Customer Interface

Interbus-S S1 381-0343xx
for
DCE Control & Power Units

Emhart Teknologies
TUCKER GmbH, Max-Eyth-Straße 1, 35394 Gießen
Tel.: 0641/405-0; Fax: 0641/405-383; Mail: Info@tucker.de
DCE Customer Interface Interbus-S S1 381-0343xx

Bytes signal assignment

Data length: 6 bytes input / 6 bytes output

Data Bit Input signals DCE Output signals DCE

0.0 Ready for service
0.1 Preselection no welding no welding
0.2 Reset fault no fault
0.3 Test mode Weld inside of tolerance
0.4 Restart Maintenance warning
0.5 Forced WC
0.6 Reset counter pre. maintenance SKK 1 Prev. maintenance 80% SKK 1
0.7 Reset counter pre. maintenance SKK 2 Prev. maintenance 80% SKK 2
1.0 Start stud feeding 1 Stud on work piece SOW 1
1.1 Start stud feeding 2 Stud on work piece SOW 2
1.2 Start stud feeding 3 Stud on work piece SOW 3
1.3 Start stud feeding 4 Stud on work piece SOW 4
1.4 Start stud feeding 5 Stud on work piece SOW 5
1.5 Reset counter pre. maintenance SKK 3 Prev. maintenance 80% SKK 3
1.6 Reset counter pre. maintenance SKK 4 Prev. maintenance 80% SKK 4
1.7 Reset counter pre. maintenance SKK 5 Prev. maintenance 80% SKK 5
2.0 Program selection 2**0
2.1 Program selection 2**1
2.2 Program selection 2**2
2.3 Program selection 2**3 Fault message (1 Byte)
2.4 Program selection 2**4
2.5 Program selection 2**5
2.6 Program selection 2**6
2.7
3.0 Start weld cycle 1 Weld complete WC (FK) 1
3.1 Start weld cycle 2 Weld complete WC (FK) 2
3.2 Start weld cycle 3 Weld complete WC (FK) 3
3.3 Start weld cycle 4 Weld complete WC (FK) 4
3.4 Start weld cycle 5 Weld complete WC (FK) 5
3.5
3.6
3.7
4.0 Weld head 1 forward Weld head 1 back position
4.1 Weld head 2 forward Weld head 2 back position
4.2 Weld head 3 forward Weld head 3 back position
4.3 Weld head 4 forward Weld head 4 back position
4.4 Weld head 5 forward Weld head 5 back position
4.5 Prev. maintenance 98% Weld head 1
4.6 Prev. maintenance 98% Weld head 2
4.7 Prev. maintenance 98% Weld head 3
5.0 Weld head 1 in front
5.1 Weld head 2 in front
5.2 Weld head 3 in front
5.3 Weld head 4 in front
5.4 Weld head 5 in front
5.5 Prev. maintenance 98% Weld head 4
5.6 Prev. maintenance 98% Weld head 5
5.7

Revision: June 2004 1

DCE Customer Interface Interbus-S S1 381-0343xx

Word signal assignment

Data length: 3 words input / 3 words output

Data Bit Input signals DCE Output signals DCE

0.00 Start stud feeding 1 Stud on work piece SOW 1
0.01 Start stud feeding 2 Stud on work piece SOW 2
0.02 Start stud feeding 3 Stud on work piece SOW 3
0.03 Start stud feeding 4 Stud on work piece SOW 4
0.04 Start stud feeding 5 Stud on work piece SOW 5
0.05 Reset counter pre. maintenance SKK 3 Prev. maintenance 80% SKK 3
0.06 Reset counter pre. maintenance SKK 4 Prev. maintenance 80% SKK 4
0.07 Reset counter pre. maintenance SKK 5 Prev. maintenance 80% SKK 5
0.08 Ready for service
0.09 Preselection no welding No welding
0.10 Reset fault No fault
0.11 Test mode Weld inside of tolerance
0.12 Restart Maintenance warning
0.13 Forced WC
0.14 Reset counter pre. maintenance SKK 1 Prev. maintenance 80% SKK 1
0.15 Reset counter pre. maintenance SKK 2 Prev. maintenance 80% SKK 2
1.00 Start weld cycle 1 Weld complete WC (FK) 1
1.01 Start weld cycle 2 Weld complete WC (FK) 2
1.02 Start weld cycle 3 Weld complete WC (FK) 3
1.03 Start weld cycle 4 Weld complete WC (FK) 4
1.04 Start weld cycle 5 Weld complete WC (FK) 5
1.05
1.06
1.07
1.08 Program selection 2**0
1.09 Program selection 2**1
1.10 Program selection 2**2
1.11 Program selection 2**3 Fault message (1 Byte)
1.12 Program selection 2**4
1.13 Program selection 2**5
1.14 Program selection 2**6
1.15
2.00 Weld head 1 in front
2.01 Weld head 2 in front
2.02 Weld head 3 in front
2.03 Weld head 4 in front
2.04 Weld head 5 in front
2.05 Prev. maintenance 98% Weld head 4
2.06 Prev. maintenance 98% Weld head 5
2.07
2.08 Weld head 1 forward Weld head 1 back position
2.09 Weld head 2 forward Weld head 2 back position
2.10 Weld head 3 forward Weld head 3 back position
2.11 Weld head 4 forward Weld head 4 back position
2.12 Weld head 5 forward Weld head 5 back position
2.13 Prev. maintenance 98% Weld head 1
2.14 Prev. maintenance 98% Weld head 2
2.15 Prev. maintenance 98% Weld head 3

Revision: June 2004 2

 DCE Customer Interface Interbus-S S1 381-0343xx

Interbus-S LED’s and DIP switches

H402 Input X402

X402 X401 H401 Input X401 X502

F/O to
X501 H502 H501 central CPU
H403
24V
+24V
+5V +24V Customer Interface Interbus-S
E 110 381x B362x
H207

IBS State
J203 H102 H101
H201

J202
X203
[:]J101 8 - DIP - 1

IBS - IN IBS - OUT ON

H308 H301

Indication LED’s

State Interbus-S
H201 CC - Cable Check
H202 BA - Bus Active
H203 RD - Remote Bus Disabled
H204 FO1 - Diagnostics range f/o interface incomming
H205 FO2 - Diagnostics range f/o interface outgoing
H206 TR - Transmit/Receive (PCP active)
H207 Ul - Status SUPI3 (LED remains lit = Interbus active)

State customer Interface

H101 - Program processing run
H102 - Fault in the program process

H501 - Control voltage +24V OK

H502 - Control voltage +5V OK

State extend customer Interface (DIP1 - DIP8 = 0)

H301 - Signal processing run
H302 - Reserved for tests internal
H303 - Communikation with DCE Central-CPU active
H304 - Reserved for tests internal
H305 - Transmission datas from Interbus active
H306..308 - Reserved for tests internal

Revision: June 2004 3

DCE Customer Interface Interbus-S S1 381-0343xx

Function of DIP-Switches (during program cycle)

DIP 7 Changing the point in time for the generation of the WC signal (FK).
OFF Æ WC is generated directly after the weld.

ON Æ WC is generated when the slide has reached the back position

after the weld.

DIP 8 Selection diagnose function

OFF Æ Displaying state or inputs/outputs of interface

ON Æ for test functions internal

Indication of inputs/Outputs (DIP8=OFF)

DIP 1...7 binary coded

1 - Input byte 0
2 - Input byte 1
3 - Input byte 2
4 - Input byte 3
5 - Input byte 4
6 - Input byte 5

7 - Output byte 0
8 - Output byte 1
9 - Output byte 2
10 - Output byte 3
11 - Output byte 4
12 - Output byte 5

Displaying of inputs/outputs see LEDs H 301 to H 308.

Function Jumpers:
J101 - Standard open (only for flash programming in BSL mode)

J202 - Data transfer rate Interbus-S without Jumper 2 Mbaud

with Jumper 500 KBaud
J203 - Standard open
(only use with connecting a external Interbus diagnosis LED on X203)

Revision: June 2004 4

DCE Customer Interface Interbus-S S1 381-0343xx

Connection plugs:
X203 - External diagnostic Interbus

X401 - Input for H401 (Operation-Stop)

X402 - Input for H402 (not connected)

X501 - Power supply 24V inputs

X502 - Power supply 24V outputs for external units (e. g. for f/o converter)

Description Configuration - Interface:

Configuration Interbus-S:
ID-Code # Interbus: 0x03 (general subscribers with digital I/O’s)

Data length Interbus: 3 words Input / Output

Protocol Interface:
Data length: Process data: 3 words input / 3 words output

The bus-transfer of the bytes of an data word is effected in the order High-Byte -
Low-Byte.

Revision: June 2004 5

DCE Customer Interface Interbus-S internal slide rail control

Weld inside tolerance Weld out of tolerance

Start weld cycle

SKK back position

SOW

Weld cycle
WIP WOP
Weld complete *

Inside tolerance

Weld cycle with fault Repeat weld cycle with “Restart“

Start weld cycle

SKK back position

SOW

Weld cycle FAULT WIP

Weld complete *

Inside tolerance

No fault

Restart

SOW = Stud on work piece

* The point in time for the generation of the WC signal depends upon DIP switch 7

Revision: June 2004 6

DCE Customer Interface Interbus-S internal slide rail control

Weld cycle with fault, receipt with “Forced WC“ Weld cycle with fault, receipt with “Reset fault“

Start weld cycle

SKK back position

SOW

Weld cycle
FAULT FAULT
Weld complete

Inside tolerance

No fault

Forced WC

Reset fault

Revision: June 2004 7

DCE Customer Interface Interbus-S S1 381-0343xx external slide rail control

Weld inside tolerance Weld out of tolerance

Start weld cycle

SKK back position

SOW

Weld cycle
WIP WOP
Weld complete *

Inside tolerance

Weld cycle with fault Reset fault

Start weld cycle

SKK back position

SOW

Weld cycle
FAULT
Weld complete *

Inside tolerance

No fault

Rest fault

* The point in time for the generation of the WC signal depends upon DIP switch 7

Revision: June 2004 8

DCE Customer Interface Interbus-S S1 381-0341xx

Maintenance counter

For preventive maintenance of the collets warning signals are generated by the
customer interface. When 80 % and/or 98 % of the maximum programmed value is
reached, the corresponding output signals are activated.

The reference value in this respect is the value set in the DCE for the welding
quantity counter, at which the DCE generates a fault. For the respective output this
value is set in the "Programming maintenance counter" menu under the point "Fault
at" (see also "DCE programming instructions").

Programming Maintenance Counter

Outlet: X ----------------

Collet: Maintenance at....#####

Collet: Fault at..........#####
Feed Maintenance at....#####
tube: Fault at..........#####
Weld Maintenance at....#####
tool: Fault at..........#####
User: Maintenance at....#####
User: Fault at..........#####

Programming output.<↓>

<↑,←,→,↓> Selection file

The value set under the point "Collet warning" is of no significance for the generation
of the warning signals at the customer interface.

By means of the reset inputs "Reset service life counter" the corresponding welding
quantity counters in the DCE are set to zero irrespective of their current value. Thus
any imminent warning signals of the DCE and the customer interface are also reset.

Example:
Setting Collet warning at 2000
Collet fault at 3000
• After 2000 welds the DCE generates the maintenance warning
"Maintenance collet".

• After 2400 welds (80 % of 3000) the signal "80 % service life reached" is
activated.

• After 2940 welds (98 % of 3000) the signal "98 % service life reached" is
activated.

• After 3000 welds the DCE generates the fault

"Collet service life exceeded".

Revision: June 2004 9

Notizen/Notes: