltage-controlled
A4 BS Channel SN
B1 +24V internal Output
Internal 24V-power supply. Beware!
B7 024V internal
only to connect with A2/A8!
A1 +24V external Input
Supply voltage of customer interface
A7 024V external

BS = Operator protection BU = Stop-Operation

SP = Positive voltage SN = Negative voltage

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Safety module E485A

4.2 Example configuration 1

X2 B2
B8

B9
E10
A9
B11

A11
B10
A10

B12
A12

A5
B5
+ BU
B6
A6
- BU
A2
A8

A3
A4

B1
B7

A1
A7

• 24V to +BU and -BU deactivated stop operation.

• Agree button for maintenance operation as per Chapter 3.5.

• Operator protection is not used. OP is always deactivated.

4.3 Example configuration 2

BU

X2 B2
B8
E7
B9
E10
A9
B11

A11
E11
B10
A10

B12
A12

A5
B5
B6
A6

A2
A8

A3
A4

B1
B7

A1
A7

• Contact-controlled stop operation (BU)

• Agree button for maintenance operation as per Chapter 3.5.

• Operator protection is not used: OP is always deactivated.

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Safety module E485A

4.4 Example configuration 3

X2 B2
B8

B9
E10
A9
B11

A11
B10
A10

B12
A12

A5
B5
+ BU
B6
A6
- BU
A2
A8

A3
A4
+ BS
- BS
B1
B7

A1
A7

• 24V to +BS and -BS deactivated operator protection.

• 24V to +BU and -BU deactivated stop operation.
• Agree button for maintenance operation as per Chapter 3.5.

4.5 Example configuration 4

X2 B2
B8
E2
B9
E10 BS
A9
B11

A11
E6
B10
A10

B12
A12

A5
B5

B6
A6
E7
A2
A8 BU
A3
A4

B1
E11
B7

A1
A7

• Contact-controlled operator protection (OP)

• Contact-controlled stop operation (BU)
• Agree button for maintenance operation as per Chapter 3.5.
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Safety module E485A

4.6 Example configuration 5

If the DCE 1500 stud welding unit is only to be used for manual stud welding by
means of PL/PLM welding guns, a plug is to be connected to X2 with the
following jumpers:

X2 B2
B8

B9

A9
B11

A11
B10
A10

B12
A12

A5
B5

B6
A6

A2
A8

A3
A4

B1
B7

A1
A7

• Jumpering of all safety functions.

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Safety module E485A

5 Certain fault situations

5.1 Protection against switching back on

The DCE 1500 stud welding equipment is secured against being switching on in
the presence of certain faults. The following faults prevent the unit being
switched back on:

• Safety circuit E1 is interrupted (internal error, service required)

Check connection safety module, plug X2 to central CPU, plug X13.

• Operator protection channels E2 and E6 were not switched simultaneously

or a channel (E2 or E6) was not switched at all.

• Feedback loop of the feeder safety relays (internal error, service required)
Check connection safety module, plug X2 to central CPU, plug X26.

• Feedback loop E4 is separated from contactor K2 or K2 is hanging (internal

error, service required)
Check connection safety module, plug X6 to protection K2 (mounting plate)

• Feedback loop E5 is separated from contactor K1 or K1 is hanging (internal

error, service required).

• Check connection safety module, plug X4 to contactor K1 (power circuit-

SMPS).

5.2 Single-channel cases of error

If the switching action for the operator protection is caused by an error in the
feedback system or the cabling on a single-channel basis only, i.e. only E2 or
E6 switched, the device can only be put back into operation after the error has
been rectified, followed by switching the device off/on via the main switch.

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Safety modul E485A

6 Diagrams

6.1 Operator Protection

Start welding before BS Start welding during BS
Start weld cycle

Operator protection
don’t care don’t care
Stop of operation

Welding process

Net SMPS (K1)

Net feeder (K2)

Valve voltage (SF K3)

Impulse inhibitor SMPS

Feedback BU (M2)

Feedback BS (M3)

~300 ms ~1600 ms
~300 ms ~1600 ms

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Safety modul E485A

6.2 Stop- and maintenance operations

Start welding before BU Start welding during BU Maintenance operation

Start weld cycle

Operator protection

Partial removal

Stop of operation

Welding process

Net SMPS (K1)

Net feeder (K2)

Valve voltage (SF K3)

Impulse inhibitor SMPS

Feedback BU (M2)

Feedback BS (M3)

~1600 ms ~1600 ms ~2500 ms

min. ~1600 ms

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Notizen/Notes: