APPENDIX A

TABLE OF CONTENTS

CHANGING THE DCE POWER SUPPLY PROCEDURE .......................................... 1

PROCEDURE FOR POWER VERIFICATION ............................................................ 6
PROGRAMMING STUD LENGTH DETECTION (ANGULARITY) HAND GUN .. 7
PROGRAMMING STUD LENGTH DETECTION WELD HEAD.............................. 8
CLEAR RAM PROCEDURE......................................................................................... 9
PK560 HANDGUN SET-UP (3 STEPS) .................................................................... 11
PISTON LUBRICATION PROCEDURE.................................................................... 14
 CHANGING THE DCE POWER SUPPLY PROCEDURE

IMPORTANT SAFETY NOTE:

HAZARDOUS VOLTAGES ARE
PRESENT INSIDE THE DCE
CONTROL. TURN OFF AND LOCK
OUT ALL 480VAC INPUT POWER TO
DCE WELDER CONTROL CABINET
BEFORE CONTINUING WITH THIS
PROCEDURE

• After securing and locking out the input power to the DCE cabinet, open the
front door of the DCE and remove the top cover. Continue with the
procedure on the next page.

CONTINUE TO NEXT PAGE

1
 Loos e n thre e Philips
s cre ws and re move
the wire s

Dis mount Re lay K1

Flat he ad s cre w drive r

You may ne e d to pus h the DIN bracke t
back in orde r to acce s s the re le as e tab on the
K1 re lay

CONTINUED NEXT PAGE

2
 Loos e n the flat he ad s cre w
on the te rminal block and
pull ground wire out

Re move wire -run s trip

cove rs as ne ce s s ary X-20

Re move the brown and white

wire s on X-20. The s e wire s are
going to the Safe ty M odule Pcb.

CONTINUED NEXT PAGE

3
 Re move Fibe r Optic conne ction

Re move X-14 conne ctor

Fan +24v powe r
s upply X-20 wire s

X-6

Re move X-6 conne ctor X-14

SOW +15v powe r s upply
conne ctor

Re move two 13mm he x bolts

CONTINUED NEXT PAGE

4
 Lift powe r s upply
by the s upport
bars and re move

The K-1 re lay is le ft

ins ide the controlle r

Filte r
END OF PROCEDURE
5
 PROCEDURE FOR POWER VERIFICATION H1

Examine the Green LED H1 on the outside of the front door of the DCE Control.

• If Green LED is on, continue troubleshooting with your ORIGINAL fault.

• If Green LED is off, perform the following steps

1. Verify that there is 480vac 3-phase to the controller. If not, repair plant power. If power is OK
continue with step 2.

2. Open the cabinet door and power up the control. On the inside of the front door near the top is the
Auxiliary Power Supply Board (see the figure below). Verify that the Red LED’s (D1 through
D5, and D10) on the board are lit. If any of the Red LED’s are out proceed to step 3. If not,
proceed to step 2 A.

F 5 unde r c ove r
D5
D10 D4
F3
CAUTION F4 D3
480VAC and F2
230VAC are
present under this F1 D2
cover.
D1

X9
A) If all LED’s are lit, disconnect X9 on the door power supply and carefully check for
24vdc between pins 1 & 2 on the board itself.
B) If 24vdc is present, the green LED is defective. Continue troubleshooting your original
fault. Replace the green LED at the earliest opportunity.
C) If 24vdc is not present, continue troubleshooting your original fault and replace the
Auxiliary Power Supply Board at the earliest opportunity.

3. If any of the red LED’s are out.

A) Secure power to the control and remove the corresponding fuse to the LED that is out and
check it (Note: The fuse for D3 is F4 and the fuse for D4 is F3; also, do not forget about
the fuse under the cover). Replace defective fuse and power up control checking for
green led H1 on front door of DCE Cabinet.
B) Secure power to the control and remove F1 through F6 on the Fuse Bank and check fuses
(See Appendix B Fig. 7). If any are defective replace fuse(s) and power up control
checking for green led. If the fuses are ok, replace the door power supply.

4. Once you have the Green LED lit, reset faults if possible and proceed with troubleshooting any
remaining faults.

6
PROGRAMMING STUD LENGTH DETECTION (ANGULARITY) HAND
GUN
Before you program Stud Length Detection /Angularity make sure you have a part in place, stud in
the collet, and that stick-out set properly (SEE APPENDIX B FIG. 15).

1. From DCE Keypad Main Menu, select Programming, press Enter.

2. Select Outlet Programming, press Enter.

3. Select Outlet Number, press Enter.

4. Make sure that Angularity is set to Yes; if is not change it to Yes by using (+) or (-) key.

5. Next Select "Teach!" using arrow keys then press Enter.

6. Highlight Teach Position.

7. Now take your handgun, position it on the part like you would be welding and pull the trigger (it
will not weld at that point).
Note: Make sure the flash shield is seated firmly on the part.

8. Now go back to your keypad and highlight Check Position.

9. Position your handgun on the part like you would be welding and pull the trigger (it will not
weld at that point).
Note: Make sure the flash shield is seated firmly on the part. This step is used to check
the difference. If the difference is more than .02 mm then go back to step 6.

10. Now press F5.

11. Use the arrow key to move cursor off of the "Teach!" field and press (enter).

12. Go to Main menu and select Programming, press Enter.

13. Select Weld Programming, press Enter.

14. Select Outlet Number and Weld Program, press Enter.

15. Make sure the Angularity is set to "Outlet” If not you can change to Outlet using (+) or (-) key
then press Enter.

7
 PROGRAMMING STUD LENGTH DETECTION WELD HEAD
Before you program Stud Length Detection make sure you have a part in place, stud in the collet,
and that stick-out is set properly (SEE APPENDIX B FIG. 15).

1. From DCE Keypad Main Menu, select Programming, press Enter.

2. Select Outlet Programming, press Enter.

3. Select Outlet Number, press Enter.

4. Make sure that Check Stud Length is set to Yes; if is not change it to Yes by using (+) or (-)
key.

5. Press Esc to go back to Extended Programming.

IMPORTANT NOTE: You must perform steps 6-16 for every Weld Program
(robot position) that is used on the application. Move the Robot to each successive
position and select the corresponding “Program Number” in step 7.

6. Select Weld Programming, press Enter.

7. Select the Outlet and Program Number of the position to be taught.

8. On the line Check Stud Length, ensure the first option says Program, change if necessary using
the (+) or (-) keys.

9. Next Select Teach! using arrow keys then press Enter.

10. Highlight Teach Length line. To activate this option you must hold F6 and press Enter.

11. At this point your weld head will move forward to the part and then back (It will not weld). You
will read a result -Value (ref)- on this page.
Note: Make sure you have a part in place.

12. Now highlight Check Length line. To activate this option you must hold F6 and press Enter.

13. At this point your weld head will move forward to the part and then back (it will not
weld).

This step is used to check the line labeled Difference. If the difference is more than .02 mm then
go back to step 10.

14. Now press F5.

15. Use an arrow key to move cursor off of "Teach!" and press Enter.

16. If there are more weld programs (robot positions) to teach, move robot to the next position, go
back to step 6; repeat for all Program Numbers to be used. If there are no more weld programs
(robot positions) to be taught, you are done with this procedure.

8
 CLEAR RAM PROCEDURE

IMPORTANT: Write down all of the “Outlet Programming” and “Weld Programming”
values as these values will be lost after performing this procedure.

1. Turn off main power switch to DCE Control. Wait 30 seconds. Open the door of DCE Control.

2. Locate the DCE ZCPU Board on right wall inside the DCE Control.

3. Locate the Dip Switches on the DCE ZCPU Board. SEE PICTURE ON THE FOLLOWING
PAGE.

4. Turn Dip Switch 2 “on”. Dip Switches on the DCE ZCPU Board are looked at ONLY during
“power up” of the DCE Control.

5. Close door to cabinet and power up the DCE Control.

The RAM should now be cleared. You must now reprogram the “Outlet Programming” and “Weld
Programming” under the “Main Menu”→ “Programming”.

IMPORTANT: After re programming the DCE Control, it is STRONGLY recommended that you
turn the DCE Control off, wait 30 seconds, then open the door of the DCE Control and turn Dip
Switch 2 “off”. Normal position for all Dip Switches is “off”.

If this is not done, the next time you cycle power on the DCE Control with Dip Switch 2 still “on”,
you will again clear the RAM.

SEE NEXT PAGE FOR PICTURE OF DCE ZCPU BOARD

9
DCE ZCPU Board

OFF

ON
8

DIP
SWITCHES

NOTE: DIP
SWITCHES ARE
“OFF” FOR
NORMAL
OPERATION.
ALL DIP SWITCH
POSITIONS ARE
REGISTERED
ONLY AT DCE
CONTROL
POWER-UP

10
 PK560 HANDGUN SET-UP (3 STEPS)
1. SETTING LIFT

Flash Shield

.045” lift gauge

BACK
direction

-Loosen Flash Shield setscrew, pull flash

shield fully back (this may require force).
Loosen Flash -Push on stud with .045” tooth of lift gauge
Shield setscrew as far back as it will go; hold gauge at that
position.
-Carefully pull Flash Shield forward to
gauge. Hold Flash Shield at that position
and tighten Flash Shield set screw.

-With stud in collet,

push down on gun 2. SETTINGANGULARITY
until flash shield sits
squarely on a flat
surface. Hold at this
position for the
remainder of
Angularity
adjustment.

-Turn 1.5mm allen wrench clockwise

until “∠” LED turns off, then turn
counter-clockwise until the “∠” LED
Flash Shield just barely turns on.
-This is perfect Angularity. Adjust
more counter-clockwise for less
Angularity sensitivity.

PKE BOX
CONTINUED
11 NEXT PAGE
 PK560 HANDGUN SET-UP (continued)
At the DCE Keypad, press “ESC” key until “Main Menu” is displayed at the top of the screen.
1. Use the <↓> arrow key to select the line “System Configuration”; press “Enter” key.
2. Use the <↓> arrow key to select the line “System Parameters”; press “Enter” key.
3. Use the <↓> arrow key to select the line “Outlet 1…PKE”; press “Enter” key.

You should now see the following screen:

Outlet 1 Configuration PKE

---------------------------------------
Program Select Switch.........no
Program Select Sensor.........no
Mechanical Angularity Switch..yes
Mechanical Counter............no
Slide Rail Valves.............Intern
Stud Arrival Sensor...........no
Air Pressure Monitor..........no
Gas Pressure Monitor..........no
Color Mark....................no
Airblow.......................no

Page 2.< ↓>

---------------------------------------
Help Message Area

4. Use the <↓> arrow key to select the line “Mechanical Angularity Switch”. Use the <+> or
<-> keys to ensure that this line reads “yes”; press “Enter” key.

3. SETTING DROP DOWN TIME FOR PK560 HANDGUN

At the DCE Keypad, press “ESC” key until “Main Menu” is displayed at the top of the screen.
1. Use the <↓> arrow key to select the line “Service Functions”; press “Enter” key.
2. Use the <↓> arrow key to select the line “Cycle Functions”; press “Enter” key.

You should now see the following screen:

Cycle Functions
----------------------------------------
| 1 | 2 | 3 | 4 | 5
----------+-----+-----+-----+-----+-----
Cycle |..?..|..?..|..?..|..?..|..?..
SKK ext. |..?..|..?..|..?..|..?..|..?..
SKK ret. |..?..|..?..|..?..|..?..|..?..
Start feed|..?..|..?..|..?..|..?..|..?..
Lift |..?..|..?..|..?..|..?..|..?..
Set WC |..?..|..?..|..?..|..?..|..?..
Color mark|..?..|..?..|..?..|..?..|..?..
Reference output: 1
SKK ext. . 0 ms Drop time...11,5 ms
SKK ret. . 0 ms Lift dist. . 0,0 mm
----------------------------------------
Help Message Area

3. Loosen (slightly unscrew) the black cap on the back of the PK560 handgun.
4. With a stud in the collet, hold the PK560 handgun firmly onto a grounded piece of metal.
Ensure that the Flash Shield is completely seated on the metal.

(CONTINUED ON NEXT PAGE)

12
 PK560 HANDGUN SET-UP (continued)

5. Pull the Trigger on the PK560 handgun. The stud will lift and drop without welding. On the
lower right side of the keypad, read the “Drop Time ” in ms- mille seconds.
a. The desired “Drop Time ” time reading is between 11.0ms and 11.5ms.
b. To adjust this time proceed to step 6.

6. Using a flat standard screwdriver, adjust the Plunge Spring tension by turning the adjustment
screw just inside the center of black cap that you loosened earlier.
NOTE: After each adjustment of the Plunge Spring tension, repeat
a. Turn adjustment clockwise to decrease “Drop Time ”.
b. Turn adjustment counter-clockwise to increase “Drop Time ”. Steps 4 through 6
until the “Drop Time” reads between 11.0ms and 11.5ms.

7. Once you have adjusted the “Drop Time ” to a value between 11.0ms and 11.5ms, carefully
tighten the black cap on the back of the PK560 without moving the adjustment screw. It
might be helpful to keep the screwdriver in place while tightening the black cap.

13
 PISTON LUBRICATION PROCEDURE

1. Your Weld Head, Piston and Front end Components will differ depending on the style
and fastener being welded.
2. This procedure applies to all Weld Guns also.

Boots not shown were

removed for clarity.

Remove front end components to gain access

to the piston assembly.

14
 Remove Piston Assembly

Clean Piston Head and O-Ring

15
Clean the inside of the Load Tube
thoroughly with a clean cloth.

Carefully remove the O-Ring

and clean the groove.
Clean and inspect the O-Ring for
wear and replace if necessary.

16
 Pack the groove with
Parker O Lube.

Place the O-Ring in

the groove.

With your finger spread the O Lube that was

expelled by the O-Ring, around the O-Ring.

17
 Squeeze a bead of Parker O Lube approx.
a ¼” thick by ½” long on your finger.

Apply the Parker O Lube with your finger inside

the Load Tube and spread evenly around the tube.

18
Insert the piston and move it back and forth a
few times to help spread the O Lube.

The piston should

move freely.

Wipe excess Parker O Lube off the face

of the Load Tube with a clean rag.

19
 Reassemble the front
end of the weld tool.

Install new boots if they are missing or

damaged. (not shown)

Clean Piston Head and O-Ring

20