Related Manuals for Emhart Teknologies TUCKER DCE 1500
Summary of Contents for Emhart Teknologies TUCKER DCE 1500
- Page 1 Operating Manual Control and Power Unit DCE 1500 Please read the operating manual before any operation!
- Page 2 © Emhart Teknologies TUCKER GmbH Max-Eyth-Straße 1 D-35394 Gießen Tel.: +49 (0) 641 405 0 Fax.: +49 (0) 641 405-383 E-Mail: Info@tucker.de Internet: www.tucker.de Translation of the Original Operating Manual BTA DCE1500 01/10...
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Page 3: Table Of Contents
Control and Power Unit DCE 1500 Table of Contents Table of Contents General Information....................5 Information Regarding the Operating Manual ...........5 Limitation of Liability..................5 Symbol Legend ....................6 Copyright Protection..................7 Replacement Parts....................7 Guarantee Instructions..................8 After Sales Service....................8 Safety .........................9 Responsibility of the Operating Company............9 Personnel Requisition ..................10 2.2.1 Qualification..................10... - Page 4 Control and Power Unit DCE 1500 Table of Contents 5.2.3 Connection of Measurement Lines A1-X8 SF1 - A1-X12 SF5... 28 5.2.4 Connection Weld Cables A1-X2 SF1 - A1-X6 SF5 ......29 5.2.5 Connection Control Cables X3 SF1 - X7 SF5........29 5.2.6 Connection Ground Cable A1-X1 ............
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Page 5: General Information
Control and Power Unit DCE 1500 General Information General Information Information Regarding the Operating Manual This operating manual contains important information regarding the handling of this device. The compliance with all security advisories and operation instructions is a precondition for a safe operation. Furthermore the local accident prevention regulations and the general safety regulations effective for the application area of the device have to be observed. -
Page 6: Symbol Legend
Control and Power Unit DCE 1500 General Information Symbol Legend Warning notices The warning notices in this operation manual are indicated by symbols. The notes commence with a signal word which expresses the extent of the danger. Observe the notes and act with caution to avoid accidents and damage to persons and property. -
Page 7: Copyright Protection
Control and Power Unit DCE 1500 General Information Special security advisories In order to draw attention to special dangers, the following symbols are used in connection with security advisories: DANGER! Danger to life by electric current! … indicates perilous situations by electric current. Disregarding of the security advisories can lead to severe injuries or death. -
Page 8: Guarantee Instructions
Control and Power Unit DCE 1500 General Information Guarantee Instructions For material and manufacturing faults, the guarantee period for this control and power unit amounts to 1 year from delivery date on. Excluded from this is damage that is caused by accident or by incorrect handling. The guarantee covers free-of-charge replacement of the faulty component. -
Page 9: Safety
Control and Power Unit DCE 1500 Safety Safety This paragraph gives a review about all important safety aspects for an optimal protect of the personnel as well as for the safe and failure-free operation. Disregard of the operating instructions and security advices mentioned in this manual could lead to serious dangers. -
Page 10: Personnel Requisition
Control and Power Unit DCE 1500 Safety Personnel Requisition 2.2.1 Qualification WARNING! Risk of injury on insufficient qualification! Improper handling can lead to serious damage to persons and property. Therefore: All activities are to be carried out by skilled personnel only! The following qualifications for different areas of operations are named in the operating manual: Instructed person... -
Page 11: Trespassers
Control and Power Unit DCE 1500 Safety 2.2.2 Trespassers WARNING! Danger for trespassers! Trespassers who do not fulfil the requirements mentioned in this document do not know about the dangers of this working area. Therefore: Keep trespassers away from the working area. ... -
Page 12: Intended Use
Control and Power Unit DCE 1500 Safety Intended Use The DCE 1500 control and power unit was designed exclusively for the intended use mentioned in this manual. The control and power unit DCE 1500 was designed exclusively for drawn arc welding of TUCKER weld studs and nuts and only for application in premises. -
Page 13: Personal Protective Equipment
Control and Power Unit DCE 1500 Safety Personal Protective Equipment At work wearing personal protective equipment is essential to minimize the risks for the health. During working time always wear the required protective equipment for the respective work. Observe the signs regarding the personal protective equipment which exist in the working area. -
Page 14: Special Risks
Control and Power Unit DCE 1500 Safety Special Risks The residual risks which arise from the hazard analysis are described in the following chapter. Please consider the below mentioned security advices and warnings in the following chapters of this manual to reduce health hazards and to avoid dangerous situations. -
Page 15: Safety Devices
Control and Power Unit DCE 1500 Safety Safety Devices The control and Power unit DCE 1500 is designed for the application within an installation. It can be integrated into the customer internal safety control via the connector “Safety circuit”. The connector plug for the safety circuit is included in delivery of the DCE and it serves to route the 24V power to the respective customer interface and to integrate the weld unit into a customer safety circuit control (Operator protection, stop-operation). -
Page 16: Securing Against Resetting
Control and Power Unit DCE 1500 Safety Securing Against Resetting WARNING! Mortal danger because of unauthorized resetting! When working in the danger zone, there is the risk that the power supply is reset without authority. This means the persons within the danger zone are in a life-threatening situation. Therefore: ... -
Page 17: Technical Specifications
Control and Power Unit DCE 1500 Technical Specifications Technical Specifications General Specifications Specification Value Unit Weight approx. 90 kg Width approx. 570 mm Height approx. 1000 mm Depth approx. 685 mm System of protection: IP 23 according Protected against solid Protected against IEC529 objects until 12 mm. - Page 18 Control and Power Unit DCE 1500 Technical Specifications Electrical Specification Value Unit I: 20-1500 A Weld current range t: 36-160 ms Weld time range Output peak capacity : 80 KVA at 400V AC Number of welds 60 min at I= 750A, t= 30 ms 30 min at I=1500A, t= 30 ms at 30C environmental temperature...
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Page 19: Fuse Elements
Control and Power Unit DCE 1500 Technical Specifications Fuse Elements DANGER! Opening of the appliance door as well as the inspection of the internal fuse elements is reserved for qualified electricians. In order to avoid an electrical accident caused by contact-hazardous components the below listed sequence is peremptory when exchanging defective fuse elements. - Page 20 Control and Power Unit DCE 1500 Technical Specifications The miniature fuses F1-F5 described below protect the DCE from any risk of transient current damage. The fuses are located on the printed circuit board on the control cabinet door below. Fuse F5 behind the covering The voltage of the protected circuits is 24V.
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Page 21: Dimensioned Drawing
Control and Power Unit DCE 1500 Technical Specifications Dimensioned Drawing... -
Page 22: Type Plate
Control and Power Unit DCE 1500 Technical Specifications Type Plate The type plate is located above to the right on the door of the control cabinet and contains the following information: Manufacturer Part number Power supply with frequency ... -
Page 23: General Description
Control and Power Unit DCE 1500 General Description General Description The DCE 1500 is an efficient and modern control and power unit, which was developed by TUCKER for drawn arc stud welding processes. It can be used as a single or multiple stud weld unit. Depending on the DCE 1500 model up to five "SFLM“... -
Page 24: Assembly And Connections
Control and Power Unit DCE 1500 Assembly and Connections Assembly and Connections Layout DCE 1500 The operating elements of the DCE are located on the front door and the control panel which can be affixed on the appliance door. DCE 1500 Digitally Controlled Energy Main switch Door... -
Page 25: Main Switch
Control and Power Unit DCE 1500 Assembly and Connections 5.1.1 Main Switch The control and power unit can be switch ON/OFF by means with the main switch. The main switch is located above to the left on the door of the control cabinet in standard version. 5.1.2 Key Switch Maintenance Operation Maintenance operation is released by switching the key... -
Page 26: Connection Control Terminal
Control and Power Unit DCE 1500 Assembly and Connections 5.1.5 Connection Control terminal On this connection the control panel (Keypad) can be connected to the control and power unit. Thus the programming and error correction is possible. ( chapter Display- and control elements). -
Page 27: Layout Inside Of The Device
Control and Power Unit DCE 1500 Assembly and Connections Layout Inside of the Device Apart from the interface the DCE is equipped with the connection possibilities listed below which may be configured differently depending on the selected unit configuration. A1-X1 X3-SF1 X4-SF2 X5-SF3... -
Page 28: Connection Power Supply
Control and Power Unit DCE 1500 Assembly and Connections 5.2.1 Connection Power Supply Power supply Power (A.C. and D.C.) must always be supplied by the user of the weld unit. Depending on the voltage supply available the DCE 1500 may be connected to the following AC. Voltage via CEE 32A plug: ... -
Page 29: Connection Weld Cables A1-X2 Sf1 - A1-X6 Sf5
Control and Power Unit DCE 1500 Assembly and Connections lines may not be subject to tension since the pole sockets cannot be locked. 5.2.4 Connection Weld Cables A1-X2 SF1 - A1-X6 SF5 The weld cables are to be connected to the sockets "A1-X2 SF1“ up to "A1-X6 SF5“ of the DCE control and power unit and to the feeders and then to be locked by a clockwise rotation. -
Page 30: Connection Ground Cable A1-X1
Control and Power Unit DCE 1500 Assembly and Connections Standard Operation with stud feeder and weld tool (LM/SKK/PK/PLM) Up to five "SF, SFLM or ETF“ type stud feeders each of which supply one weld head (LM/SKK) or one weld gun (PLM/PK) with studs can be connected to the connections marked X3 SF1 - X7 SF5 (see connection diagram 1). -
Page 31: Connection Of Customer Interface X8
Control and Power Unit DCE 1500 Assembly and Connections 5.2.8 Connection of customer interface X8 During automated welding operation the digital signal transmission to the external controller will be achieved by the customer interface. There are three different versions of customer interfaces available: ... -
Page 32: Layout 1: Dce In Standard Operation
Control and Power Unit DCE 1500 Assembly and Connections Layout 1: DCE in standard operation... -
Page 33: Layout 2: Dce In Sd 2 Operation
Control and Power Unit DCE 1500 Assembly and Connections Layout 2: DCE in SD 2 Operation Control cable... -
Page 34: Layout 3: Dce With Pke
Control and Power Unit DCE 1500 Assembly and Connections Layout 3: DCE with PKE Weld cable Control cable... -
Page 35: Display- And Control Elements
Control and Power Unit DCE 1500 Display- and Control Elements Display- and Control Elements The control and power unit DCE 1500 can be optionally equipped with the following operating devices. Control terminal Keypad TUV WXYZ PQRS Control terminal Touchpad The description of the control terminal can be found in the respective programming instructions. -
Page 36: Conversion From Keypad To Touchpad
Control and Power Unit DCE 1500 Conversion from Keypad to Touchpad Conversion from Keypad to Touchpad For a later conversion to control terminal Touchpad you need an additional upgrade kit with all required parts. Update ZCPU Firmware To use the control terminal Touchpad the software version on the ZCPU must be at least version 1.08. - Page 37 Control and Power Unit DCE 1500 Conversion from Keypad to Touchpad The fuse F2 on the DCE power supply board E 110 327, must be exchanged against a 1A fuse. The power supply board is located at the inside of the appliance door.
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Page 38: Notes Regarding Stud Welding
Control and Power Unit DCE 1500 Notes Regarding Stud Welding Notes Regarding Stud Welding NOTE! Stud welding causes impulsive forces of the power supply voltage. The connection of external devices to the same power system could cause malfunctions or disturbances of these devices! Remark: Due to the welding energy source (SMPS-Technology) inserted in the DCE 1500, an increased grid-bound HF-interference level is to be faced. -
Page 39: Dce 1500 Start-Up
Control and Power Unit DCE 1500 DCE 1500 Start-Up DCE 1500 Start-Up NOTE! The start-up is exclusively reserved for the authorised and qualified service personnel! It must be ensured that the DCE 1500 will be placed on a stable and level surface in order to allow an unhindered opening of unit door. - Page 40 Control and Power Unit DCE 1500 DCE 1500 Start-Up 7. In case data matches you can exit the menu ”Status - System“ by pressing twice the button ”ESC“ and switch into the menu “System configuration” - ”System parameter”. 8. Configure the connected devices of the outputs 1 to 5 according to their requirements.
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Page 41: Transport, Packaging And Storing
Control and Power Unit DCE 1500 Transport, Packaging and Storing Transport, Packaging and Storing NOTE! The installation and initial operation is effected exclusively by personnel or by authorized persons of the manufacturer. However, it may happen that in line with the installation and the further use operators or maintenance personnel of the operating company are consigned with the handling of packages. -
Page 42: Transport Check
Control and Power Unit DCE 1500 Transport, Packaging and Storing 10.2 Transport Check Upon delivery, the equipment, including accessories, should be checked for completeness and damage. On externally visible transport damage, proceed as follows: Do not accept the delivery or only accept with reservation. ... - Page 43 Control and Power Unit DCE 1500 Transport, Packaging and Storing Transport of pallets with the Packing pieces which are fixed on a pallet, can be forklift truck transported with a forklift truck under the following conditions: The forklift truck must be designed for the weight of the shipping units.
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Page 44: Terms And Conditions For Overseas Transport
Control and Power Unit DCE 1500 Transport, Packaging and Storing 10.4 Terms and Conditions for Overseas Transport NOTE! For onward transportation overseas use sea freight transport crate with the corresponding number of desiccant pouches for packing according to DIN 55473! The manufacturer bears no liability for damages caused by improper onward transportation. -
Page 45: Packaging
Control and Power Unit DCE 1500 Transport, Packaging and Storing 10.5 Packaging The respective packaging pieces are packed according to the transport conditions to expect. Exclusively non-polluting materials were used for packaging. The packaging shall protect the respective components against transport damages, corrosion and other damages until assembly. -
Page 46: Maintenance And Cleaning
Control and Power Unit DCE 1500 Maintenance and Cleaning Maintenance and Cleaning 11.1 Safety The maintenance work described can be executed by the Personnel operator, unless it is marked differently. Some maintenance work may only be executed by specially trained experts. -
Page 47: Cleaning Of The Filter Insert
Control and Power Unit DCE 1500 Maintenance and Cleaning Interval Wearing work To be carried out daily Check connection cables, connection plugs and Operator connector assembly for mechanical damage and loose contacts semi-annually Check filter insert for contamination Qualified personnel 11.3 Cleaning of the Filter Insert The contamination of the filter insert is depending on the prevalent environmental... -
Page 48: Disposal
Control and Power Unit DCE 1500 Disposal Disposal Unless no recovery- or disposal arrangement was made disassembled parts have to be recycled: Scrap metals. Recycle plastic elements. Dispose sorted all the rest of the components according material properties. CAUTION! Damage caused to the environment due to wrong disposal! - Page 49 Translation of the Original Declaration of Conformity EC-Declaration of Conformity according to the Low Voltage Directive 2006/95/EC Annex III B Document number: KFE DCE1500 02 Manufacturer: TUCKER GmbH Max-Eyth-Straße 1 35387 Gießen Germany Product name: DCE 1500 Control and power unit for short term drawn arc stud welding Serial number: Year of manufacture: The manufacturer declares that the above-mentioned product conforms to all the applicable...
- Page 51 Notizen/Notes:...
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