Emhart Teknologies TUCKER ERF User manual

Assembly Instructions
Feeding Units
ERF/ERD/EPS
Please read the assembly instructions before any operation!

2
© Emhart Teknologies TUCKER GmbH
Max-Eyth-Straße 1
D-35394 Gießen
Tel.: [phone]
Fax.: [phone]
E-Mail: [email protected]
Internet: www.tucker.de
Translation of the original assembly instructions MTA ERF ERD EPS 01

Feeding Units ERF/ERD/EPS
Table of Contents
3
Table of Contents
1General Information........................................................................................................ 5
1.1 Information Regarding the Assembly Instructions................................................. 5
1.2 Limitation of Liability.............................................................................................. 5
1.3 Symbol Legend ..................................................................................................... 6
1.4 Copyright Protection.............................................................................................. 7
1.5 Replacement Parts................................................................................................ 7
1.6 Guarantee Instructions.......................................................................................... 8
1.7 After Sales Service................................................................................................ 8
1.8 Remark to the Declaration of Incorporation .......................................................... 8
2Safety ............................................................................................................................. 9
2.1 Responsibility of the Operating Company............................................................. 9
2.2 Personnel Requisition ......................................................................................... 10
2.2.1 Qualification ............................................................................................ 10
2.2.2 Trespassers ............................................................................................ 11
2.2.3 Instruction................................................................................................ 11
2.3 Intended Use....................................................................................................... 12
2.3.1 Self-Piercing Rivet Feeder ...................................................................... 12
2.3.2 Self-Piercing Rivet Divider ERD.............................................................. 13
2.3.3 Pre-Separation EPS................................................................................ 14
2.4 Personal Protective Equipment........................................................................... 15
2.5 Special Risks....................................................................................................... 16
2.6 Safety Installations .............................................................................................. 18
2.7 Installation of the Appliance ................................................................................ 18
3Technical Data ............................................................................................................. 19
3.1 General Specifications Feeder ERF.................................................................... 19
3.2 General Specifications Divider ERD ................................................................... 19
3.3 General Specification Pre-Separation ESP......................................................... 20
3.4 Equipment Fuses ................................................................................................ 21
3.5 Fastening tTorques for Metric Screws ................................................................ 23
3.6 Table of Control Cables/Hoses ........................................................................... 23
3.7 Accessories......................................................................................................... 23
4System Components .................................................................................................... 24
4.1 Rivet Feeder ERF ............................................................................................... 24
4.2 Rivet Divider ERD ............................................................................................... 27
4.3 Control Pre-Separation ....................................................................................... 29
4.4 Pre-Separation EPS............................................................................................ 30
4.5 Feeding Tube ...................................................................................................... 31
4.6 Receiver .............................................................................................................. 32

Feeding Units ERF/ERD/EPS
Table of Contents
4
4.7 Manual Feeding Device....................................................................................... 33
5Connection and Installation .......................................................................................... 34
5.1 Connection Compressed air................................................................................ 34
5.2 Connecting Feeder without Divider ..................................................................... 35
5.2.1 Connecting Feeder to the Control Unit.................................................... 35
5.2.2 Connecting Feeder to Rivet Spindle........................................................ 36
5.3 Connecting Feeder with Rivet Divider ................................................................. 38
5.3.1 Connecting Master Feeder to Control Unit.............................................. 38
5.3.2 Connecting Slave Feeder to Master Feeder............................................ 39
5.3.3 Connecting Divider to Slave and Master Feeder..................................... 39
5.3.4 Connecting Divider with Spindle or Tool Changer System...................... 42
5.4 Connecting Feeder with Divider and Pre-Separation .......................................... 43
5.4.1 Control Pre-Separation............................................................................ 43
5.4.2 Connecting Pre-Separation EPS to Control EPS .................................... 44
5.4.3 Connecting Pre-Separation to Rivet Divider............................................ 45
5.4.4 Connecting Pre-Separation to Spindle or Tool Changer System ............ 46
5.5 Connecting Manual Feeding Device ................................................................... 47
6Operating the Rivet Feeder .......................................................................................... 48
6.1 Replenish Rivets ................................................................................................. 48
6.2 Check Correct Level............................................................................................ 49
7Transport, Packaging and Storing ................................................................................ 50
7.1 Security Advice for the Transport ........................................................................ 50
7.2 Transport Check.................................................................................................. 50
7.3 Terms and Conditions for Overseas Transport ................................................... 51
7.4 Packaging............................................................................................................ 52
7.5 Storing ................................................................................................................. 52
8Maintenance and Cleaning........................................................................................... 53
8.1 Safety .................................................................................................................. 53
8.2 Maintenance and Cleaning Schedule.................................................................. 53
8.3 Pre-Separation (Small Cleaning)......................................................................... 55
8.4 Pre-Separation (Large Cleaning) ........................................................................ 56
8.5 Stopper with Housing .......................................................................................... 57
8.6 Self-Piercing Rivet Feeder (Small Cleaning)....................................................... 58
8.7 Self-Piercing Rivet Feeder (Large Cleaning)....................................................... 59
8.8 Feeding Tubes .................................................................................................... 60
8.9 Emptying the Maintenance Unit........................................................................... 60
9Disposal........................................................................................................................61
Appendix: Declaration of Incorporation

Feeding Units ERF/ERD/EPS
General Information
5
1 General Information
1.1 Information Regarding the Assembly Instructions
These assembly instructions contain 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.
Please read the assembly instructions carefully before any operation! It is a part of
the product and has to be stored in an accessible location in the direct vicinity of
the device for use by the appropriate personnel.
1.2 Limitation of Liability
All instructions and information in these assembly instructions have been compiled
in consideration of the valid standards and regulations, the state of the art as well
as our experience of many years.
The manufacturer assumes no liability for damages due to:
Non-observance of the assembly instructions.
Not intended use.
Employment of unskilled personnel.
Arbitrary rebuilding.
Technical modifications.
Use of non-licensed replacement parts.
On special design, on demands of additional order options or due to latest
technical modifications the actual shipment may differ from the explanations and
expositions described here.
Effective are the obligations agreed in the supply contract, the general terms and
conditions as well as the delivery conditions of the supplier and the legal
regulations valid to the time of conclusion of the contract.
Technical modifications within the improvement of the usage properties and the
further development are reserved.

Feeding Units ERF/ERD/EPS
General Information
6
1.3 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.
DANGER!
… points to a directly dangerous situation which can lead to
death or severe injuries if it is not avoided.
WARNING!
… points to a possibly dangerous situation which can lead to
death or severe injuries if it is not avoided.
CAUTION!
… points to a possibly dangerous situation which can lead to
slight injuries if it is not avoided.
! CAUTION!
… points to a possibly dangerous situation which can lead to
damage of property if it is not avoided.
Tips and recommendations
NOTE!
… highlights useful tips and recommendations as well as
information for an efficient and failure-free operation.

Feeding Units ERF/ERD/EPS
General Information
7
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.
The operations which need to be carried out may only be
executed by electronic technicians.
1.4 Copyright Protection
This instruction is protected by copyright and only intended for internal purposes.
The provision of the instruction to a third party, duplications in all kinds and forms -
also in extracts - as well as the utilisation and/or communication of the content are,
aside from internal purposes, not permitted without a written authorization of the
manufacturer.
Non-compliances obligate to damages. Further claims remain reserved.
1.5 Replacement Parts
WARNING!
Safety risk due to false replacement parts!
False or defective replacement parts can affect the safety as well
as lead to damages, malfunctions or total breakdown.
Therefore:
- Use original TUCKER replacement parts.
Purchase replacement parts via licensed dealer or directly at manufacturer.
Address see page 2.

Feeding Units ERF/ERD/EPS
General Information
8
1.6 Guarantee Instructions
For material and manufacturing faults, the guarantee period for this feeding 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. In this
connection, liability for consequential damage is excluded.
Guarantee void in case of attempts to repair by personnel that has not been
trained by the manufacturer and/or when using spare parts that TUCKER has not
approved of. In the event of a defect the non-conforming appliance must be sent to
the next TUCKER agent or directly to the manufacturer.
The guarantee claim lapses when attempts at repair are carried out by
unauthorised or unqualified persons. In the event of a defect the non-conforming
appliance must be sent to the next TUCKER agent or directly to the manufacturer.
For further information concerning national representation, our customer service is
at your disposal. The corresponding contact data can be found on page 2.
1.7 After Sales Service
Our service department is available for technical support.
Information about the responsible contact person is available via telephone, fax, E-
Mail or anytime via the Internet, please see manufacturer address on page 2.
Furthermore, our employees are constantly interested in new information and
experiences that result from the single applications and could be helpful for
improving our products.
1.8 Remark to the Declaration of Incorporation
Note!
A declaration of incorporation for the inc of an incomplete ma-
chine with the corresponding details according to the EC ma-
chinery directive 2006/42/EG, appendix II, paragraph B is
attached to the documents.

Feeding Units ERF/ERD/EPS
Safety
9
2 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.
2.1 Responsibility of the Operating Company
The stud feeding unit is used industrially. Therefore the operating company of the
unit is liable to the legal obligations of operational safety.
In addition to the operational safety advisories in this assembly instructions the
safety-, accident prevention- and environmental regulations in force for the area of
application need to be observed.
Please consider particularly the following:
The operating company has to inform himself about the valid industrial safety
regulations and determine additional dangers in an assessment of hazards
which occur by the special working conditions on the site of the unit. He has to
implement these for the operation of the unit in the form of operating
instructions.
The operating company has to verify that the operating instructions are state
of the art during the complete operating time of the unit. If necessary, the
operating company is to adjust the operating instructions to the valid rules and
regulations.
The operating company has to manage and determine the responsibilities for
installation, operation, maintenance and cleaning in an explicit manner.
The operating company has to ensure that all employees dealing with the unit
have read and understood this manual. Moreover, the operating company has
to train the operating personnel in regular intervals and has to provide
information on possible dangers.
The operating company has to provide the personnel with the required
protective equipment.

Feeding Units ERF/ERD/EPS
Safety
10
2.2 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
assembly instructions:
Instructed person
Has been informed about the tasks assigned and possible dangers of
improper execution of an instruction by the operating company.
Qualified personnel
Qualified personnel are able to carry out the assigned tasks due to their
qualified training, knowledge and job experience. In addition, the personnel
are able to recognize and avoid possible dangers on their own.
Electrician
The electrician is able to carry out activities on electric units due to his
qualified training, knowledge and job experience. In addition, he is able to
recognize and avoid possible dangers on his own.
The electrician has been trained for the special site he is working on and
knows about the relevant rules and regulations.
Only persons who can be expected to carry out their work in a reliable manner can
be accepted as personnel. Persons whose reactivity is influenced, e.g. by drugs,
alcohol or medicaments, are not admitted.
Please consider the regulations at site specific to age and profession when
choosing personnel!

Feeding Units ERF/ERD/EPS
Safety
11
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.
- When in doubt, approach persons and banish them from the
working area.
- Interrupt your work as long as there are trespassers within the
working area.
2.2.3 Instruction
The personnel have to be instructed regularly by the operating company. For a
better traceability the implementation of the instruction should be recorded.
Date Name Kind of instruction Instruction
carried out by
Signature

Feeding Units ERF/ERD/EPS
Safety
12
2.3 Intended Use
2.3.1 Self-Piercing Rivet Feeder
The Self-piercing rivet feeder is designed exclusively for the intended use
mentioned in this manual.
The feeder ERF is intended to mount self-piercing rivets in industrial and commercial
areas and only for application in premises. The feeder ERF has been designed for
automatic operation in robots, semiautomatic operation and manual operation.
Intended use also includes observing all the symbols and information in the
assembly instructions.
WARNING!
Risk by not intended use!
Every not intended use and/or different use of the device is con-
sidered as misuse and can lead to dangerous situations.
Therefore:
- No operation with other system components which are not
indicated in the assembly instructions
- No use with rivet tools of other manufacturers.
- No use of improper rivets.
- No use in explosive areas.
- No use in damp locations.
Claims of any kind because of damages due to not intended use are excluded.

Feeding Units ERF/ERD/EPS
Safety
13
2.3.2 Self-Piercing Rivet Divider ERD
The self-piercing rivet divider is designed exclusively for the intended use men-
tioned in this manual.
The divider ERD is intended to mount self-piercing rivets in industrial and commercial
areas and only for application in premises. The divider ERD can only operate in
conjunction with two self piercing rivet feeders. The divider ERD has been designed for
automatic operation in robots, semiautomatic operation and manual operation.
Intended use also includes observing all the symbols and information in the
assembly instructions.
WARNING!
Risk by not intended use!
Every not intended use and/or different use of the device is con-
sidered as misuse and can lead to dangerous situations.
Therefore:
- No operation with other system components which are not
indicated in the assembly instructions
- No use with rivet tools of other manufacturers.
- No use of improper rivets.
- No use in explosive areas.
- No use in damp locations.
Claims of any kind because of damages due to not intended use are excluded.

Feeding Units ERF/ERD/EPS
Safety
14
2.3.3 Pre-Separation EPS
The pre-separation EPS is designed exclusively for the intended use mentioned in
this manual.
The pre-separation EPS is intended to mount self-piercing rivets in industrial and
commercial areas and only for application in premises. The pre-separation EPS can
only operate in conjunction with a self piercing rivet feeder. The pre-separation EPS has
been designed for automatic operation in robots, semiautomatic operation and manual
operation.
Intended use also includes observing all the symbols and information in the
assembly instructions.
WARNING!
Risk by not intended use!
Every not intended use and/or different use of the device is con-
sidered as misuse and can lead to dangerous situations.
Therefore:
- No operation with other system components which are not
indicated in the assembly instructions
- No use with rivet tools of other manufacturers.
- No use of improper rivets.
- No use in explosive areas.
- No use in damp locations.
Claims of any kind because of damages due to not intended use are excluded.

Feeding Units ERF/ERD/EPS
Safety
15
2.4 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.
Strictly to wear Strictly to wear at working:
Protective glasses
For the protection of the eyes from foreign
bodies.
Protective clothing
is close-fitting work wear with low tear strength,
with tight-fitting sleeves and without flared parts.
It is principally used to protect against capture by
moving machinery parts. Do not wear rings,
necklaces and other jewellery.
Safety boots
For the protection from heavy, falling parts and
from slipping on slippery surfaces.
Wear on special work
Protective gloves
For the protection of the hands against friction,
abrasives, stabbing or deeper injuries as well as
for the protection against contact with hot
surfaces.

Feeding Units ERF/ERD/EPS
Safety
16
2.5 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.
Electric current
DANGER!
Danger of life by electric current!
Contact with components under current is perilous. Damage of
the electrical isolation or of several components can be perilous.
Therefore:
- On damages of the electrical isolation cut-off immediately the
power supply and induce repairing.
- Work on the electric installation may only be executed by
qualified electricians/electronic technicians.
- Do not connect or disconnect the live plug connector.
- On maintenance- and corrective maintenance work
disconnect the feeding units from the power supply.
- Pay attention to the minimum bending radius of the electrical
connecting cables.
- First, connect the feeding units in an orderly fashion before
you link the feeding units with the control unit and the other
system components.
- Lay all electric supply cables in a completely rolled out state
so as to avoid any electromagnetic influences, e.g. inductive
heat build-up.
- Prior to each putting-into-operation perform a visual
inspection of the electric connecting cables and plugs.
- Never reach into open, non-utilised sockets.

Feeding Units ERF/ERD/EPS
Safety
17
Moved components
WARNING!
Risk of injury by moved components!
Rotating and/or linearly moved components could cause severe
injuries.
Therefore:
- Do not grasp in or handle on moved components while
operation.
- No not open the coverings while operation.
- Consider the follow-up time.
Before opening the covers ensure that parts do not move
anymore.
Pneumatic
WARNING!
Risk of injury by pneumatic energy!
Pneumatic energies could cause severe injuries.
Pneumatically driven parts could move unexpectedly.
On damages of several components air can discharge under high
pressure and damage e.g. the eyes.
Therefore:
- Wear protective glasses when working on the ERT tool.
- Use only clean and oil-free air.
- Pay attention to the minimum bending radius of the
pneumatically connecting cables.
- When repairing at location of operation the ERT tool must be
cut off from compressed-air supply.
- Check all pneumatic lines and the feeding tube for intactness
before commissioning.
- In all cases any kind of maintenance and adjustments must be
agreed on with the operating personnel.
WARNING!
Hand injuring!
Get your hands off from areas with this warning sign.
- Risk of crush or worse injury to hands.

Feeding Units ERF/ERD/EPS
Safety
18
2.6 Safety Installations
The Self-Piercing rivet feeding units are intended for the application within an
installation. The self-piercing rivet feeding units are to be integrated into the safety
concept of the self-piercing rivet installation.
2.7 Installation of the Appliance
The housing cover of the feeding units may not be used as a shelf area.
Ensure that the base area is smooth and stable and makes it possible to reach
the feeding units unhindered.
Do not place the feeding units on liquid-bearing pipelines so as to avoid liquid
penetration.
To allow ambient temperature exchange a minimum clearance of 2 m between
the feeding units and permanent heat sources must be complied with
Place the ERF feeders into the points on the frame provided for this.
Ensure that all connections are able to be reached without danger.

Feeding Units ERF/ERD/EPS
Technical Data
19
3 Technical Data
3.1 General Specifications Feeder ERF
Specification Value Unit
Weight without rivets approx. 35 kg
Length approx. 600 mm
Width approx. 270 mm
Height approx. 480 mm
System of protection:
Protected against dust penetra-
tion
IP 54 ac-
cording to
IEC 529
Splash-
Protected
Operating temperature 15 - 40 °C
Stocking temperature -25 - 55 °C
Relative humidity of air, not
condensing
5 to 95 %
Working position 0 ± 2 Grad
Noise emission Sound pressure level < 75 dB (A)
Electrical Control voltage
24V DC / 230V AC
Provided in the ERC con-
trol unit
Pneumatically Operating pressure; manually
regulated by maintenance unit
6 to 8 Bar
Operating pressure max 8 Bar
3.2 General Specifications Divider ERD
Specification Value Unit
Weight ca. 8,5 Kg
Length ca. 240 mm
Width ca. 355 mm
Height ca. 180 mm
System of protection:
Protected against dust penetra-
tion
IP 54 ac-
cording to
IEC 529
Splash-
Protected
Operating temperature 15 - 40 °C
Stocking temperature -25 - 55 °C

Feeding Units ERF/ERD/EPS
Technical Data
20
Divider ERD
Specification Value Unit
Relative humidity of air, not
condensing
5 to 95 %
Working position Indefinite
Noise emission Sound pressure level < 75 dB (A)
Type of rivets: D3,3 Length 4 - 5 mm
D5,3 Length 6,5 mm
D5,3 Length 5 - 8 mm
Electrical Control voltage 24V DC Provided in the ERF feeder
Pneumatically Operating pressure 6 to 8 Bar
Hose connection Ø = 8 mm Provided in the ERF feeder
Operating pressure max. 8 Bar
3.3 General Specification Pre-Separation ESP
Specification Value Unit
Weight ca. 6,5 Kg
Length ca. 190 mm
Width ca. 350 mm
Height ca. 100 mm
System of protection:
Protected against dust pene-
tration
IP 53 ac-
cording to
IEC529
Protected
against driz-
zle
Operating temperature 15 - 40 °C
Stocking temperature -25 - 55 °C
Relative humidity of air, not
condensing
5 to 95 %
Type of rivets D5,3 Length 5 to 8 mm
Electrical Control voltage 24V DC Provided in ERF feeder
Pneumatically Operating pressure 6 to 8 Bar
Hose connection Ø = 8 mm Provided in the LSC or from
the customer
Operating pressure max. 8 Bar