TX Control Operating Manual DOC100445104
Uploaded by
luis angelTX Control Operating Manual DOC100445104
Uploaded by
luis angelEN
Operating Manual
Control Unit TX
DOC100445104_MDC084_TX_08_EN 08 • 22/05/2023
Operating Manual
Model / Device: Controller TX
Original Operating Manual
Manufacturer
TUCKER GmbH
A Division of STANLEY Engineered Fastening
Max-Eyth-Straße 1
D-35394 Giessen, Germany
Tel.: +49 (0) 641 405-0
Fax: +49 (0) 641 405-38
www.stanleyengineeredfastening.com/brands/tucker
Imprint
Responsible for the content from STANLEY Engineered Fastening in this medium according to Section 5 of
the German Teleservices Act: the manufacturer Tucker GmbH
Stanley, Tucker and other logos are registered trademarks belonging to Stanley Black & Decker, Inc.
No part of this operating manual is to be electronically or mechanically transferred, reproduced and/or copied
without the prior written consent of Tucker GmbH.
© 2023 STANLEY Engineered Fastening. All rights reserved.
Control Unit TX
Table of Contents
Table of Contents
1 About this manual.......................................................................................................................................... 8
1.1 Validity................................................................................................................................................. 8
1.2 Applicable documents ......................................................................................................................... 8
1.2.1 Other documents ................................................................................................................ 8
1.3 Presentation conventions.................................................................................................................... 9
1.3.1 User group symbols ............................................................................................................ 9
1.3.2 Warning indicators .............................................................................................................. 9
1.3.3 Identification of lists and actions ......................................................................................... 10
1.3.4 Assignment of illustrations .................................................................................................. 11
1.4 Terms in this manual........................................................................................................................... 11
1.5 Abbreviations in this manual ............................................................................................................... 12
2 For your safety .............................................................................................................................................. 13
2.1 Intended use ....................................................................................................................................... 13
2.2 Stud welding system hazards ............................................................................................................. 14
2.3 Safety warnings on the product........................................................................................................... 16
2.4 Qualifications required of users........................................................................................................... 17
2.4.1 Training ............................................................................................................................... 17
2.4.2 Personnel qualifications ...................................................................................................... 17
2.5 Personal safety equipment.................................................................................................................. 18
2.6 Safety devices..................................................................................................................................... 19
2.6.1 EMERGENCY-STOP.......................................................................................................... 19
2.6.2 Releasing the stud welding system .................................................................................... 20
2.6.3 Access limitation ................................................................................................................. 21
2.6.4 Self-testing the safety devices ............................................................................................ 21
3 Scope of delivery........................................................................................................................................... 22
3.1 Condition upon delivery....................................................................................................................... 22
3.2 Unpack and check the scope of delivery............................................................................................. 22
4 System overview ........................................................................................................................................... 23
4.1 Processing sequence.......................................................................................................................... 23
4.2 Connecting to the higher-level system controller ................................................................................ 26
4.3 Function of the components................................................................................................................ 27
4.3.1 TX, TE control unit .............................................................................................................. 30
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Table of Contents
4.3.2 REC receiver ...................................................................................................................... 31
4.3.3 TF feeder ............................................................................................................................ 31
4.3.4 Stud welding head TH, TR.................................................................................................. 32
4.3.5 PLM, TGX stud welding guns ............................................................................................. 32
4.3.6 Feed tube............................................................................................................................ 32
4.3.7 Peripherals.......................................................................................................................... 32
4.4 Topologies........................................................................................................................................... 33
4.4.1 Overview of the maximum connectible components .......................................................... 33
4.4.2 Examples of automatic systems ......................................................................................... 33
4.4.3 Examples of manual systems ............................................................................................. 34
5 Product overview........................................................................................................................................... 36
5.1 Controls inside the product housing the.............................................................................................. 36
5.2 Controls on the product housing ......................................................................................................... 41
5.2.1 Status display LEDs............................................................................................................ 43
5.3 Connections ........................................................................................................................................ 44
5.4 Transport equipment ........................................................................................................................... 49
5.5 Control panel/operating unit ................................................................................................................ 50
5.6 Type plate ........................................................................................................................................... 51
6 Transporting .................................................................................................................................................. 53
6.1 Transport conditions............................................................................................................................ 53
6.2 Transporting with a crane.................................................................................................................... 53
6.3 Transporting with a forklift ................................................................................................................... 55
6.4 Transporting with rollers...................................................................................................................... 56
7 Storage.......................................................................................................................................................... 58
7.1 Storage conditions .............................................................................................................................. 58
8 Setting up ...................................................................................................................................................... 59
8.1 Acclimation.......................................................................................................................................... 59
8.2 Positioning the product........................................................................................................................ 59
9 Connecting up ............................................................................................................................................... 61
9.1 Adhere to the connecting up sequence............................................................................................... 61
9.2 Connecting the safety circuit ............................................................................................................... 61
9.3 Connecting the emergency-stop circuit............................................................................................... 61
9.4 Connecting the client interface to the industrial robot ......................................................................... 62
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9.5 Connect up the ground cable .............................................................................................................. 63
9.6 Connecting the shielding gas supply................................................................................................... 63
9.7 Connecting system components ......................................................................................................... 64
9.8 Connecting the operating device......................................................................................................... 64
9.9 Connecting up the compressed air supply .......................................................................................... 65
9.10 Connect power supply......................................................................................................................... 66
10 Starting up ..................................................................................................................................................... 68
10.1 Commissioning.................................................................................................................................... 68
10.2 Restarting............................................................................................................................................ 68
10.3 Making a functional check with the software....................................................................................... 69
11 Configuration ................................................................................................................................................. 70
11.1 Parameterising by the manufacturer ................................................................................................... 70
11.2 Customizing the parameters ............................................................................................................... 70
12 Programming................................................................................................................................................. 71
13 Operation....................................................................................................................................................... 72
13.1 Turning on the product ........................................................................................................................ 72
13.2 Releasing the stud welding system..................................................................................................... 72
13.3 Turing off the product .......................................................................................................................... 73
13.3.1 Draining the pressure from the product .............................................................................. 73
13.3.2 Draining the product of pressure and voltage..................................................................... 74
13.4 Turning the product back on after shutdown....................................................................................... 74
13.5 Operating conditions ........................................................................................................................... 75
13.6 Monitoring operation ........................................................................................................................... 75
13.7 Opening the housing doors ................................................................................................................. 75
13.7.1 Unlocking the upper housing door ...................................................................................... 76
13.7.2 Unlocking the lower housing door....................................................................................... 76
13.8 Locking the housing doors .................................................................................................................. 76
13.8.1 Locking the upper housing door ......................................................................................... 76
13.8.2 Locking the lower housing door .......................................................................................... 76
14 Troubleshooting............................................................................................................................................. 77
14.1 Monitoring messages .......................................................................................................................... 77
14.2 Using trouble-shooting methods ......................................................................................................... 77
14.3 Changing the filter cartridge in the filter regulator valve...................................................................... 79
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14.4 Resetting the compressed air on the pneumatic unit .......................................................................... 82
14.5 Reset the pressure of the shielding gas on the pneumatic unit .......................................................... 83
14.6 Using the program memory card in a different product....................................................................... 84
14.6.1 Removing the program memory card ................................................................................. 84
14.6.2 Inserting the program memory card.................................................................................... 85
15 Cleaning ........................................................................................................................................................ 87
15.1 Cleaning the housing surface.............................................................................................................. 87
16 Maintenance.................................................................................................................................................. 88
16.1 Maintenance interval ........................................................................................................................... 88
16.2 Replacing the filter insert..................................................................................................................... 89
16.3 Emptying the pneumatic unit's collection container ............................................................................ 90
16.4 Replacing a defective manometer....................................................................................................... 91
17 Shutting down................................................................................................................................................ 93
18 Dismantling.................................................................................................................................................... 94
18.1 Undoing the connections..................................................................................................................... 94
18.2 Removing the product ......................................................................................................................... 94
19 Disposal......................................................................................................................................................... 95
19.1 Disposing of packaging material ......................................................................................................... 95
19.2 Product disposal.................................................................................................................................. 95
20 Technical data ............................................................................................................................................... 96
20.1 Dimensions and weight ....................................................................................................................... 96
20.2 Safety control ...................................................................................................................................... 96
20.3 Door closing ........................................................................................................................................ 96
20.4 Protection class................................................................................................................................... 96
20.5 Ambient conditions.............................................................................................................................. 96
20.5.1 Transport ............................................................................................................................ 96
20.5.2 Storage ............................................................................................................................... 97
20.5.3 operation ............................................................................................................................. 97
20.6 Electronics........................................................................................................................................... 97
20.7 Pneumatics ......................................................................................................................................... 98
20.8 Shielding gas....................................................................................................................................... 98
20.9 Weld parameters................................................................................................................................. 98
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Table of Contents
20.9.1 Welding device performance .............................................................................................. 99
Keyword index............................................................................................................................................... 103
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Control Unit TX
About this manual
1 About this manual
1.1 Validity
This operating manual applies to the TX control unit.
1.2 Applicable documents
The manuals for the connected components (See Chapter Other documents [} 8]),
the owner’s guidelines and applied standards all apply in addition to this manual:
1.2.1 Other documents
Document Component Content description
Troubleshooting TX controller Steps for troubleshooting the controller
Fault messages TX controller List of controller error messages
Service and maintenance TX control unit contains information on service and maintenance
Software manual for HMI TX controller Software manual for HMI SWS software
SWS
Translation of the original TX controller System controller manual
operating manual
Translation of the original TH stud welding head Stud welding head instructions
operating manual
Translation of the original TGX stud welding gun Stud welding gun instructions
operating manual
Operating manual TSD stud divider Stud divider instructions
Translation of the original TF feeder Stud feeder instructions
operating manual
Service catalogue TX controller Contains order-specific documents such as replacement
parts lists, reference drawings, electrical and pneumatic
diagrams
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About this manual
1.3 Presentation conventions
1.3.1 User group symbols
Sections of this manual describing actions contain symbols for the users who are authorized to perform these
actions on the product.
Symbol Meaning User group
Operating personnel Technical personnel who
For this work, qualification as operating personnel is have completed basic training
required.
Expert personnel Technical personnel who
For this work, qualification as expert personnel is have completed expert train-
required. ing and who, if applicable,
have the necessary additional
qualifications for the specific
work
Manufacturer personnel Tucker is the manufacturer
For this work, manufacturer’s qualification is re-
quired.
1.3.2 Warning indicators
Before action instructions, this manual shows warnings if following these action instructions may pose hazards.
The warnings are structured as follows:
Warnings at the beginning of a section
CAUTION
Type and source of hazard
Consequences if not heeded
⇒ Action to prevent hazard
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Control Unit TX
About this manual
Warning within a section
CAUTION Hazard type and source Consequences if ignored. Action to prevent a hazard
Warning triangle
The warning triangle indicates death or injury hazards for people. Warnings without a warning triangle indic-
ate property damage.
Signal word
The signal word indicates the severity of the hazard:
Signal word Meaning
DANGER Indicates an immediate hazard that will cause death or severe injury if not
prevented.
WARNING Indicates a possible hazard that may cause death or severe injury if not pre-
vented.
CAUTION Indicates a possible hazard that may cause mild or moderate injury if not
prevented.
ATTENTION! Indicates a situation that may cause property damage if not prevented.
Type and source of hazard
This paragraph describes the type of hazard and what causes it.
Consequences if not heeded
This paragraph explains what happens if the hazard is not prevented.
Action to prevent hazard
These paragraphs indicate how the hazard can be prevented. These measures absolutely must be taken!
1.3.3 Identification of lists and actions
Example Meaning
● Bullet point A bullet point that marks an item in a list
⇒ Enter a value An arrow indicates that an action is needed.
✓ The value was accepted. A checkmark indicates the result of an action step or a se-
quence of action steps.
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About this manual
1.3.4 Assignment of illustrations
For easier understanding, this operating manual contains example illustrations of the product and its compon-
ents. Illustrations always appear before the text to which the illustration is related.
Position numbers in the illustrations show the user which product components action is to be taken on. In the
text, “Illustration, item x” relates to the position numbers.
Example
Fig. 1: Sample illustration “Position of filling flap”
⇒ Open the filling flap (illustration, item 1) of the filling shaft (illustration, item 2).
⇒ If there are weld studs in the filling shaft, remove them.
1.4 Terms in this manual
This manual uses the following terms:
Term Definition
Burn-off Burn-off refers to the part of the welding stud that is melted during
the welding process and where the weld pool forms.
Stud ID The stud ID is the ID in a program that will be used to set up a stud in
the stud welding system. The stud ID is a program that includes all of
the process-relevant parameters that are needed to weld a stud on at
the required welding spot.
Stick out Stick out is the distance between the end face of the loaded welding
stud and the welding head’s tip. The loaded welding stud protrudes
from the tip by the stick out length.
CleanFlash CleanFlash is a light arc that removes impurities from the surface of
the sheet metal to be welded
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About this manual
Term Definition
Docking Docking refers to the industrial robot's ability to lay down a tool and
pick up another tool by itself.
Customer interface The software is integrated into your network via the CI (Customer In-
terface). The CI passes signals from the controller to the industrial
robot and vice versa.
MAC Magnetic Arc Control (MAC) is a coil fitted at the tip of the welding
tool that uses a magnetic field to stabilise the arc’s movement
Robot cell A robot cell is a manufacturing cell that contains at least one indus-
trial robot. It is surrounded by a protective enclosure and secured
through access restrictions.
SMPS The SMPS is a switch-mode power supply. The SMPS generates the
current needed by the welding process.
TF TF is the name of a feeder (F) made by Tucker (T). It feeds welding
studs into other components in the stud welding system.
TX TX indicates a control unit for automatic arc stud welding manufac-
tured by Tucker (T). The control unit starts welding tools and
provides the welding tools with welding current.
1.5 Abbreviations in this manual
This manual uses the following abbreviations:
Abbreviation Meaning
SOW Stud on workpiece
CI Customer Interface
MAC Magnetic Arc Control
SMPS Switched Mode Power Supply
SWS Stud Welding Systems
TCS Tucker Cleaning Station
TF Tucker Feeder
TP Tucker Control Panel
TPS Tucker Pre-Separator
TSD Tucker Stud Director
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For your safety
2 For your safety
2.1 Intended use
This product is a controller for automatic arc stud welding using the drawn arc process. The product is designed
for continuous operation in industry, with a service life of about seven years. The product can be run in a pro-
duction mode and in a set-up mode (manual operation for functional inspections).
The product controls the welding tools and it supplies the welding current to the welding tools.
The product must be connected to the higher-level system controller via a customer interface (CI) in order to
automatically control the welding heads on an industrial robot.
For automatic control of PLM stud welding guns, the product must also be connected to the stud welding gun
via an adapter box.
The product must be integrated into the earthing concept by Tucker service.
Furthermore, the product must also be integrated into the control system and the higher-level system’s safety
concept.
Using a public supply network to operate it is expressly prohibited, as electromagnetic compatibility is not en-
sured due to conducted or radiated interference. The operator will be responsible for any problems caused by
operating the product if it is used for purposes other than those for which it is intended in the public supply net-
work.
The product is intended for use in an industrial network that provides the necessary power to operate it without
interference.
Based on your requirements, the product is delivered in various versions, such as those with specific perform-
ance features, interfaces, communications protocols, and specific power supply connections.
The product is only to be combined with Tucker components (feeder, welding tools, cables and hoses, etc.) to
form a stud welding system.
The product must never be modified by operating personnel.
The following applications, among others are unintended:
● Operation in unsuitable ambient conditions or at unsuitable installation sites such as in potentially explosive
or flammable environments, in damp areas or outdoors
● operating it without any safety devices
● Using with an unsuitable media supply, e.g. with compressed air that does not have the properties stipulated
in the technical data
● used in conjunction with unsuitable components
● using unsuitable tools to carry out maintenance or repair work
● Design changes to components, such as changing the polarity
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Control Unit TX
For your safety
2.2 Stud welding system hazards
The product has been manufactured according to the generally accepted rules of technology. Nonetheless,
there can be personal hazards and property damage if this chapter and the warnings in this operating manual
are not heeded.
⇒ Read this operating manual before you start using the product.
⇒ You must ensure that this operating manual is always accessible to the personnel who will be working with
the product.
⇒ Include this operating manual if you pass the product on to a third party.
Mortal danger from electrical voltage!
After the product is shut off, its capacitors still carry high voltage. A deadly electric shock will occur if people
open the door and touch electrically charged parts.
⇒ After you have switched the product off you must wait two minutes before opening the doors, so that the
voltage stored in the capacitors can dissipate.
⇒ Keep liquids away from all components of the stud welding system.
Injury hazard from automatic startup
Unexpected movements can occur that might result in injuries if the compressed air is switched on again, the
system was not shut down correctly or if the isolating safety devices fail.
This might cause welding studs to shoot out of the feed tube and injure people.
Pneumatically operated moving parts can make unexpected movements and cause crushing-type injuries.
⇒ Deenergize and depressurize the system before removing any of the separating safety equipment.
⇒ Secure the power disconnection devices against reactivation.
⇒ Always use a protective tube around the feed tube.
⇒ Only specialist personnel are allowed to perform maintenance and cleaning
⇒ Ensure that everyone present is wearing an industrial safety helmet, safety goggles and protective gloves.
Risk of being Injured by compressed air
Some situations can cause welding studs to shoot out of the feed hose and injure people.
● disconnected or broken compressed air lines
● open connections or valves
● mistakes, e.g. during the setting up work
⇒ have specialists lay and connect up compressed air and feed hoses
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For your safety
⇒ all of the connected system components must be supplied with the safely switched central air supply from the
control unit
⇒ always use a protective hose around the feed hose.
Risk of being injured due to missing or ineffective access restrictions
If the system is not being operated in a robot cell with secured access or if accessing the robot cell does not res-
ult in the system being stopped, then personnel might be injured.
Use a controller-locked access restriction to secure the robot cell.
Ensure that the robot cell’s safety circuit opens when the access to the safety-related interface is opened.
Injury hazard from light arc
When welding tools are being used an excessive voltage can occur between the welding stud and the work-
piece if a fault occurs and this might injure personnel in the immediate vicinity.
⇒ Ensure that a secure welding current return is installed.
⇒ A protection system that detects excessive voltage and shuts it off safely must be installed whenever welding
guns are to be used.
⇒ Never use electrical lines with damaged insulation.
⇒ Make sure that the personnel present during welding are insulated from the floor, the welding device and the
workpiece and that they are wearing clean and dry protective clothing.
Hearing damage from noise
The compressed air used to feed the studs creates noise.
⇒ Measure the noise that occurs and, if necessary, require hearing protection to be worn.
Burn hazard from heat or flying sparks
The welding tool becomes hot during operation. This can burn people. Highly combustible materials nearby may
catch fire.
⇒ Do not touch the welding tool until it has cooled.
⇒ Keep highly combustible materials away.
Poisoning hazard from gases, smoke or particles
Various toxic gases, smoke or particles can be released during welding, depending on the materials being wel-
ded.
⇒ Always ensure that there is adequate ventilation and extraction from the stud welding system.
⇒ T stud welding system is only to be operated with a functioning extraction system.
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For your safety
Risk of being injured by bright light flashes
Welding creates UV light that can cause eye injuries.
⇒ Ensure that any personnel nearby are wearing safety goggles.
Injury hazard from magnetic fields
The product’s components generate magnetic fields that can interfere with implanted medical devices.
⇒ Put up warning signs prohibiting entry for people with metal implants or pacemakers.
⇒ Ensure that personnel with metal implants or pacemakers stay well away.
Equipment damage caused by the wrong angle between the welding stud and the workpiece
Studs welded at the wrong angle create expensive scrap.
⇒ Always ensure that the stud protrusion is set correctly when using stud welding guns.
⇒ When using welding heads, you must ensure that the robot is programmed so that the welding head is posi-
tioned precisely at a 90° angle to the workpiece.
Equipment damage caused by charges at the USB port
Stud welding causes shock loads to the grid voltage, to other devices in the electrical network and it can also in-
terfere with the product's USB port.
⇒ Do not use the product's USB port for recharging or for supplying power to sensitive devices, e.g. mobile
phones.
⇒ Never connect sensitive devices to the stressed power network.
2.3 Safety warnings on the product
The following safety warnings must always be legible and attached to the product undamaged.
Symbol Meaning To prevent the hazard...
Electric shock hazard despite ⇒ Wait two minutes before opening the doors
voltage interruption after you have switched the product off.
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For your safety
Symbol Meaning To prevent the hazard...
Beware of electrical voltage ⇒ Never touch electrically charged parts.
⇒ Keep fluids away.
⇒ Restricts access to electricians.
Warning about automatic start-ups! ⇒ Before all work on the product, make sure
that the product has been deenergized and
depressurized, and that the product’s power
supply and compressed air supply are se-
cured against reactivation.
⇒ Replace illegible or missing safety warning signs immediately.
⇒ Clean safety signs made illegible by dirt.
2.4 Qualifications required of users
2.4.1 Training
2.4.1.1 Basic training
Basic training given by Tucker Service is needed for all operators.
2.4.1.2 Expert training and maintenance training
Expert training from Tucker service is required for all other work apart from operation. Tasks beyond operation
include tasks during set-up mode, among others.
For maintenance tasks (maintenance, repair and replacement), maintenance training is required.
2.4.2 Personnel qualifications
2.4.2.1 Personnel to be used as operators - Operating personnel
Welders must hold a welder certificate to be able to use a stud welding gun.
Operating personnel must have completed basic training with Tucker and have been oriented in the assigned
work during ongoing operation, such as in production monitoring.
Simple maintenance may be done only by authorized technicians or people with adequate qualifications and au-
thorization. A technician is someone who, based on his technical training, knowledge and experience, and
knowledge of the relevant standards, can assess the assigned work and recognize possible hazards.
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For your safety
2.4.2.2 Setting up personnel - Expert personnel
Hazards can occur during system setting up or during functional system testing that normally does not occur
during operation. This is why only specialists who have been trained by Tucker Service for this work in an expert
training course are allowed to set up the system and run the functional tests.
Work on the electrical equipment can be done only by electrical professionals. An electrician is a person who,
due to his professional training and experience and knowledge of the relevant regulations, can assess the work
assigned to him, recognize possible hazards and take suitable safety measures.
Work on the pneumatic components is to be done only by technical personnel with special knowledge and ex-
perience in pneumatics. Personnel with special knowledge of pneumatics who can read and fully understand
pneumatic diagrams and who also have knowledge of the functioning and design of pneumatic components.
2.4.2.3 Personnel for repairs and troubleshooting – Expert personnel
The product is only to be serviced or repaired by service personnel who have received expert and maintenance
training from Tucker Service.
2.4.2.4 Personnel for transport with lifting devices and industrial trucks
Only instructed and authorized persons are allowed to transport the product using the intended and intact lifting
trucks, industrial forklifts or cranes on internal traffic routes. Forklift drivers need an industrial truck driving li-
cense and written authorisation. Crane drivers must certify their ability to operate and maintain the crane system
and must be at least 18 years old.
2.4.2.5 Commissioning by Tucker service
Only a member of the Tucker service staff who has been authorized to perform commissioning is allowed to put
the product into operation.
2.5 Personal safety equipment
The following personal safety equipment must be undamaged at all times.
Symbol Description
Hearing protection
Hearing protectors protect against hearing damage caused by noise.
Industrial safety helmet
An industrial safety helmet protects the head against falling objects, suspended loads and impacts
against stationary objects.
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For your safety
Symbol Description
Safety goggles
Safety goggles protect the eyes from flying parts and liquid splashes.
safety gloves
Safety gloves protect your hands from friction, abrasions, cuts and deep injuries as well as contact
with hot or cold surfaces.
Welding mask
A welding mask protects against glaring light and flying sparks. The welding mask must have pro-
tection level 3.
Safety shoes
Safety shoes protect the feet from crushing, falling parts and skidding on slippery floors.
2.6 Safety devices
The following safety devices must be installed correctly and be functional at all times.
2.6.1 EMERGENCY-STOP
Automatic system
Fig. 2: EMERGENCY STOP smash-button on the system (example image)
When the product is connected up to the CI with the higher-level system controller, the EMERGENCY STOP
smash-button or the EMERGENCY OFF switch are not fitted on the control unit, but at easily accessible loca-
tions inside and outside the robot cell. Moreover, additional actuators, such as contact switches or key switches
on the robot cell access doors are typically integrated into the safety concept.
The stud welding system automatically shuts down if a robot cell access door is opened or if the higher-level
system causes a shutdown for some other reason.
Proceed as follows to shut down the stud welding system manually:
⇒ Press one of the emergency-stop smash-buttons or one of the emergency-off switches.
✓ The product will be powered down. This shuts off the compressed air supply and the welding current source.
✓ The software shuts down. This process lasts about 10 seconds.
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For your safety
Manual system
Fig. 3: Emergency-off switch on the product
There will be an emergency-off switch on the product if the product does not have a connection to the higher-
level system controller. The stud welding system cannot be shut down with external actuators.
To shut down the stud welding system manually:
⇒ Turn the product's emergency-off switch into the "0" position.
✓ The product will be powered down. This shuts off the compressed air supply and the welding current source.
✓ The software shuts down. This process lasts about 10 seconds.
To end the shutdown of the stud welding system:
⇒ Fix the cause of the shutdown.
⇒ Turn the product's emergency-off switch into the "I" position.
✓ The product is switched on. This turns on the compressed air supply and the welding current source.
✓ The software boots up. This process lasts about 10 seconds.
2.6.2 Releasing the stud welding system
After the control unit is turned on; the stud welding system is still not released and you cannot start welding.
Automatic system
If the product is connected up through the CI to the higher-level system controller, then either the higher-level
system controller can release the stud welding system automatically or an operator can release the stud welding
system manually using the ON switch on the control unit.
Proceed as follows to release the stud welding system manually:
⇒ Press the ON button on the control unit.
✓ The safety control is acknowledged. It can now weld.
Manual system
The stud welding system can be released manually if the product does not have a connection to the higher-level
system controller.
⇒ On the controls, press the ON button to release the stud welding system for welding.
✓ The safety control is acknowledged. It can now weld.
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For your safety
2.6.3 Access limitation
The system has various optional safety keys for the housing and the programming key switch.
● The safety key for the housing restricts access to the inside of the product to authorised personnel only.
● The safety key for the programming key switch restricts the programming option to authorised personnel
only.
2.6.4 Self-testing the safety devices
The controller’s safety devices automatically run self-tests every 24 hours. All of the connected system compon-
ents are briefly switched off for this test. These self-tests are carried out when no request has been sent to the
controller to start a process, which ensures that ongoing production is not interrupted.
The safety devices tests will be run when the safety door is opened. This will delay the automatic self-test.
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Control Unit TX
Scope of delivery
3 Scope of delivery
The following table lists the main components in the scope of delivery. The detailed scope of delivery can be
found in your order overview and in the packing list.
Name Number Description
HMI SWS software 1 Preconfigured to your system requirements
TX control unit 1 Pre-assembled and configured according to
your contract documents
Operating manual for TX control unit 1 on CD
HMI SWS software manual 1 on CD
Control panel/operating unit 1 with touch display
Service catalogue 1 contains parts lists and plans according to
your contract documents, such as replacement
parts lists, reference drawings, and electrical
schematics
3.1 Condition upon delivery
The product is delivered pre-assembled:
3.2 Unpack and check the scope of delivery
⇒ Check the packaging for obvious damage.
⇒ Take the product and included documents individually out of the packaging.
⇒ Check the scope of delivery against your contract documentation for completeness.
⇒ Check all parts in the delivery for obvious damage.
⇒ Check the signs on the product for legibility and intactness.
⇒ Immediately report damage to the product’s packaging and damage to the product and its signs to the carrier
company and to the manufacturer.
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System overview
4 System overview
4.1 Processing sequence
The control unit controls the arc stud welding as a drawn arc process with or without shielding gas. The welding
process is as follows. You can adapt the individual phases and details to your own requirements.
External welding start
When using a stud welding head
The welding process begins as soon as the weld stud loaded into the stud welding head comes into contact with
the workpiece. For this, the stud welding head is moved forward. The contact creates an electrical connection
that triggers the SOW (stud on workpiece) signal in the control unit.
When using a stud welding gun
The welding process begins as soon as the weld stud contacts the workpiece and the SOW signal (stud on
workpiece) and the welding start signal have triggered. For this the stud welding gun is manually placed on the
workpiece. The contact between the weld stud and workpiece creates an electrical connection that triggers the
SOW (stud on workpiece) signal in the control unit. The weld start signal can then be triggered by pressing the
stud welding gun’s start button.
During welding with shielding gas, the shielding gas starts to flow and forces the oxygen onto the welding point.
Internal welding start
Depending on the welding tool being used, either the support foot or the tip of the welding tool touches the work-
piece and this determines the starting position for the stroke. The internal start of welding is triggered as soon
as the following starting conditions are met:
The tip touches the workpiece and this establishes the start position for the stroke. The internal start of welding
is triggered as soon as the following starting conditions are met:
● An external start welding has been triggered.
● The SOW signal has been triggered.
● The loaded weld stud’s protrusion is within the present stud protrusion tolerance.
● No welding stud has been moved in yet.
● The welding parameters are being monitored.
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System overview
Bias current light arc
The bias current will flow through the welding stud and the workpiece after an internal start welding signal has
been generated. After the bias current's stabilization time has expired, the linear motor will lift the welding stud
away from the workpiece, which causes bias current light arc. The bias current light arc maintains the electrical
connection and partially cleans the stud and workpiece of oil, grease or a coating.
During AC welding, especially intensive cleaning (CleanFlash) can be set up during the bias current light arc
time. CleanFlash cleans the workpiece at the weld point using an arc against impurities, such as dry lubricants.
Main light arc
After the arc’s bias current time has expired, the main current then flows for the main arc time (welding time) as
DC. In the main arc's plasma, electricity is transformed into heat. The heat causes a melt bath to form on both
the welding stud and the workpiece. After a specific time, the linear motor slides the welding stud up to the
workpiece under the main current.
After the arc’s bias current time has expired, the main current then flows for the main arc time (welding time) as
AC. In the main arc's plasma, electricity is transformed into heat. The heat causes a melt bath to form on both
the welding stud and the workpiece. After a specific time, the linear motor slides the welding stud up to the
workpiece under the main current.
Submersion
As soon as the stud meets the workpiece, the main current light arc voltage drops to 0V and the welding current
shuts off. The molten bath cools down. The welding head can be removed from the welded stud after the melt
bath has cooled down and this completes the welding process.
The shielding gas also stops flowing during welding with shielding gas.
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Welding process diagram using DC
Current
Path
Voltage
Pilot current Bias current Main arc Submersio
light arc n
Fig. 4: Arc stud welding phases in a drawn arc process using DC
The welding process diagram shows the phases during arc stud welding in a drawn arc process using DC.
The shielding gas flow is not shown.
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Control Unit TX
System overview
Welding process diagram with AC
Current
Path
Voltage
Bias current
Pilot current Main light arc Submersion
light arc
Fig. 5: Arc stud welding phases in a drawn arc process using AC
The heat in the fusion zone can be specifically controlled by changing the polarity during stud welding using AC.
Overheating is prevented.
The shielding gas flow is not shown.
4.2 Connecting to the higher-level system controller
Automatic system
A higher-level system controller, e.g. a robot, controls the system in which the product is integrated as well as
the other processing technologies used in the same robot cell and this also includes the relevant safety func-
tions. This is why the switching devices for emergency-stop, emergency-off as well as the safety door locks are
not connected to the system but to the higher-level system controller.
The stud welding system can be switched off either automatically from the higher-level system controller or
manually from its main switch. The hall PLC or robot controls the stud welding system by sending the external
start welding signal to the control unit.
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System overview
Manual system
The stud welding system is a separate unit. Start welding is triggered by the welder when he places his stud
welding gun on the workpiece and then presses the start button.
If there is a failure, the stud welding system can be manually disconnected from the power network using the
emergency-stop button on the control unit. This interrupts the stud welding guns with automatic stud feed and
compressed air supply.
4.3 Function of the components
1 2 3 4 5 7
12 11
15 6
13 10
14
8
9
Fig. 6: System overview of the components in the stud welding system and its connections —with stud divider and two feed-
ers
No. Name Description
1 TP control panel ● optional
● for operating the TX control unit
2 TX controller controls and monitors the welding process
3 Control cables connect the controller and the peripherals
4 Tube package contains the welding current line, measuring cable, compressed air line,
protective gas line (optional)
5 Stud divider Stud dividers
● TD
● TSD
6 Feed tube
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No. Name Description
7 Welding tool Welding heads
● TH welding head
● TR weld head
8 Work piece
9 Grounding and ground
measuring lines
10 other peripherals ● magnetic arc deviation (MAC)
● Stud pre-separation units (TPS)
● Cleaning station (TCS)
11 TF feeder
12 Compressed air line
13 Compressed air supply 4-bar to 8-bar
14 Shielding gas supply 3.5 bar to 8 bar
15 Power supply 400 V AC to 500 V AC, 32 A (63 A)
1 2 3
4
7 6
8
5
Fig. 7: Stud welding system with stud welding gun
No. Name Description
1 TP control panel ● optional
● for operating the TX control unit
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System overview
No. Name Description
2 TX controller controls and monitors the welding process
3 Stud welding gun ● PLM stud welding gun
● TG stud welding gun
4 Work piece
5 Grounding and ground
measuring lines
6 Tube package contains the welding current line, measuring cable, compressed air line,
protective gas line (optional)
7 TE adaptor box
8 Shielding gas supply 3.5 bar to 8 bar
9 Power supply 400 V AC to 500 V AC, 32 A (63 A)
1 2 3
10 7 6
8
9
5
Fig. 8: Stud welding system with stud welding gun
No. Name Description
1 TP control panel ● optional
● for operating the TX control unit
2 TX controller controls and monitors the welding process
3 Stud welding gun ● PLM stud welding gun
● TG stud welding gun
4 Work piece
5 Grounding and ground
measuring lines
6 Tube package contains the welding current line, measuring cable, compressed air line,
protective gas line (optional)
7 TE adaptor box
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No. Name Description
8 Compressed air supply 4-bar to 8-bar
9 Shielding gas supply 3.5 bar to 8 bar
10 Power supply 400 V AC to 500 V AC, 32 A (63 A)
4.3.1 TX, TE control unit
The control unit is typically outside the robot cell. It has the following functions:
The control unit has the following functions:
● Control of all connected components
● Monitors and controls all of the welding tools as well as their feeders and stud dividers.
● Coordinates and monitors the welding process using the following components:
● Linear motor output stage
The LPS linear motor output stage controls the welding tool’s linear motor, which first lifts the welding
stud from the workpiece and then presses in into the melt bath on the workpiece.
● SMPS welding current source
A switch-mode power supply delivers the welding current that creates the arc.
● Error control
Error control monitors all of the lines for signals, interruptions and communication errors.
● Monitoring
All welding parameters of the welding program, such as stud stroke height and penetration are mon-
itored before, curing and after welding.
● Connecting to the higher-level system controller
● Communications with the system or the robot
Variants of the client interface (CI) with a different physical interface and different communication proto-
cols are available.
● Safety connection (master safety control) for all components of the stud welding system
Variants a different physical interface and system-specific communication protocols are available. There
are either contact-controlled inputs or voltage-controlled inputs.
● central media supply for the entire stud welding system
Versions with different mains plugs, mains filters and with different designs and numbers of connectors are
available.
● Power supply for all connected electrical components
● Compressed air supply to all connected pneumatic components
● Protective gas supply going to all connected welding tools
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System overview
4.3.2 REC receiver
The receiver is mounted on the self-piercing rivet tool. It receives rivets from the feed system and keeps it cor-
rectly positioned under the self-piercing rivet tool’s punch.
Based on their specifications, receivers can be designed as active or passive.
In a passive receiver, the rivet is moved under the punch by the pneumatic energy of the last unit in the feed
system, such as a feeder or a magazine.
An active receiver has a pneumatically moved slider that slides the rivet under the punch. With this slider, and
active receiver can also isolate rivets from rivet packages.
4.3.3 TF feeder
The feeder is normally outside the robot booth. It stocks and separates the weld studs and guides them pneu-
matically into the next component in the feed system. That can be a stud divider, a stud pre-separator or a weld
head. The feeder is supplied from a control unit with control signals, compressed air and voltage. Voltage and
compressed air supplies to several feeders can be connected in series to the control unit.
The feeder stocks and separates the welding studs and guides them pneumatically into the next component in
the feed system. This could be a stud divider or a stud welding gun. The feeder is supplied from a control unit
with control signals, compressed air and voltage. Voltage and compressed air supplies to several feeders can
be connected in series to the control unit.
The following feeder versions exist:
● Drum feeder
The rotating separating drum accepts the weld studs from the filling shaft and guides them in the preferred
locations to the rail, and over the rail in correct position to the stud slider, and from the stud slider individu-
ally to the blow-out position. A compressed air flow moves the welding stud to the next component of the
feed system through the feed tube.
● Level feeder
The escapement accepts the weld studs from the bunker and guides them with a lifting motion in the pre-
ferred locations to the rail, and over the rail in correct position to the stud slider, and from the stud slider indi-
vidually to the blow-out position. A compressed air flow moves the welding stud to the next component of
the feed system through the feed tube.
● Vibrating hopper feed
The lifting system takes the weld studs from the bunker and guides them with a lifting motion to the vibrating
hopper. Then the weld studs are moved in the preferred positions from the vibrating hopper to the baffle
plate, from the baffle plate lengthwise over the rail to the stud slider and from the stud slider to blow-out pos-
ition. A compressed air flow moves the welding stud to the next component of the feed system through the
feed tube.
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System overview
4.3.4 Stud welding head TH, TR
In automatic systems, the stud welding head welds the studs fed to it to the workpiece. Either the stud welding
head or the workpiece is guided by an industrial robot. The following versions exist:
● The TH stud welding head has a fixed linear motor.
● The TR stud welding head has a rotating front end.
4.3.5 PLM, TGX stud welding guns
Welders use hand-held stud welding guns to weld studs onto workpieces in manual systems. Welding studs can
be fed to the stud welding guns either automatically by a feeder or manually by the welder, depending on the
model being used. Stud welding guns are connected to the control unit in series.
PLM stud welding guns need an adapter box.
4.3.6 Feed tube
The feed tube transports individual weld studs in a compressed air flow. A resistant protective jacket protects
the feed tube from external effects and it also stops the weld studs from shooting out and injuring personnel if
the feed tube is accidentally torn off.
4.3.7 Peripherals
The following components are optional.
4.3.7.1 TP operating device
The control device is on the control unit. Using the control device, you can parameterize and program the con-
trol unit and stud welding system.
Alternatively, you can create welding programs with the HMI SWS software on a computer or transfer them
through the Ethernet on the control unit.
4.3.7.2 TSD stud divider
Depending on the self-piercing stud director, up to five feeders can be connected to the same welding tool
through the self-piercing stud director. This allows feeding of weld studs with different dimensions.
4.3.7.3 Magnetic arc deviation (MAC)
Magnetic arc deviation on the welding head improves quality when welding large studs, such as earthing studs
or ring flange studs. An electrified coil creates a magnetic field that sets the arc in rotation, so that the heat is
distributed uniformly.
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System overview
4.3.7.4 Stud pre-separation unit TPS
A stud pre-separation unit on the industrial robot stores the welding studs close to the welding head. It can feed
studs to the stud pre-separation unit even during the welding process. This minimizes reload time.
4.3.7.5 TCS cleaning station
In the cleaning station, 2 brushes cleans the smoulder off of welding head’s tip. For this, either the industrial ro-
bot moves the welding head to the cleaning station, or — with a stationary welding head — the cleaning station
is swung in front of the welding head with a swivel device.
4.4 Topologies
A control unit has up to 5 outlets. For each outlet, up to 10 welding tools can be docked. Up to 10 feeders can
be connected.
4.4.1 Overview of the maximum connectible components
Property Number
max. TH weld heads 5, TX MAX: 2, TX 15AC: 3
max. TR weld heads 1
max. TF feeders 10
4.4.2 Examples of automatic systems
Symbol Meanings of the colours in the following topology diagrams
Stud welding system voltage supply (e.g. 3 x 400V AC)
Compressed air supply to the stud welding system (at least 4 bar)
Power supply to feeder
Cable package (welding current, compressed air, shielding gas)
Welding stud feeder hose
Safety interface
Field bus (industrial robot to superordinate system or industrial robot)
Ethernet (data, e.g. transfer of welding programs)
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Control Unit TX
System overview
Automatically guided settings system without additional peripherals
1 x TX control unit
1 x TP operating device
1 x TF feeder
1 x TH welding head
Automatically guided set-up system with stud divider
1 TX control unit
1 TP operating device
2 TF feeders
1 TD stud divider
1 TH weld head
The stud welding system can weld studs of various lengths.
Automatic multi-point system with two welding heads
1 x TX control unit
1 x TP operating device
2 x TF feeders
2 x TH welding heads
Further weld heads and feeders are possible.
4.4.3 Examples of manual systems
Manually guided set-up system with manual feed
1 TX control unit
1 TP operating device
1 PLM stud welding gun
1 adaptor box (not necessary for model TG stud welding guns)
Further stud welding guns can be connected.
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System overview
Manually guided set-up system with automatic feed
1 TX control unit
1 TP operating device
1 TF feeder
1 PLM stud welding gun
1 adaptor box (not necessary for model TG stud welding guns)
Further stud welding guns and feeders can be connected.
Manually guided multi-point system with partially automatic and partially manual feed and
three older welding guns
1 x TX control unit 1 x TP operating device
3 x PLM welding guns 1 x TGX-M stud welding gun
3 x adapter boxes 2 x TF feeders
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Product overview
5 Product overview
5.1 Controls inside the product housing the
Product version for direct-current welding processes
Automatic system
2
3 4 5
Fig. 9: Operating elements in product housing (automatic system)
No. Name Description
1 Motherboard
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Product overview
No. Name Description
2 Socket takes the program memory card
3 Safety board for turning off the product for a safety issue, such as during an EMER-
GENCY STOP
4 Residual current circuit for the linear motor
breaker
5 Fuses Access for maintenance personnel
6 Fan
7 Compressed air distributor guides the compressed air from the pneumatic unit (Pos. 8) to the com-
ponents of the stud welding system
8 Pneumatic unit Pressure regulator with a maintenance unit and a magnetic safety valve
for shutting off the central compressed air supply.
9 Plexiglas pane protects the operating elements inside the housing from being touched ac-
cidentally.
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Control Unit TX
Product overview
Product version for direct-current welding processes
Manual system
2
3 4
Fig. 10: Operating elements in product housing (manual system)
No. Name Description
1 Motherboard
2 Socket takes the program memory card
3 Residual current circuit for the linear motor
breaker
4 Fuses Access for maintenance personnel
5 Fan
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Product overview
No. Name Description
6 Compressed air distributor guides the compressed air from the pneumatic unit (Pos. 8) to the com-
ponents of the stud welding system
7 Pneumatic unit Pressure regulator with a maintenance unit and a magnetic safety valve
for shutting off the central compressed air supply.
8 Plexiglas pane protects the operating elements inside the housing from being touched ac-
cidentally.
Product version for alternating-current welding processes
1 2
3 4 5
9
7
Fig. 11: Operating elements in product housing (automatic system and manual system)
No. Name Description
1 Socket takes the program memory card
2 Motherboard
3 Safety board ● on automatic system only
● for turning off the product for a safety issue, such as during an EMER-
GENCY STOP
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Product overview
No. Name Description
4 Residual current circuit for the linear motor
breaker
5 Fuses Access for maintenance personnel
6 Plexiglas pane protects the operating elements inside the housing from being touched ac-
cidentally.
7 Fan
8 Compressed air distributor guides the compressed air from the pneumatic unit (Pos. 8) to the com-
ponents of the stud welding system
9 Pneumatic unit Pressure regulator with a maintenance unit and a magnetic safety valve for
shutting off the central compressed air supply.
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5.2 Controls on the product housing
Product version for direct-current welding processes
1 2 3 9
4
8
Fig. 12: Operating elements on the front and back of the product (automatic system and manual system)
No. Name Description
1 Sealed keyboard with status display (See Chapter 5.2.1 [} 43])
2 One-button control ● releases the stud welding system after the control unit is turned on or
after an EMERGENCY STOP
● with status LED: If the status LED lights up, then the product is ready to
operate
3 Main switch Turns off the product's electricity and pressure
● Main switch, black
● EMERGENCY OFF switch, red
4 Type plate
5 Door lock For unlocking and locking the housing doors
6 Pneumatic main switch Shuts off the product's pressure
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Product overview
No. Name Description
7 Manometer ● for showing the compressed air pressure
● Depending on your configuration, a further manometer can optionally be
installed to show the pressure of the shielding gas used.
8 Function panel Contains components for additional optional functions based on your con-
figuration, e.g. a key switch for locking the programming function
9 Fan
Product version for alternating-current welding processes
1 2 3 9
4
8
Fig. 13: Operating elements on the front and back of the product (automatic system and manual system)
No. Name Description
1 Sealed keyboard with status display (See Chapter 5.2.1 [} 43])
2 One-button control ● releases the stud welding system after the control unit is turned on or
after an EMERGENCY STOP
● with status LED: If the status LED lights up, then the product is ready to
operate
3 Main switch Turns off the product's electricity and pressure
● Design as main switch, black (automatic system)
● Design as emergency off switch, red (manual system)
4 Type plate
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Product overview
No. Name Description
5 Door lock For unlocking and locking the housing doors
6 Pneumatic main switch Shuts off the product's pressure
7 Manometer ● for showing the compressed air pressure
● Depending on your configuration, a further manometer can optionally be
installed to show the pressure of the shielding gas used.
8 Function panel Contains components for additional optional functions based on your con-
figuration, e.g. a key switch for locking the programming function
9 Fan
5.2.1 Status display LEDs
The status display of the sealed keyboard can show the following statuses.
LED Description
green lights ● Normal operation
● The stud welding system works in automatic mode.
flashes ● Normal operation
● The stud welding system works in manual mode.
yellow lights A warning message is active.
Red lights A fault message is active.
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Control Unit TX
Product overview
5.3 Connections
Product version for direct-current welding processes
Automatic system
2
13 14
3
4
5
6
12
11 10 9 8
Fig. 14: Connections (automated system)
No. Name Description
1 USB connection ● covered with a cap
● for maintenance tasks
2 Operating device connec- For connecting the optional operating device
tion
3 Power supply connection Takes up the power supply line
4 Ground connection For connecting the ground cable; connects the control unit to the work-
piece
5 Ground measuring cable For connecting the ground measuring cable; for monitoring the welding
connection process through the control unit
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No. Name Description
6 Emergency-stop connection for connecting the emergency stop circuit and control of the operating
mode of the TR welding head
7 Safety circuit connection For connecting the safety circuit based on your configuration
8 Welding tool coupler bush- Holds the multi-coupling for the welding tool hose package for supplying
ing the welding tool
9 Holder For locking the multi-coupling
10 Shielding gas connection For connecting the shielding gas supply
for control unit
11 Compressed air connection For connecting the compressed air supply
for control unit
12 Feeder coupler bushing Holds the multi-coupling on the feeder hose package for supplying the
feeder
13 Round plug bushing For connecting the pneumatic unit's safety valve (See Chapter Fig. 8 [
} 36], page )
14 Connections to the client in- For connecting the client interface to the industrial robot
terface
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Product overview
Product version for direct-current welding processes
Manual system
2
11
3
4
5
10
9 8 7 6
Fig. 15: Connections (manual system)
No. Name Description
1 USB connection ● covered with a cap
● for maintenance tasks
2 Operating device connec- For connecting the optional operating device
tion
3 Power supply connection Takes up the power supply line
4 Ground connection For connecting the ground cable; connects the control unit to the work-
piece
5 Ground measuring cable For connecting the ground measuring cable; for monitoring the welding
connection process through the control unit
6 Welding tool coupler bush- Holds the multi-coupling for the welding tool hose package for supplying
ing the welding tool
7 Holder For locking the multi-coupling
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No. Name Description
8 Shielding gas connection For connecting the shielding gas supply
for control unit
9 Compressed air connection For connecting the compressed air supply
for control unit
10 Feeder coupler bushing Holds the multi-coupling on the feeder hose package for supplying the
feeder
11 Round plug bushing For connecting the pneumatic unit's safety valve (See Chapter Fig. 8 [
} 36], page )
Product version for alternating-current welding processes
1
3
2
14
4
13
5
6
12
7
9
11
10
Fig. 16: Connections (automatic system and manual system)
No. Name Description
1 USB connection ● covered with a cap
● for maintenance tasks
2 Operating device connec- For connecting the optional operating device
tion
3 Power supply connection Takes up the power supply line
4 Ground connection For connecting the ground cable; connects the control unit to the work-
piece
5 Ground measuring cable For connecting the ground measuring cable; for monitoring the welding
connection process through the control unit
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Product overview
No. Name Description
6 Emergency-stop connection for connecting the emergency stop circuit and control of the operating
mode of the TR welding head (only when using an automatic system)
7 Safety circuit connection for connecting the safety circuit based on your configuration (only when
using an automatic system)
8 Welding tool coupler bush- Holds the multi-coupling for the welding tool hose package for supplying
ing the welding tool
9 Holder For locking the multi-coupling
10 Feeder coupler bushing Holds the multi-coupling on the feeder hose package for supplying the
feeder
11 Compressed air connection For connecting the compressed air supply
for control unit
12 Shielding gas connection For connecting the shielding gas supply
for control unit
13 Round plug bushing for connecting the safety valve of the pneumatic unit
14 Connections to the client in- For connecting the client interface to the industrial robot (only when using
terface an automatic system)
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Product overview
5.4 Transport equipment
1
3 2
Fig. 17: Positions of the transport lugs and rollers
No. Name Description
1 Transport lug For attaching the lifting equipment
2 Roller brake For locking the rollers (Pos. 3)
3 Roller For plant-internal transport of the product
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Control Unit TX
Product overview
5.5 Control panel/operating unit
Fig. 18: Touchpad control panel
No. Name Description
1 Control panel/operating unit with touch display
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Product overview
5.6 Type plate
1
19
2
18
3
17
4
16
15 5
14
13
6
12
11 10 9 8 7
Fig. 19: Design of the model plate
1 Name and address of the manufacturer
2 Model – Item No.: Item No.
3 Serial No.: Serial-No.
4 IEC 60974-1 Standards observed in designing the product
5 ● X = relative duty cycle as %
● I2 = standardized welding current
● V2 = standardized voltage load
6 Ieff = highest effective network power
7 Weight: Product weight
8 Imax = measurement value of maximum network power
9 Year: production year
10 V1 measurement value of network voltage
11 Protection type: Product's IP protection class
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Product overview
12 Power plug symbol
Operating it from the public supply network is expressly prohibited.
13 V0 Measurement value of no-load voltage
14 Welding current symbol
15 S An "S" symbol in this field indicates a welding current source that is suit-
able for welding in an environment of elevated electrical hazard.
16 Welding process symbol, i.e. arc stud welding here
17 Welding current source symbol
18 Description 2: Description and indication of the product model, here TX
19 Description: Description and indication of the product type, here it is a controller
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Transporting
6 Transporting
Only specialist storage and transporting personnel are allowed to undertake this work.
WARNING
Risk of being injured by falling or tipping over components
During improper transport, the product or parts included with the product may fall or tip over, injuring people
nearby.
⇒ Have the product transported only by specialists in storage and transport.
⇒ Transport the product according to the transport conditions.
6.1 Transport conditions
Ambient conditions Value Unit
Temperature range > 24 h -25 to +55 °C
Temperature range < 24 h -25 to +70 °C
relative humidity (non-condensing) ≤ 80 %
6.2 Transporting with a crane
Only specialist storage and transporting personnel are allowed to undertake this work.
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Control Unit TX
Transporting
WARNING
Risk of being injured by suspended loads
If the product is being transported by a crane, it might start to swing uncontrollably and injure personnel nearby.
⇒ Never stand beneath suspended loads.
⇒ Only use approved lifting gear and slings with sufficient load-bearing capacity.
⇒ Only attach the slings to the eyebolts provided on the product. Ensure that the slings do not touch sharp
corners or edges and that they do not knot or twist.
ATTENTION!
The product can be damaged if unsuitable lifting tackle is used
Metal lifting tackle may damage the product.
⇒ Never use metal lifting tackle if the lifting tackle may come into contact with the product during transport.
ATTENTION!
Damage to the eyebolts from overloading
The product's eyebolts are designed for transporting by crane without any other attachments. The eyebolts
might become damaged during crane transporting if the product is weighed down by attachments or other ob-
jects.
⇒ Transport the product without attachments, cables, etc.
⇒ Make sure that during crane transport, no objects are lying on the product or fastened to it.
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Transporting
Fig. 20: Eyebolt positions
⇒ Secure lifting tackle to the product using the eyebolts provided for this purpose (Fig. , Item 1).
⇒ Transport the product to the destination.
⇒ At the destination, set down the product without shocks or jerks.
⇒ At the destination, set down the product upright on an even floor.
⇒ Remove the lifting tackle.
6.3 Transporting with a forklift
Only specialist storage and transporting personnel are allowed to undertake this work.
WARNING
Injury hazard from overturning
If the product tilts during transport, people nearby can be injured.
⇒ Secure the packaged product to the pallet against accidental movements, such as tipping, falling and sliding.
⇒ Use only an industrial truck (lift truck, forklift) with adequate load-bearing capacity.
⇒ Transport the product upright to the destination.
⇒ At the destination, set down the product without shocks or jerks.
⇒ At the destination, set down the product upright on an even floor.
⇒ Remove the materials used to secure the product, such as screws or lashing straps.
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Transporting
6.4 Transporting with rollers
For this work, qualification as operating personnel is required.
WARNING
Injury hazard from heavy weight
When the roller brakes are released, the product can greatly accelerate on slopes due to its heavy weight and
slam into people. People may be severely injured by the impact.
⇒ Transport the product on rollers only on a level floor with a maximum slope of 4%.
ATTENTION!
Damage to rollers from improper transport
The product's rollers are for transport inside the plant on an even floor. Transporting the product on rollers in un-
protected outdoor areas and over stairways can damage the rollers.
⇒ Transport the product only in protected indoor spaces on rollers.
1
Fig. 21: Secure the castors against rolling away
⇒ Press the roller brakes (figure, Pos. 1) upward so that the roller brakes release.
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Transporting
⇒ Push the product on the rollers to the destination.
⇒ Press the roller brakes (figure, Pos. 1) downward until they latch in, so that the product is secured from rolling
away.
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Storage
7 Storage
Only specialist storage and transporting personnel are allowed to undertake this work.
⇒ Store the product upright.
⇒ Store the product in dry, ventilated indoor rooms.
⇒ Protect the product from direct sunlight.
⇒ Store the product protected in keeping with the storage conditions.
7.1 Storage conditions
Ambient conditions Value Unit
Temperature range > 24 h -25 to +55 °C
Temperature range < 24 h -25 to +70 °C
relative humidity (non-condensing) ≤ 80 %
Installation site dry, ventilated interior spaces
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Setting up
8 Setting up
8.1 Acclimation
ATTENTION!
Short circuit from condensation
If the product is brought in from a cold to a warm environment, then the humidity inside might condense and
cause a short circuit.
⇒ Allow the product to acclimatize for a few hours at the installation site after the product has been brought
from a warm environment and placed in a cold one.
8.2 Positioning the product
For this work, qualification as expert personnel is required.
ATTENTION!
Overheating due to inadequate ventilation
If the controller is placed too close to the wall, the fan cannot cool the electronics sufficiently and the product will
overheat.
⇒ Keep a distance of at least 10 cm from the wall when you position the controller.
⇒ When selecting the installation site, follow the plans and reference drawings in the included service cata-
logue.
⇒ Set the product up according to the included service catalogue at the installation site.
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Setting up
1
Fig. 22: Secure the castors against rolling away
⇒ Press the roller brakes (Fig. , Item 1) downward until they latch in, so that the product is secured from rolling
away.
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Connecting up
9 Connecting up
The qualifications needed for this work are expert and qualified electrician.
9.1 Adhere to the connecting up sequence
⇒ Connect the product’s voltage supply last.
9.2 Connecting the safety circuit
The safety circuit must be connected to the robot cell's safety circuit for running automatic mode.
⇒ Open the lower housing door.
⇒ Guide the safety plugs for the safety circuit into the housing from underneath.
Fig. 23: Positions of the safety circuit connections
⇒ Connect the safety plugs for the safety circuit to the safety circuit connections (figure, Pos. 1).
9.3 Connecting the emergency-stop circuit
⇒ Open the lower housing door.
⇒ Guide the safety plugs for the emergency-stop circuit into the housing from underneath.
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Fig. 24: Emergency-stop connection position
⇒ Connect the emergency-stop circuit’s safety plug to the emergency-stop connector (figure, Pos. 1).
9.4 Connecting the client interface to the industrial robot
For automatic operation, the product must be connected to higher-level system controls, such as an industrial
robot.
⇒ Open the lower housing door.
Fig. 25: Position of the client interface connection.
⇒ Guide the line cable for the client interface into the housing from underneath.
⇒ Connect the line to the higher-level system controller to the client interface connections (Fig. , Item 1).
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Connecting up
9.5 Connect up the ground cable
⇒ Open the lower housing door.
⇒ Guide the ground cable from underneath into the housing.
Fig. 26: Position of the ground connection.
⇒ Connect the ground cable to the ground connection (figure, Pos. 1).
9.6 Connecting the shielding gas supply
WARNING
Asphyxiation hazard from high shielding gas concentration
If the protective gas feed is leaky, there is a danger of inhaling protective gases and suffocating.
⇒ Do not open the valves of the shielding gas tanks until all components have been correctly connected.
⇒ Check the shielding gas line regularly for leaks.
⇒ Before working on any components carrying shielding gas, shut off the shielding gas supply and drain the
pressure from the lines.
⇒ Use shielding gas only in well-ventilated spaces.
⇒ Observe the safety data sheet of the shielding gas tank manufacturer.
⇒ Open the lower housing door.
⇒ Guide the shielding gas supply line from underneath into the housing.
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Connecting up
1
Fig. 27: Position of the shielding gas connection
⇒ Connect the feed to the control unit’s protective gas connection (figure, Pos. 1).
9.7 Connecting system components
⇒ Open the lower housing door.
⇒ Guide the ground measuring cable from underneath into the housing.
⇒ Connect the ground measuring cable to the ground measuring cable connection.
⇒ Guide the multicouplings of the welding tool hose package from underneath into the housing.
⇒ Connect one multicoupling of a welding tool hose package to each welding tool coupler bushing.
⇒ Lock the multicoupling to the holder on the welding tool coupler bushing.
✓ The multi-coupling is correctly locked when it cannot be loosened by pulling the plug.
⇒ Guide the multicouplings of the feeder hose package from underneath into the housing.
⇒ Connect one multicoupling of a feeder hose package to each feeder coupler bushing.
⇒ Lock the multicoupling to the holder on the feeder coupler bushing.
✓ The multi-coupling is correctly locked when it cannot be loosened by pulling the plug.
⇒ Connect the compressed air line from the feeder to the compressed air distributor.
9.8 Connecting the operating device
⇒ Connect the connecting cable from the optional control panel to the product’s control panel connection.
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Connecting up
9.9 Connecting up the compressed air supply
CAUTION
Injury hazard from compressed air
Weld studs can shoot out of torn pressurized supply lines and injure people.
⇒ Do not turn the compressed air on until all of the pneumatic components have been correctly connected.
⇒ Regularly check the compressed air feed tubes for proper condition.
⇒ Always fasten the compressed air feed tubes firmly.
⇒ Use suitable hose clamps to fasten the compressed air feed tubes.
⇒ Wear safety glasses.
⇒ Open the lower housing door.
⇒ Guide the compressed air feed tube from underneath into the housing.
Fig. 28: Position of the compressed air connection
⇒ Connect the compressed air supply line to the compressed air connection of the control unit (figure, Pos. 1).
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Connecting up
9.10 Connect power supply
DANGER
Mortal danger from electric shock!
Damaged or unprofessionally laid power lines can kill people by electric shock.
⇒ Lay the cables so that neither pulling nor pressure will release them.
⇒ Lay cables with an adequate diameter (especially for the welding current ground cable and the power line).
⇒ Do not loop the cables.
⇒ Make sure that the clamp connections cannot be loosened by pulling.
WARNING
Mortal danger from electric shock!
The wrong supply voltage or excessive resistance in the welding circuit may cause arcing that can kill people
nearby.
⇒ Compare the network voltage with the information on the product's model plate.
⇒ Use different network voltage paths for different welding processes.
⇒ For different, simultaneous welding processes on the same workpiece, use a separate welding current path
and a separate network current path.
⇒ Perform work steps using current on the welding process, such as welding processes with high-frequency ig-
nition, plasma welding processes or flame cutting, in areas that are separated from one another and have
separate power supplies.
⇒ Provide a low-resistance ground connection.
⇒ Connect the product to a low-resistance ground, so that the leakage currents occurring during welding can
flow off.
ATTENTION!
Short circuit from condensation
If the product is brought in from a cold to a warm environment, then the humidity inside might condense and
cause a short circuit.
⇒ Allow the product to acclimatise for a few hours at the installation site after the product has been brought
from a warm environment and placed in a cold one.
⇒ Make sure that the main switch is in "0" position.
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Connecting up
Fig. 29: Position of power supply connection
⇒ Connect the plug of the power supply line to the product’s voltage supply connection (Fig.28, Item 1).
⇒ Lock the plug connector.
⇒ ATTENTION! Abrupt loading of the network voltage through the welding process Connect the stud
welding system to the company’s own industrial network.
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Starting up
10 Starting up
10.1 Commissioning
Commissioning can be done only by a Tucker employee who is authorized for the task. During commissioning,
a commissioning log is created. The commissioning log is part of the product.
10.2 Restarting
For this work, qualification as expert personnel is required.
Proceed as follows before restarting after a planned or unplanned stud welding system shutdown:
⇒ Disconnect the product from its voltage supply and depressurise it.
⇒ WARNING Danger of electric shock from residual voltage. After the product is shut off, its capacitors
still carry high voltage. After the product is switched off, wait two minutes before opening the doors, so that
the voltage stored in the capacitors can dissipate.
⇒ Check all attached signs for completeness and legibility.
⇒ Check the product for visible damage.
⇒ Check all cables and hoses for visible damage.
⇒ Replace defective hoses and lines.
⇒ Check all plug connectors for correct seating.
⇒ Make sure that the power supply line is connected.
⇒ Turn the main switch to the “I” position.
⇒ Check whether the product is turned off if the following status is present:
● Main switch on the product is in the “0” position.
● The higher-level emergency-off switch is OFF.
● The safety circuit is interrupted.
⇒ Turn off the compressed air and shielding gas supplies.
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Starting up
⇒ Set the main pneumatics switch of the control unit to “I” position.
⇒ Check the pressure of the compressed air and the shielding gas.
⇒ If the pressures are outside the desired range, check their hoses again.
Fig. 30: Position of the control unit ON button
⇒ Press the control unit ON button (figure, Pos. 1).
✓ The stud welding system is released.
✓ The green LED of the sealed keyboard goes on as soon as the stud welding system is ready to operate.
10.3 Making a functional check with the software
⇒ Check the proper functioning of the product and the connected components of the system by performing
functional tests of all of the system's components according to the instructions in the expert training and in
the software manual.
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Configuration
11 Configuration
11.1 Parameterising by the manufacturer
For this work, manufacturer’s qualification is required.
The product is pre-assembled and delivered for the customer's specific requirements. Authorised Tucker service
staff will configure and parameterise the product during the commissioning.
All configurations are documented and handed over to you together with the service catalogue (e.g. layout dia-
grams, parameter lists and settings).
11.2 Customizing the parameters
For this work, qualification as expert personnel is required.
⇒ If any of the components in the stud welding system have to be replaced or repaired, parameterise the stud
welding system components according to the instructions given in the expert training and as described in the
HMI SWS software manual.
⇒ If a welding program has been changed or newly created, run functional tests on the stud welding system
components afterwards according to the instructions given in the expert training and as described in the HMI
SWS software manual.
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Programming
12 Programming
Only an expert is allowed to do the programming, i.e. creating a stud welding process program.
A programming condition is that set-up and all of the functional tests have been completed.
⇒ Program according to the instructions given in the expert training and as described in the HMI SWS software
manual.
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Operation
13 Operation
13.1 Turning on the product
For this work, qualification as operating personnel is required.
Fig. 31: Positions of the main switch and the pneumatic main switch
⇒ Turn the main switch to position “I” (figure, Pos. 1).
✓ The power supply to the product and all connected electrical components is turned on.
⇒ Make sure that the product's compressed air supply is turned on.
⇒ Turn the main pneumatics switch to “I” position (figure, Pos. 2).
✓ The product has been switched on. This turns on the compressed air supply to all connected pneumatic
components.
13.2 Releasing the stud welding system
⇒ Ensure the controller has been switched on.
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Operation
Fig. 32: Position of the control unit ON button
⇒ Press the control unit ON button (figure, Pos. 1).
✓ The stud welding system is released .
✓ The green LED of the sealed keyboard goes on as soon as the stud welding system is ready to operate.
13.3 Turing off the product
For this work, qualification as operating personnel is required.
13.3.1 Draining the pressure from the product
Fig. 33: Position of the main pneumatics switch
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Operation
⇒ Turn the main pneumatics switch to “0” position (figure, Pos. 1).
✓ The product and all connected pneumatic components have been drained of pressure.
13.3.2 Draining the product of pressure and voltage
Fig. 34: Position of main switch
⇒ Turn the main switch to “0” position (figure, Pos. 1).
⇒ ATTENTION! Equipment damage from power interruption or restart. Wait 10 seconds before you dis-
connect the power supply or switch the unit back on.
✓ The product and all connected components have been drained of pressure and voltage.
✓ The product shuts down. This process lasts about 10 seconds.
13.4 Turning the product back on after shutdown
For this work, qualification as operating personnel is required.
⇒ ATTENTION! Equipment can be damaged by switching back on too quickly! Ensure that at least 10
seconds of shut-down time have passed before you turn the device back on. Only then should the main
switch be turned into the "I" position.
✓ The product starts up. This process lasts about 10 seconds.
✓ The product and all connected components are ready to operate.
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Operation
13.5 Operating conditions
Data Value Unit
Temperature range +5 to +50 °C
relative humidity (non-condensing) at ≥ 5°C ≤ 95 %
relative humidity (non-condensing) at ≥ 20°C ≤ 90 %
relative humidity (non-condensing) at ≥ 40°C ≤ 50 %
Setting up altitude above sea level ≤ 3000 m
Installation site dry, ventilated interior spaces
13.6 Monitoring operation
For this work, qualification as operating personnel is required.
⇒ Monitor the product's operation as described in the HMI SWS software manual, in the TX controller fault mes-
sages document and in the message monitoring chapter (See Chapter 14.1 [} 77]).
13.7 Opening the housing doors
For this work, qualification as expert personnel is required.
CAUTION
Danger from unauthorized access
If unqualified or unauthorized people have access to the connections or controls inside the housing, people
might be injured and equipment damaged.
⇒ Limit key access to authorized people.
⇒ Keep the housing doors locked as long as no work is going on inside the housing.
⇒ Lock the housing doors as soon as you interrupt or complete work inside the housing.
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Operation
13.7.1 Unlocking the upper housing door
⇒ Disconnect the product from its voltage supply and depressurise it.
⇒ WARNING Danger of electric shock from residual voltage. After the product is shut off, its capacitors
still carry high voltage. After the product is switched off, wait two minutes before opening the doors, so that
the voltage stored in the capacitors can dissipate.
⇒ Lock the two locks of the upper housing door.
13.7.2 Unlocking the lower housing door
⇒ Depressurise the product.
⇒ Unlock the lock on the lower housing door.
13.8 Locking the housing doors
For this work, qualification as expert personnel is required.
13.8.1 Locking the upper housing door
⇒ Close the upper housing door.
⇒ Lock the two locks of the upper housing door.
⇒ Keep the key safe.
13.8.2 Locking the lower housing door
⇒ Close the lower housing door.
⇒ Lock the lock on the lower housing door.
⇒ Keep the key safe.
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Troubleshooting
14 Troubleshooting
14.1 Monitoring messages
For this work, qualification as operating personnel is required.
The status LEDs on the product housing show whether there is a warning message or fault message. You can
use the HMI SWS software to view fault or warning messages (see HMI SWS software manual).
⇒ Stop all work on the system if any system faults occur.
⇒ Get a troubleshooting expert.
14.2 Using trouble-shooting methods
For this work, qualification as expert personnel is required.
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Troubleshooting
1 2
Fig. 35: Status LEDs on the product housing
Fault Cause Troubleshooting steps
The yellow status LED on the For the product or a sys- ⇒ Use the software to show the warning message.
product housing comes on tem component, there is a ⇒ Use the TX controller fault message handbook to
(Fig. , Item 1). warning message in the eliminate the cause of the warning message.
software.
The red status LED on the For the product or a sys- ⇒ Use the software to show the fault message.
product housing comes on tem component, there is a ⇒ Use the TX control unit fault message handbook
(Fig. , Item 2). fault message in the soft- to eliminate the cause of the fault message.
ware.
Connected system components The system components ⇒ Make sure that all system components are cor-
such as the feeder or welding are not correctly connec- rectly connected to the control unit.
tool are not detected or dis- ted to the control unit. ⇒ Check the system components' plug connections
played by the control unit. to the control unit for firm seating.
The compressed air supply The pre-pressure of the ⇒ Readjust the pre-pressure at the pneumatic unit
pressure is too low. compressed air supply is (see Chapter See Chapter Resetting the com-
not correctly set on the pressed air on the pneumatic unit [} 82]).
pneumatic unit.
The compressed air flow rate is The filter cartridge in the ⇒ Change the filter cartridge in the filter control
lower than expected. filter control valve is valve (See Chapter Changing the filter cartridge
clogged. in the filter regulator valve [} 79]).
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Troubleshooting
Fault Cause Troubleshooting steps
The shielding gas pressure is The pre-pressure of the ⇒ Readjust the pre-pressure at the shielding gas
too low. shielding gas supply is not pressure regulator (see Chapter See Chapter
correctly set on the shield- Reset the pressure of the shielding gas on the
ing gas unit. pneumatic unit [} 83]).
14.3 Changing the filter cartridge in the filter regulator
valve
For this work, qualification as expert personnel is required.
Fig. 36: Position of the filter regulator valve of the pneumatic unit
If the filter cartridge on the filter regulator valve (illustration, item 1) of the pneumatic unit is too dirty, it must be
replaced.
Condition
● A new, clean filter cartridge is ready.
⇒ Disconnect the product from its voltage supply and depressurise it.
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Troubleshooting
⇒ WARNING Danger of electric shock from residual voltage. After the product is shut off, its capacitors
still carry high voltage. After the product is switched off, wait two minutes before opening the doors, so that
the voltage stored in the capacitors can dissipate.
⇒ Open the lower housing door.
Fig. 37: Position of the unlocking slider on the filter control valve’s water separator
⇒ Move the unlocking slider (figure, Pos. 1) downward.
⇒ Turn the water separator counterclockwise.
⇒ Pull the water separator from the filter control valve.
Fig. 38: Filter control valve’s filter plate position
⇒ Unscrew the filter plate (figure, Pos. 1).
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Troubleshooting
Fig. 39: Filter control valve’s filter cartridge position
⇒ Unscrew the filter cartridge (figure, Pos. 1) from the filter control valve.
⇒ Screw a new filter cartridge into the filter control valve. Do this by holding the bottom of the filter cartridge and
screwing the new filter cartridge tightly in place by hand.
⇒ Place the filter plate on the new filter cartridge and screw it on tightly.
Fig. 40: Position of the locking pin on the filter control valve’s water separator
⇒ Slide the water separator in up to the stop in the filter control valve’s opening. You must ensure that the water
separator’s retention pin (figure, Pos. 1) is aligned with the large recess (figure, Pos. 2) at the edge of the
opening in the filter control valve.
⇒ Lock the water separator in the filter control valve’s opening. Do this by turning the water separator.
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Troubleshooting
✓ The unlocking slide (figure, Pos. 3) will audibly engage.
⇒ Now restart the product. You might have to readjust the filter control valve (See Chapter Resetting the com-
pressed air on the pneumatic unit [} 82]).
14.4 Resetting the compressed air on the pneumatic unit
⇒ Disconnect the product from its voltage supply and depressurise it.
⇒ WARNING Danger of electric shock from residual voltage. After the product is shut off, its capacitors
still carry high voltage. After the product is switched off, wait two minutes before opening the doors, so that
the voltage stored in the capacitors can dissipate.
⇒ Secure the product's power supply and compressed air supply from being turned back on.
⇒ Open the lower housing door.
Fig. 41: Position of the filter control valve’s regulator button on the pneumatic unit
⇒ Pull the filter control valve's setting knob on the pneumatic unit (figure, Pos. 1) upward.
✓ The regulator button is unlocked.
⇒ Turn the regulator button to set the compressed air pre-pressure to the operational value that you want to
use.
⇒ Press the regulator button downward until it clicks in place.
✓ The regulator button has been locked.
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Troubleshooting
14.5 Reset the pressure of the shielding gas on the
pneumatic unit
⇒ Disconnect the product from its voltage supply and depressurise it.
⇒ WARNING Danger of electric shock from residual voltage. After the product is shut off, its capacitors
still carry high voltage. After the product is switched off, wait two minutes before opening the doors, so that
the voltage stored in the capacitors can dissipate.
⇒ Secure the product's power supply and compressed air supply from being turned back on.
⇒ Open the lower housing door.
Fig. 42: Position of the regulator button on the shielding gas pressure regulator of the pneumatic unit
⇒ Pull the setting knob of the protective gas pressure regulator upward (figure, Pos. 1).
✓ The regulator button is unlocked.
⇒ Turn the setting knob of the protective gas pressure regulator to set the protective gas pre-pressure to the
desired operating value.
⇒ Press the regulator button for the shielding gas pressure regulator downward until it clicks in.
✓ The regulator button has been locked.
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Troubleshooting
14.6 Using the program memory card in a different
product
For this work, qualification as expert personnel is required.
If you replace your control unit with another one, e.g. because of a defect, you can transfer your stored data to
the new control unit. To do this, you need to insert the program memory card from the defective control unit in
the control unit.
Your stud IDs, the event memory and control unit parameters are stored in the program memory card.
ATTENTION!
Defective PCBs caused by static discharges
The product contains sensitive electronic components that can be damaged by static discharges.
⇒ Ensure that you can discharge any electrostatic charges by earthing both your body and the product.
14.6.1 Removing the program memory card
Tools needed
● a set of Allen screwdrivers
⇒ Disconnect the product from its voltage supply and depressurise it.
⇒ WARNING Danger of electric shock from residual voltage. After the product is shut off, its capacitors
still carry high voltage. After the product is switched off, wait two minutes before opening the doors, so that
the voltage stored in the capacitors can dissipate.
⇒ Secure the product's power supply and compressed air supply from being turned back on.
⇒ Open the upper housing door.
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Troubleshooting
Fig. 43: Position of the program memory card and the Plexiglas pane
⇒ Screw off the Plexiglas pane (figure, Pos. 2).
⇒ Carefully pull the program memory card out of the socket on the motherboard (figure, Pos. 1).
⇒ Screw the Plexiglas pane back on.
⇒ Close the upper housing door.
14.6.2 Inserting the program memory card
Tools needed
● a set of Allen screwdrivers
⇒ Disconnect the product from its voltage supply and depressurise it.
⇒ WARNING Danger of electric shock from residual voltage. After the product is shut off, its capacitors
still carry high voltage. After the product is switched off, wait two minutes before opening the doors, so that
the voltage stored in the capacitors can dissipate.
⇒ Secure the product's power supply and compressed air supply from being turned back on.
⇒ Open the upper housing door.
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Troubleshooting
Fig. 44: Position of the program memory card and the Plexiglas pane
⇒ Screw off the Plexiglas pane (figure, Pos. 2).
⇒ Insert the program memory card into the socket on the motherboard (figure, Pos. 1).
⇒ Screw the Plexiglas pane back on.
⇒ Close the upper housing door.
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Cleaning
15 Cleaning
For this work, qualification as expert personnel is required.
15.1 Cleaning the housing surface
Cleaning agents needed
● non-corrosive, grease-removing cleaning agent
● a soft, lint-free cloth
⇒ Disconnect the product from its voltage supply and depressurise it.
⇒ WARNING Danger of electric shock from residual voltage. After the product is shut off, its capacitors
still carry high voltage. After the product is switched off, wait two minutes before opening the doors, so that
the voltage stored in the capacitors can dissipate.
⇒ Use only non-corrosive, grease-dissolving cleaning agents, no abrasives.
⇒ Clean the product's surface using a soft, lint-free cloth that has been slightly dampened with a cleaning
agent.
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Maintenance
16 Maintenance
16.1 Maintenance interval
Interval Task To be done by
Daily ⇒ Check the product for external damage.
⇒ Testing the safety circuit function.
⇒ If there is visible damage, notify service personnel (experts).
Operator
Every 3 months ⇒ Check the filter inserts of both the product's fans for dirt.
⇒ Replace the filter insert if necessary (See Chapter Replacing
the filter insert [} 89]).
Expert
Every 6 months ⇒ Inspect the filter cartridge in the filter control valve on the pneu-
matic unit for dirt and replace it as necessary (See Chapter
Changing the filter cartridge in the filter regulator valve [} 79]).
⇒ Check that the pneumatic unit's manometer is working correctly
and replace it if necessary (See Chapter Replacing a defective
manometer [} 91]).
Expert
⇒ Check all of the pneumatic unit's components for tight fits.
every year ⇒ Have the unit undergo a complete wear check and overhaul by
Tucker Service.
88 / 108 08 • 22/05/2023
Control Unit TX
Maintenance
Interval Task To be done by
depending on wear ⇒ Check the condensate level in the pneumatic unit's collecting
container.
⇒ Empty the collecting container is full to its "max" mark (See
Chapter Emptying the pneumatic unit's collection container [
} 90]).
Expert
16.2 Replacing the filter insert
For this work, qualification as expert personnel is required.
⇒ Shut the product off at the main switch.
⇒ Open the lower housing door.
Fig. 45: Fan positions
⇒ Pull off the fan grille (figure, Pos. 1).
⇒ Remove the filter insert from the fan's grille.
⇒ Place a new filter insert into the fan's grille.
08 • 22/05/2023 89 / 108
Control Unit TX
Maintenance
⇒ Press the fan grille onto the product housing until the grille clicks in.
⇒ Close the housing door.
✓ The control unit is ready to turn on.
16.3 Emptying the pneumatic unit's collection container
For this work, qualification as expert personnel is required.
⇒ Disconnect the product from its voltage supply and depressurise it.
⇒ WARNING Danger of electric shock from residual voltage. After the product is shut off, its capacitors
still carry high voltage. After the product is switched off, wait two minutes before opening the doors, so that
the voltage stored in the capacitors can dissipate.
⇒ Open the lower housing door.
Fig. 46: Position of the drain screw on the pneumatic unit
⇒ Place a suitable collecting container under the drainage screw (illustration item 1).
⇒ Open the drain screw.
✓ The condensate flows into the collecting container.
⇒ Screw the drain screw back in and tighten.
⇒ Remove the collecting container.
⇒ Close the lower housing door.
⇒ Turn the product on at the main switch.
⇒ Turn on the product's compressed air supply at the main pneumatics switch.
90 / 108 08 • 22/05/2023
Control Unit TX
Maintenance
16.4 Replacing a defective manometer
Tools needed
● a set of Allen screwdrivers
⇒ Disconnect the product from its voltage supply and depressurise it.
⇒ WARNING Danger of electric shock from residual voltage. After the product is shut off, its capacitors
still carry high voltage. After the product is switched off, wait two minutes before opening the doors, so that
the voltage stored in the capacitors can dissipate.
⇒ Secure the product's power supply and compressed air supply from being turned back on.
⇒ Open the lower housing door.
Fig. 47: Replace manometer
⇒ Pull the 2 compressed air lines (Fig. , Item 2) for the manometer out of the plug-in connectors.
⇒ Undo the 2 Allen screws (illustration, item 1) on the manometer.
⇒ Remove the defective manometer.
⇒ Fit a new manometer in the product.
⇒ Retighten the 2 Allen screws on the manometer.
⇒ Pull the compressed air line (figure, Pos. 5) from the insertion lock.
⇒ Screw off the push-in fitting (figure, Pos. 4).
⇒ Loosen the 2 slotted screws (figure, Pos. 3).
⇒ Swing the clamping ring (figure, Pos. 1) 60 degrees and pull the clamping ring off toward the compressed air
connection.
⇒ Remove the defective manometer (figure, Pos. 2) in the opposite direction from the product (left figure, direc-
tion of arrow).
08 • 22/05/2023 91 / 108
Control Unit TX
Maintenance
⇒ Fit a new manometer in the product.
⇒ Stick the clamping ring (figure, Pos. 1) onto the new manometer and swing the clamping ring 60 degrees.
⇒ Tighten the 2 slotted screws (figure, Pos. 3).
⇒ Tighten the push-in fitting (figure, Pos. 4) firmly onto the manometer.
⇒ Insert the compressed air line (figure, Pos. 5) into the insertion lock.
⇒ Push the 2 compressed air lines into the manometer's plug-in connectors.
92 / 108 08 • 22/05/2023
Control Unit TX
Shutting down
17 Shutting down
For this work, qualification as expert personnel is required.
⇒ Disconnect the product from its voltage supply and depressurise it.
⇒ WARNING Danger of electric shock from residual voltage. After the product is shut off, its capacitors
still carry high voltage. After the product is switched off, wait two minutes before opening the doors, so that
the voltage stored in the capacitors can dissipate.
⇒ Secure the product's power supply and compressed air supply from being turned back on.
08 • 22/05/2023 93 / 108
Control Unit TX
Dismantling
18 Dismantling
For this work, qualification as expert personnel is required.
18.1 Undoing the connections
⇒ Taking the product out of operation (See Chapter Shutting down [} 93]).
⇒ Open the lower housing door.
⇒ Disconnect the device from the electrical network.
⇒ Disconnect the product from the shielding gas supply.
⇒ Disconnect the product from the compressed air supply.
⇒ If an optional control panel was connected to the controller, then you must disconnect the optional control
panel's connection cable from the control panel connection on the controller.
⇒ Unlock the multi-coupling on the feeder hose package.
⇒ Pull the feeder hose package from the feeder coupler bushing.
⇒ Unlock the multi-coupling on the welding tool hose package.
⇒ Pull the welding tool hose package from the welding tool coupler bushing.
⇒ Pull the earth measuring cable off the earth measuring cable connection.
⇒ Pull off the safety circuit’s safety plugs from the safety circuit connections.
⇒ Pull off the emergency-stop circuit’s safety plug from the emergency-stop circuit connection.
⇒ Pull the ground cable from the ground connection.
⇒ Pull the client interface plugs from the client interface connections.
⇒ Removed the disconnected lines by pulling them down out of the housing.
18.2 Removing the product
Required tool
⇒ Undo all the product's screw connections and remove the individual product components, so that the elec-
tronic components can be disposed of separately.
94 / 108 08 • 22/05/2023
Control Unit TX
Disposal
19 Disposal
For this work, qualification as operating personnel is required.
19.1 Disposing of packaging material
⇒ Dispose of the packaging material sorted by material and according to applicable regulations.
19.2 Product disposal
Condition
● The product is completely dismantled.
⇒ Dispose of the product's individual components separately from one another and according to applicable reg-
ulations.
⇒ Observe the regulations that apply to the following materials:
● Batteries
● Metal
● Plastic
● Electronic components and circuit boards
08 • 22/05/2023 95 / 108
Control Unit TX
Technical data
20 Technical data
20.1 Dimensions and weight
Data Value Unit
Weight 132; TX AC: 166 kg
Width 500; TX AC: 510 mm
Height 963; TX AC: 1314 mm
Depth 673; TX AC: 753 mm
20.2 Safety control
Data Value Unit
Process safety time 2.6 s
20.3 Door closing
Data Value Unit
Key for housing doors Square
optional triangle, BKS, double bit, E3524 or STUV
20.4 Protection class
Data Value Unit
Protection class in accordance with IEC 60529 IP54
20.5 Ambient conditions
20.5.1 Transport
Ambient conditions Value Unit
Temperature range > 24 h -25 to +55 °C
Temperature range < 24 h -25 to +70 °C
relative humidity (non-condensing) ≤ 80 %
96 / 108 08 • 22/05/2023
Control Unit TX
Technical data
20.5.2 Storage
Ambient conditions Value Unit
Temperature range > 24 h -25 to +55 °C
Temperature range < 24 h -25 to +70 °C
relative humidity (non-condensing) ≤ 80 %
Installation site dry, ventilated interior spaces
20.5.3 operation
Data Value Unit
Temperature range +5 to +50 °C
relative humidity (non-condensing) at ≥ 5°C ≤ 95 %
relative humidity (non-condensing) at ≥ 20°C ≤ 90 %
relative humidity (non-condensing) at ≥ 40°C ≤ 50 %
Setting up altitude above sea level ≤ 3000 m
Installation site dry, ventilated interior spaces
20.6 Electronics
Data Value Unit
U1 supply voltage ± 10%, 3/PE 400/440/500 V
Ieff nominal current 32, TX MAX: 50 A
I1max maximum nominal current 200 A
Grid frequency ± 5% 50/60 Hz
maximum duration of a supply voltage interruption at 5 ms
I2 = 1500 A
Output voltage V2 at 400V 50 V
Safety circuit (US2) +20%/–15% 24 V
Client interface (US1) +20%/–15% 24 V
Minimum standard for the network feed to the client interface or CAT.6 S/FTP
to the external network adapter
Device class as per IEC 60974-10 A
Upstream fuse 32 A (T)
maximum upstream fuse 50 A (T)
08 • 22/05/2023 97 / 108
Control Unit TX
Technical data
20.7 Pneumatics
Data Value Unit
Nominal operating pressure 5 -bar
System pressure 4 to 8 -bar
Pressure switch threshold 4 -bar
Purity class as per ISO 8753-1 [7:4:4]
20.8 Shielding gas
Data Value Unit
Operating pressure 4 -bar
System pressure 4 to 8 -bar
Pressure switch threshold 3.5 -bar
maximum permissible portion of external gases per 40 ppm
DIN EN ISO 14175
20.9 Weld parameters
Data Value Unit
effective output current I 2 TX1500 + TX1800: 130A, TX 15AC: 170 A
A
Peak output power P2 at 400V 80, TX 1800: 90 kVA
Number of welds at I2 = 710 A, t = 100 ms 20 rpm
Number of welds at I2 = 1500 A, t = 15 ms 20 rpm
Maximum welding current I2 1500, TX 1800: 1800 A
Maximum welding current I2 100 A
Welding time TX1500/1800: 100, TX15AC: 200 (1500 ms
A), 200 to 350 (1000 A)
Welding current frequency 100 Hz
98 / 108 08 • 22/05/2023
Control Unit TX
Technical data
20.9.1 Welding device performance
Graphic overview of the number of welds per minute based on time at various amperages.
The overview provides guidelines for designing typical applications. The values may vary. Influence factors in-
clude the ambient temperature, the welding circuit design, the welding process options (such as cleaning phase)
and the ratio of welding frequency to pause (pulse load).
1500 amperes DC
Fig. 48: Overview of the number of welds per minute at 1500 amperes DC
1500 amperes AC
1500A AC Weld Unit (SMPS) Performance
Fig. 49: Overview of the number of welds per minute at 1500 amperes AC
08 • 22/05/2023 99 / 108
Control Unit TX
Technical data
1800 amperes DC
Fig. 50: Overview of the number of welds per minute at 1800 amperes DC
100 / 108 08 • 22/05/2023
Control Unit TX
List of Figures
List of Figures
Fig. 1 Sample illustration “Position of filling flap”........................................................................................ 11
Fig. 2 EMERGENCY STOP smash-button on the system (example image) ............................................. 19
Fig. 3 Emergency-off switch on the product............................................................................................... 20
Fig. 4 Arc stud welding phases in a drawn arc process using DC ............................................................. 25
Fig. 5 Arc stud welding phases in a drawn arc process using AC ............................................................. 26
Fig. 6 System overview of the components in the stud welding system and its connections —with stud
divider and two feeders .................................................................................................................... 27
Fig. 7 Stud welding system with stud welding gun..................................................................................... 28
Fig. 8 Stud welding system with stud welding gun..................................................................................... 29
Fig. 9 Operating elements in product housing (automatic system) ............................................................ 36
Fig. 10 Operating elements in product housing (manual system)................................................................ 38
Fig. 11 Operating elements in product housing (automatic system and manual system)............................ 39
Fig. 12 Operating elements on the front and back of the product (automatic system and manual system) 41
Fig. 13 Operating elements on the front and back of the product (automatic system and manual system) 42
Fig. 14 Connections (automated system) .................................................................................................... 44
Fig. 15 Connections (manual system).......................................................................................................... 46
Fig. 16 Connections (automatic system and manual system)...................................................................... 47
Fig. 17 Positions of the transport lugs and rollers ........................................................................................ 49
Fig. 18 Touchpad control panel.................................................................................................................... 50
Fig. 19 Design of the model plate ................................................................................................................ 51
Fig. 20 Eyebolt positions .............................................................................................................................. 55
Fig. 21 Secure the castors against rolling away........................................................................................... 56
Fig. 22 Secure the castors against rolling away........................................................................................... 60
Fig. 23 Positions of the safety circuit connections ....................................................................................... 61
Fig. 24 Emergency-stop connection position ............................................................................................... 62
Fig. 25 Position of the client interface connection........................................................................................ 62
Fig. 26 Position of the ground connection.................................................................................................... 63
Fig. 27 Position of the shielding gas connection .......................................................................................... 64
Fig. 28 Position of the compressed air connection ...................................................................................... 65
Fig. 29 Position of power supply connection................................................................................................ 67
Fig. 30 Position of the control unit ON button .............................................................................................. 69
08 • 22/05/2023 101 / 108
Control Unit TX
List of Figures
Fig. 31 Positions of the main switch and the pneumatic main switch .......................................................... 72
Fig. 32 Position of the control unit ON button .............................................................................................. 73
Fig. 33 Position of the main pneumatics switch ........................................................................................... 73
Fig. 34 Position of main switch..................................................................................................................... 74
Fig. 35 Status LEDs on the product housing................................................................................................ 78
Fig. 36 Position of the filter regulator valve of the pneumatic unit................................................................ 79
Fig. 37 Position of the unlocking slider on the filter control valve’s water separator .................................... 80
Fig. 38 Filter control valve’s filter plate position ........................................................................................... 80
Fig. 39 Filter control valve’s filter cartridge position ..................................................................................... 81
Fig. 40 Position of the locking pin on the filter control valve’s water separator............................................ 81
Fig. 41 Position of the filter control valve’s regulator button on the pneumatic unit ..................................... 82
Fig. 42 Position of the regulator button on the shielding gas pressure regulator of the pneumatic unit ...... 83
Fig. 43 Position of the program memory card and the Plexiglas pane......................................................... 85
Fig. 44 Position of the program memory card and the Plexiglas pane......................................................... 86
Fig. 45 Fan positions.................................................................................................................................... 89
Fig. 46 Position of the drain screw on the pneumatic unit............................................................................ 90
Fig. 47 Replace manometer......................................................................................................................... 91
Fig. 48 Overview of the number of welds per minute at 1500 amperes DC ................................................ 99
Fig. 49 Overview of the number of welds per minute at 1500 amperes AC ................................................ 99
Fig. 50 Overview of the number of welds per minute at 1800 amperes DC ................................................ 100
102 / 108 08 • 22/05/2023
Control Unit TX
Keyword index
Keyword index
optional control device 32
A
Receiver 31
Automatic system 26
Stud divider 32
Example 33
Stud pre-separation units 33
Stud welding guns 32
B Stud welding heads 32
Bias current light arc 24 TX control unit 30
Burn-off 11 Functions of the cleaning station 33
Functions of the control unit 30
C Functions of the feeder 31
Functions of the stud divider 32
CI 12
Functions of the stud pre-separation unit 33
CleanFlash 11
Functions of the stud welding head 32
CleanFlash function 24
Configuration 70
Connecting to the higher-level system controller 30 K
Control device (optional) Key for housing doors 96
Function 32 Key switch 21
Control unit functions 30
Customer interface 12 M
MAC 12, 32
D MAC functions 32
Docking 12 Magnetic Arc Control 12
Draining the condensate 90 Magnetic arc deviation (MAC) 32
Main light arc 24
E Maintenance chart 89
Manual system 27
Emergency stop 19
Example 34
EMERGENCY-STOP 19
Examples of automatic systems 33
Examples of manual systems 34 P
Pre-separation unit 33
F
Feed tube 32 R
Functional description Receiver
Cleaning station 33 active 31
Feeder 31 Function 31
MAC 32 passive 31
08 • 22/05/2023 103 / 108
Control Unit TX
Keyword index
Release 73
Robot cell 12
S
Safety devices
Automatic system 19, 20
Manual system 20
Safety key 21
SMPS 12
SOW 12
SOW signal 23
Starting to weld
external 23
internal 23
Stick out 11
Stud ID 11
Stud pre-separation unit TPS 33
Stud welding gun functions 32
SWS 12
T
TCS 12
TCS cleaning station 33
TD stud divider 32
TF 12
TF feeder 31
TP 12
TPS 12
TSD 12
TSD stud divider 32
TX 12
Type plate 101
W
Welding process 23
Welding process diagram
with AC 26
with DC 25
104 / 108 08 • 22/05/2023
Control Unit TX
Notes
08 • 22/05/2023 105 / 108
Control Unit TX
106 / 108 08 • 22/05/2023
Control Unit TX
08 • 22/05/2023 107 / 108
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