Emhart Installation Requirements Rev K

I nstallation Requirements
For N orth American

Drawn Arc Welding Systems
Stanley Engineered Fastening, 2400 Meijer Dr., Troy,MI. 48084

Application Engineering: (248) 677-9445 Technical Services: (248) 677-9439
Release Date: 5/25/16 Revision K

Revision Level
Release Revision Released By Description

Date
12/17/03 Initial S. Ramasamy
Release
5/26/04 A S. Ramasamy
8/23/04 B S. Ramasamy
12/07/04 C S. Ramasamy
4/08/05 D S. Ramasamy
8/21/07 E K. Glover
Added Desc. To Revision Table.
Added section 1.1 Sample Drawing
Revised section 1.2
Revised section 1.5
Added section 2.1.1 Item B
Revised section 2.1.1 Item D and E
Added to 2.1.1 a revised power drop table
Revised 3 F. and J.
11/03/08 F S. Ramasamy Revised 3.5 and 3.5 A.
C. Meloche Revised 4. A.
Revised 6.2 A. and G.
Added 6.4 L.
Clarification of 6.5.3 A.
Removed 6.6.1 & 6.7.1 adapter plates Replaced Section 8 check
list with a reference to buyoff checklist.
3/30/09 G S. Ramasamy Revised section 2.1.1 Item H
C. Meloche
Section 1.2 Added ETF30, LM240 & LM90 drawings.
Section 1.3 added NEMA 2 to item B.
Section 1.5 Added ETF30 dimension drawing.
Section 1.5 revised item D.
Section 2.1.1 items D, G, & I updated to include DCE Max.
Section 2.1.1 removed items C and K.
Section 2.2.1 added table.
Section 3.E. item E and F combined and updated to include DCE
Max.
1/26/10 H T. Osborne Section 3 revised ground drawings.
C. Meloche Section 6.2 added LM240 & LM90 dimension drawing.
Section 6.2.1 added teaching and tooling.
Section 6.3 added table to item D. Added PK600 dimension
drawing to Figure 8.
Section 6.4 items A and B revised. Item E removed.
Section 6.4 item K revised and is now J.
Section 6.5.1 item B revised.
Section 6.5.3 item A revised.
Section 6.5.3 item B added M5 nut to the table.
Section 6.6 & 6.7 added reference to Figure 10. Added Figure 10.
Section 1.4 Item C Revised Figure 1 and added table.
Section 2.1.1 Item G revised power feed length chart.
Section 4.D. Added Profinet connector type to table.
12/4/12 I C. Meloche Added Addendum Section and Addendum A for Nut Welding
and Addendum B for Aluminum Welding.
Moved all prior references to nut welding from the main body to
Addendum A.
Release Revision Released By Description
Date
4/9/15 J C. Meloche Merged Addendums into main body of document. Added Ground
J. Walsh drawings for Aluminum.
K. Dillon
5/13/16 K C. Meloche Section 1.2.; Added LM310 w/gas non-contact nozzle, PLM200
J. Walsh w/gas boot and non-contact nozzle.
K. Dillon Section 3.1.F; Added Duty Cycle recommendation.
Section 3.1.G.; Revised Statement to include spring loaded
ground.
Figure 6 revised to include dimension drawings for LM310 w/gas
non-contact nozzle.
Section 6.2.I.2; Revised to include 10% statement.
Figure 9 revised to include dimension drawings for PLM200
w/gas and PLM200 w/gas non-contact nozzle.
Added Section 8.B. statement and table.
TABLE OF CONTENTS
1. INSTALLATION INFORMATION ................................................................................... 1
1.1 SAMPLE INSTALLATION LAYOUTS ................................................................................... 1
1.2 EQUIPMENT IDENTIFICATION ........................................................................................... 2
1.3 GENERAL INFORMATION .................................................................................................. 5
1.4 WELDER CONTROL .......................................................................................................... 5
1.5 FEEDER ............................................................................................................................ 7
2. UTILITY REQUIREMENTS .............................................................................................. 9
2.1. POWER SUPPLY ................................................................................................................ 9
2.1.1 Welder Control............................................................................................................ 9
2.1.2 Feeder ...................................................................................................................... 11
2.2. COMPRESSED AIR SUPPLY ............................................................................................. 11
2.2.1 Air Blow Requirements for Nut Welding .................................................................. 12
2.2.2 Protective Gas Requirement for Drawn Arc Welding .............................................. 12
3. THE WELDING AND GROUNDING CIRCUIT ........................................................... 13
3.1 GENERAL WELDING/GROUNDING .................................................................................. 13
3.1.1 Aluminum Welding Specific ...................................................................................... 14
3.2 SAMPLE GROUNDINGS ................................................................................................... 16
3.2.1A STANDARD FIXTURE GROUNDING .............................................................................. 16
3.2.1b Robot End Effector Grounding ............................................................................. 17
3.2.1c Multiple Controls Grounding .............................................................................. 19
3.2.1d Multiple Fixtures Single Control Grounding........................................................ 20
3.2.1e Narrow Part and Laminate Grounding ................................................................ 21
3.2.1f Aluminum Grounding Basics ............................................................................... 22
3.2.1g Aluminum Grounding Multiple (DCE15AC) ........................................................ 23
3.2.1h Aluminum Grounding (Combined AC and DC welding) ...................................... 24
3.3 WELD CABLE LENGTH AND CONDUCTOR SIZE .............................................................. 25
4. INTERFACING AND EXTERNAL CONTROL CABLES ........................................... 26
5. WELDING UNIT - SYSTEM CABLES ........................................................................... 27
5.1 WELDING CABLES ROUTING AND DRESS ....................................................................... 29
5.2 FEED TUBE ROUTING AND DRESS .................................................................................. 29
5.3 ALUMINUM WELDING SPECIFIC DRESS .......................................................................... 29
6. TOOLING INSTALLATION ............................................................................................ 30
6.1 GENERAL INSTALLATION INFORMATION ........................................................................ 30
6.2 WELD HEAD .................................................................................................................. 30
6.3 WELD HEAD TEACHING AND TOOLING SET-UP .............................................................. 37
6.4 WELD GUN .................................................................................................................... 37
6.5 FIXTURE REQUIREMENTS ............................................................................................... 42
6.5.1 Part Location and Clamping .................................................................................... 42
6.5.2 Part Deflection .......................................................................................................... 42
6.5.4 Nut Welding Specific Tooling ................................................................................... 43
6.6 ATTACHING THE WELD HEAD TO A STATIONARY UNIT ................................................. 43
6.7 ATTACHING THE WELD HEAD TO THE ROBOT................................................................ 43
7. SAFETY ............................................................................................................................... 45
8. DESIGN / INSTALLATION BUYOFF ............................................................................ 45
Drawn Arc Welding Installation Requirements
1. Installation Information
1.1 Sample Installation Layouts
System Layout
System Layout with Gas (i.e.: Aluminum)
1
Copyright  2015, Stanley Engineered Fastening
1.2 Equipment Identification
DCE AC
Welder Control
DCE
Welder Control PKE Module
Feeders Styles
Vibratory Feeder Drum Feeder
(ETF12 & ETF 13) Elevator Feeder (ETF52)
(ETF20)
2
Weld Head Styles
LM240
Weld Head
LM310
Weld Head
LM310
Weld Head with Gas
LM310
Weld Head with Gas
Non-Contact Nozzle
LM90
Weld Head
3
Weld Gun Styles
PLM200
Weld Gun
PLM200
Weld Gun with Gas
PLM200
Weld Gun with Gas
Non-Contact Nozzle
PK600
Weld Gun
PK560
Weld Gun
4
1.3 General Information
A. Stable surface, with a minimum load capacity of 90 kg (199 lbs) per welder control and
114 kg (250 lbs) per feeder weight.
B. The welder must not be placed above water pipes or hoses because they are not
waterproofed from below. The welder control is designed according to the IP 23
(NEMA 2) protection system.
C. Nothing should be placed on or mounted to the top of the welder control with the cover
bolts, with the exception of a PKE Module, which was designed for top mounting.
D. The welder controller is supplied with lockable casters, which elevate it above the floor.
This clearance is necessary for cooling airflow and cable routing.
Operating temperature: 40°F – 104°F ; 4°C − 40°C

Storing temperature: -40°F – 167°F ; -40°C − 75°C
Relative humidity of air: 10% - 90%
1.4 Welder Control
A. The welder control contains the programming keypad or touchpad and must be installed
in a location that is readily accessible while the equipment is in the operating mode.
Programming is also available via the feeder if the control is remotely mounted.
B. The welder control must be located where it is readily accessible from the top, front,
and outside of any safety barriers.
C. The welder control dimensions are shown in Figure 1.
5
Figure 1
Welder Control
Dimensions
Cabinet Dimensions Control Terminal Add-on XFMR

H D W Keypad Touchpad Box
DCE1500 998 566 604 78 110 66 150
DCE1800 Global Style 998 566 572 78 N/A N/A 150
DCE1800 1052 566 604 78 110 66 150
DCE1500AC 1308 566 572 78 110 66 150
DCEMax 998 566 572 78 110 66 150
All dimensions are metric
6
1.5 Feeder
A. Feeder base: 750mm x 620mm (29.5” x 24.4”) minimum.
B. The feeder contains tactile control functions, which must be readily accessible.
C. The feeder must be located in a location that is readily accessible for fastener loading
and maintenance. It cannot be mounted on top of the welder control. It must be located
outside of any safety barriers.
D. All feeder tables must be securely located and level for proper operation.
E. Cable length and routing will dictate position of feeder with respect to Weld Head.
F. The dimensions of all 3 styles of ETF feeders are shown in Figures 2a-c.
Figure 2a
Vibratory Feeder
Dimensions
Standard dimensions in brackets
7
Figure 2b
Drum Feeder Dimensions
Figure 2c
ETF20 Feeder
Elevator Feeder Dimensions
Standard dimensions in brackets

(Feeder stands available for purchase)
8
2. Utility Requirements
2.1. Power Supply

2.1.1 Welder Control
A. The welder control must be connected to a voltage supply that has a separate fused
power drop for each control.
B. Due to the increase in “Arc Flash Safety” requirements, a fused power disconnect box
(if used) must be mounted within 10 feet of the welder control. This is to facilitate
troubleshooting of the welder control.
C. Due to the low power consumption of the welder control, wiring the source power from
the control or house buss (clean power) is required. If not available customer is to
supply filter/regulator to maintain normal operating range. See statement E below.
D. The welder is protected with fuses or breaker switch depending on the model. The
source must be fused higher than the welder for fuse coordination and protection of
plant power.
Welder Type: Equipped Fuse Protection:

DCE1500 30A Slow Blow
DCE1800 30A Slow Blow
DCE1800 Global 30A Breaker Switch
DCE15AC 30A Breaker Switch
DCE Max 50A Slow Blow
E. The welder control requires line-to-line balanced 480VAC power supply for proper
operation. Nominal operating range of + 10% and - 5% are preferred.
Input Voltage: 3/Phase AC 480V (575V w/transformer)

Nominal operating range: + 10%, - 5%
Supply Frequency: 60 Hz
F. Voltage is factory set and must be specified before ordering. For 575Y/347 VAC
applications a step-down transformer is integrated with the welder control and requires
a “Y” input power configuration.
9
G. To achieve the “Maximum” current power output, the diameter of the power supply
cable connecting the welder control must be designed to assure that a voltage drop of
less than 5% at the maximum impulse current in the circuit is guaranteed. Use the
appropriate gauge wire for your power drop, based on the maximum amperage of your
control and buss fusing.
See chart below for proper wire gauge per feed length requirements; your application
may vary.
Power Feed Length for Maximum Output

DCE1500, DCE15AC, DCE1800 DCEMAX
Length (ft) AWG Length (ft) AWG

32 and under 10 4 – 79 6
33 – 49 8 80 – 126 4
50 – 79 6 127 – 202 2
80 – 126 4
127 – 202 2
If maximum current output (1500A for DCE1500, DCE15AC or DCEMAX series

control, 1800A for DCE1800 series control) is not required for an application, smaller
gage power supply cable may be utilized. The DCE Max requires a minimum 6 AWG
wire as per NEC code. Contact Stanley Engineered Fastening Application Engineering
to determine the allowable wire size for your application.
In the event the power supplied to the control through the power supply cable is not
sufficient to meet the weld schedule power requirements for the application, power
supply faults will be experienced. In these instances, the wire size of the power supply
cable will need to be increased until the power supplied exceeds the weld schedule
power requirements for the application.
H. The welder control will not accept cable sizes larger than 8 AWG, and will require a
fused disconnect box sized for the appropriate cable used according to the chart above.
I. All distances above are from the power buss/PDP to a disconnect break out box. The
disconnect box must be located at a distance not to exceed 10 feet from the control,
with an 8 AWG wire (DCE1500, DCE15AC and DCE1800 amp) or 6 AWG wire (DCE
Max) running from the disconnect box to the control.
10
2.1.2 Feeder
A. The feeder is supplied with voltage by the welder control. These feeders are protected
in the welder by a 12 Amp slow-blow fuse.
2.2. Compressed Air Supply
A. All feeders have a filter regulator module input for compressed air connection which is
a 3/8 inch internal thread.
B. A minimum air pressure of clean, dry, and oil free plant air is required to be plumbed
to each feeder. A surge tank may be required to maintain these requirements, especially
on multiple feeder applications. (See chart below)
C. The compressed air supply for optimal performance must be within the minimum and
maximum air pressures according to feeder type in the table below.
Feeder Min. Air Pressure Max. Air Pressure
ETF12 & 13 5.5 bar (80 psi) 7 bar (100 psi)
ETF20 5.5 bar (80 psi) 8 bar (116 psi)
ETF52 5.5 bar (80 psi) 7.8 bar (113 psi)
D. Input air supply must be a minimum of 25 SCFM (Standard Cubic Foot per Minute)
during the feed cycle, using a maximum feed time of 5000 ms per feeder.
E. Air pressures of maximum psi can be useful for minimizing fastener feed times. This
is especially true with a heavy fastener, which could have a direct impact on cycle time
(See chart above).
F. The inner diameter of the compressed air supply hose must be a minimum ½ inch in
order to keep the pressure drop in the feed tube as low as possible.
11
2.2.1 Air Blow Requirements for Nut Welding
A. The piston air blow requirements are measured in liters per minute (lpm). A flow
meter can be purchased and used for calibrating the proper flow. See proper weld
head drawing for part number of the flow meter.
Nut Size Minimum Recommended Maximum
M5 95 lpm 105 lpm 110 lpm
M6* 95 lpm 105 lpm 110 lpm
M8 30 lpm 40 lpm 50 lpm
* For weld heads with a fluted piston tip use 30 lpm, 40 lpm, 50 lpm respectively.
2.2.2 Protective Gas Requirement for Drawn Arc Welding
A. All bracket welding systems and aluminum stud welding systems require protective
gas. Protective gas requirements differ based on stud and base material combinations.
Consult with Stanley Engineered Fastening for protective gas requirements.
B. The protective gas supply must be at a pressure between 4.1 bar (60 psi) to 6.8 bar (100
psi).
C. Protective gas supply flow must be at a flow rate between 8-22 lpm, which is weld head
style and application dependant.
D. A gas box to control the protective gas is required. The protective gas is delivered from
the gas box to the weld zone through the cables supplied by Stanley Engineered
Fastening.
12
3. The Welding and Grounding Circuit
3.1 General Welding/Grounding
A. Consult with your Stanley Engineered Fastening Application Engineer for

recommendations on proper grounding for your application. Reference figures 3a-
e for the recommended grounding.
B. Simultaneous welding of any type on the same part is not allowed. The high frequency
noise and magnetic field will increase the susceptibility for nuisance faults among
welder controls firing simultaneously.
C. The common measurement line must not run through any robot controller or PLC
where the circuit will be vulnerable to noise.
D. The weld power return connection between the welder control and the component to
be welded must be as direct as possible to keep overall resistance to a minimum.
E. In order to keep welding energy losses as small as possible to achieve the maximum
current capability of a welder control, Stanley Engineered Fastening utilizes a heavy-
duty weld power return cable with a 4/0 conductor to reduce weld loop resistance. The
total required weld loop resistance for maximum output for the DCE1500 and DCE
Max is 13.3 milli-ohms, the DCE1800 is 11.1 milli-ohms, and is application dependant.
F. The Duty Cycle of the system must be 85% or less of the system capability to allow for
changes that could affect the welder control performance. Consult with your Stanley
Engineered Fastening Application Engineer to calculate the Duty Cycle.
G. When not using the recommended Stanley spring loaded ground block (Ref. part#
M108976), the necessary pressure force on the surface contact area must be a minimum
of 133N (30 lbs).
H. Copper blocks of at least 645mm² (1 in²) clamping surface are required for grounding
and not in contact with any other welds. Any deviations from this must be approved by
the Stanley Engineered Fastening Application Engineer.
I. The common measurement line and weld power return cable must be electrically
isolated from one another up to the ground block or power distribution block.
J. The grounding connections must be away from the welding points a minimum of 50mm
(2”) with a recommendation of 152mm (6”) for best results. Should there be
electromagnetic influence from the welding operation, then the individual grounding
connections must be adapted accordingly.
13
K. Grounding connections must be made through clean non-painted connections. They

must never go through pivot points, hinges, bearings, etc., (use flexible jumpers around
these movements as needed).
L. When attaching the weld power return cable to a clamp, it must be attached to the fixed
side of the clamp to prevent cable failure. If it is absolutely necessary to connect it to
the dynamic side of a clamp, it is highly recommended that it terminate at an isolated
power distribution block with a sacrificial super flex cable between the block and the
clamp.
M. When welding on laminated material a ground block must be located on the side of the
panel being welded. If welding on both sides a ground block is required on both sides
(Refer to item K above).
N. In robotic applications the weld power return and common measurement line from the
welder must connect to terminals in a junction box at the base of the robot. High flex
and Super flex cables are highly recommended to be used to continue these circuits
from the junction box up to the end effector (See Figure 3.b). The High flex and Super
flex cables are available from Stanley Engineered Fastening as an option.
3.1.1 Aluminum Welding Specific
A. Consult with your Stanley Engineered Fastening Application Engineer for

recommendations on proper grounding for your application. Reference figures 3f-
h for the recommended grounding.
B. In order to keep welding energy losses as small as possible to achieve the maximum
current capability of a welder control, Stanley Engineered Fastening utilizes a heavy-
duty weld power and weld power return cable with a 4/0 conductor to reduce weld loop
resistance. The total required weld loop resistance for maximum output on the
DCE15AC is 6.67 milli-ohms, and is application dependant.
C. Simultaneous welding of any type on the same part is not allowed. The high frequency
noise and magnetic field will increase the susceptibility for nuisance faults among
welder controls firing simultaneously.
D. Aluminum stud welding (AC Welding) requires at least 2 ground blocks (Ref. part#
M108976) per weld controller on small part. At least 4 ground blocks per weld
controller are required on larger parts (i.e. under bodies). Consult with your Stanley
Engineered Fastening Application Engineer on proper grounding for your
application.
E. Ground blocks must be installed with a maximum allowable space between each other
in the outer areas of the component.
14
F. Components consisting of multiple panels and being connected to each other by

adhesive and rivet joints need at least one ground terminal for each panel being welded
on. Ground terminals and terminal blocks must be insulated from each other and their
underlayment.
G. Ground blocks for different AC welders on the same panel cannot be connected
together.
H. Base material must be free of moisture, lubricants, gluing materials, sealers, and other
foreign substances in the weld area and clear of the flash shield or boot. Gluing
materials, lubricants, moisture and sealers directly beneath the weld zone are also
prohibited. Dry film lubricant may be acceptable if evenly applied.
15
3.2 Sample Groundings
A. Consult with your Stanley Engineered Fastening application engineer for

recommendations on proper grounding for your application. Reference figures 3a-
h for the recommended grounding for your application.
B. A bond wire to earth ground from the part is required if there are no other paths through
the fixture. Recommend using a green 8 AWG wire if required.
3.2.1a Standard Fixture Grounding
Figure 3a Standard Fixture Grounding

Grounding
16
3.2.1b Robot End Effector Grounding
A. When performing pedestal welding, it is highly recommended that the end effector
is used to apply the ground to the work piece.
B. The weld power return and common measurement line must be dressed from the
base of the robot to the end effector.
C. In robotic applications the weld power return and common measurement line from
the welder must connect to terminals in a junction box at the base of the robot. High
flex and Super flex cables are highly recommended to be used to continue these
circuits from the junction box up to the end effector (See Figure 3.b). The High flex
and Super flex cables are available from Stanley Engineered Fastening as a
purchased option.
17
Figure 3b Robot End Effector Grounding

Grounding
18
3.2.1c Multiple Controls Grounding
Figure 3c
Grounding Multiple Controls Grounding
19
3.2.1d Multiple Fixtures Single Control Grounding
Figure 3d
Grounding Multiple Fixtures Single Control Grounding
20
3.2.1e Narrow Part and Laminate Grounding
A. When using multiple ground blocks the weld power return cable and common
measurement line must go to an isolated power distribution block, along with
multiple cables that connect to each isolated ground block in a star configuration.
Figure 3e Multiple Ground Blocks for Narrow

Grounding Part, (Arc Blow) Balancing
Or
Two Sided Welding/Grounding of
Laminate Material.
21
3.2.1f Aluminum Grounding Basics
Figure 3f
Grounding Aluminum Grounding Basics
22
3.2.1g Aluminum Grounding Multiple (DCE15AC)

Figure 3g
Grounding Aluminum Grounding DCE15AC
23
3.2.1h Aluminum Grounding (Combined AC and DC welding)
Figure 3h Aluminum Grounding

Grounding (Combined AC and DC welding)
24
3.3 Weld Cable Length and Conductor Size
A. Based on the equipment and fixture locations the correct cabling for the amperage
welder control can be determined using a weld loop resistance calculation, to comply
with 3.1E requirements. Contact Stanley Engineered Fastening Application
Engineering to calculate the proper cable length and conductor size for your
application.
Figure 4
Cable Length
Identification
L1 = Length of the cable connecting the welder controller and the feeder
L2 = Length of the cable connecting the feeder and the weld head
L3 = Length of the weld common cable to work piece
25
4. Interfacing and External Control Cables
A. Logic must be written according to Stanley Engineered Fastening system requirements.

Refer to the Interface Integration Procedures for Robot/PLC Programmers
document provided by Stanley Engineered Fastening Engineering.
B. A separate weld program must be used for each fastener location being welded on the
workpiece.
C. A panel with connections for safety-related functions, the customer interface and
feeders is located on the right-hand sidewall on the inside of the control.
D. The welder customer interface power is to be supplied externally, (i.e.: by the customer)
with 24 VDC with the exception of the EtherNet/IP and RS-485 interfaces. This
external voltage can also be used for supplying the Ethernet Data interface for systems
without an Ethernet based control interface (i.e.: DeviceNet). See table below for
examples of the different styles of interface and connector types.
Interface Connector Type

Parallel Han 72 D
DeviceNet 5 pin Turk Mini-Fast
EtherNet/IP M-12 D
RS-485 3 pin Terminal Block
Profibus DP Subminiature D-sub9
Interbus S F-SMA
Ethernet Data RJ-45
Profinet 25mm Split Gland
E. Refer to interface documentation for control cable connections.
F. Emergency Stop and Operation Stop: Han 10B modular connector.
26
5. Welding Unit - System Cables
A. Reference the System Diagram located in the document holder on the inside of the front
door of the welder control, for assistance with cabling.
B. The connection to supply AC power and for the transmission of control signals and
data between the welder and the feeders is made with a hybrid cable. It contains plastic
fiber optic and cables for main voltage supply.
C. When routing the hybrid cable it must be assured that the bending radius does not go
below 80mm (3.2”). The maximum length of the hybrid cable must not exceed 30m
(98.3’). Cable length must be indicated when ordering the system.
D. The connection between feeder and weld head is achieved via a cable package, which
contains a 35mm2 welding cable, a 23-way control cable and up to 5 air hoses. A
separate feed tube achieves feeding of the fastener to the weld head.
E. The minimum bending radius of the cable package should be larger than 305mm (≈
12”).
F. An optional corrugated hose package may be used for applications with robots. The
corrugated hose is used for strain relief and provides a pinch-free connection.
G. Torsion and tensile stress on any cable or feed tube must be avoided.
H. When installing the cable package and feed tube, no restrictions to the weld head
movement can be allowed. The weld head full extension forward is a maximum of
50mm, and a service loop must be maintained to allow free motion. Robot path or fixed
automation slides must not damage the cable bundle or feed tube (Figure 5).
I. Cables and tubes should be secured with easily opened and closed attachments (i.e.:
velcro straps and quick disconnect clamps).
J. The cable package and feed tube must be adequately supported to prevent kinking and
stress.
27
Figure 5
TOP FEED ROBOT DRESS
BOTTOM FEED ROBOT DRESS
28
5.1 Welding Cables Routing and Dress
A. A robot with end effector grounding must not be dressed with a resistance welding
cable package consisting of a single 2 AWG wire for carrying weld current. Attach
multiple 2 AWG wires in parallel to achieve the equivalent of at least a 1/0 cable.
B. Weld return and common measurement line must be run together.
C. Power supply cables and control cables must be installed so that they are isolated from
each other and from welding and weld return cables. If they have to be installed in a
joint cable channel an electro-magnetic shield between the welding circuit, control
circuit, and power supply cable must be provided.
D. Welding cables must not be coiled. This will cause a change in the impedance of the
cable, thus cause fluctuations in weld quality.
5.2 Feed Tube Routing and Dress
A. The standard feed tube length is 6 meters (≈ 20’). Deviations from standard feed tube
lengths will directly influence the feeding time and thus will affect the total cycle time.
B. The minimum bending radius of the feed tube primarily depends on the fastener type
being fed.
1. The bend radius for a stud feed tube should be larger than 305mm (≈ 12”)
2. The bend radius for a nut feed tube should be larger than 400mm (≈ 16”).
5.3 Aluminum Welding Specific Dress
A. Coiling of welding or grounding cables is strictly prohibited. Even a single coil of cable
will increase the inductivity of the weld circuit during aluminum (AC) welding. All
cable lengths must be as short and direct as possible.
29
6. Tooling Installation
6.1 General Installation Information
A. In order to keep compressed air usage and feed time as low as possible, avoid
unnecessary loops, coils and excessive lengths in the feed tube suspensions.
B. It must be observed that the multi-cable package and the feeding tube are to be hung
without tension.
6.2 Weld Head
A. The pneumatically controlled movement of the weld head slide rail has a maximum
travel of 50mm from its full forward to its full backward position. Weld heads are
provided in two basic feed configurations depending on application or fastener.
1. In-line (LM310 Rear Feed), positions the feed tube parallel to the weld head.
2. Tangential (LM240 Top Feed), positions the feed tube tangential to the weld head.
B. Weld heads are supplied with a Dovetail wedge mounting system, which permits rapid
removal and replacement.
C. Typical weld head dimensions and mounting hole locations are shown in Figures 6 and
7.
D. The weld head must be mounted perpendicular to the workpiece (±3°).
E. The weld head must be mounted to promote easy accessibility for set-up and
maintenance.
F. Positional tolerance of the fastener is ±2.0mm (≈ 0.080”) when changing with an

unaligned weld head, and ±0.5mm (≈ 0.019”) when changing with an aligned weld
head. If the tighter tolerance is necessary an alignment fixture is available for
calibrating the weld head, contact Stanley Engineered Fastening sales department for
more information.
G. Weld head base must be electrically isolated from its mount. This is normally done
through the mounting bracket typically using 1/8” insulation (i.e.: micarta™).
30
H. Approximate weld head weights are in the table below.
Head Style Approx. Weight

LM240 12 lbs
LM310 12 lbs
LM315 12 lbs
LM90 11.5 lbs
Figure 6
Weld Head Dimensions
LM310 Style
All dimensions are metric (reference only)
31
LM310 Style with Gas
LM310 Style with Gas

Non-Contact Nozzle
32
LM240 Style
LM90 Style
33
Figure 7
Dovetail Mounting Hole Locations for Weld Heads
I. Three weld head positions can be used. Typical orientations of the weld head are shown
in Figures 8.
1. Horizontal – Preferred.
2. Vertical Down – Acceptable – Note: A minimum 10 degree angle maintaining an

angularity of ±3 degrees to the work piece, is preferred to allow a miss-fed stud to
fall away allowing for an automatic retry.
3. Vertical Up – Not recommended - Note: Welding in the vertical up position is a

viable way to weld fasteners, provided that each weld head is installed with a weld
head cover to prevent weld slag build up. The standard preventative maintenance
schedule should be evaluated to determine if the application may or may not require
preventative maintenance on a more frequent basis depending on the material being
welded, weld head location, and adjoining equipment.
34
Figure 8
Weld Head Orientation
Vertical Down Horizontal Vertical Up
35
A. All aluminum weld systems will have a flash shield to contain the protective gas in the
weld zone, and possibly a secondary boot which is application dependent.
B. All aluminum stud welding systems must have the weld head taught vertical down
(±45°), with an angularity of ±3 degrees to the work piece. Each application is different,
reference the Stanley Engineered Fastening, Aluminum Drawn – Arc Stud Welding
Application Guide, Addendum A for more assistance.
C. Base material must be flat in the area of the flash shield. The bellows or boot (if
applicable) on the flash shield must “seal” on the base material in order to contain the
shielding gas. Each application is different, reference the Stanley Engineered
Fastening, Aluminum Drawn – Arc Stud Welding Application Guide, Addendum
A for more assistance.
D. In order to reduce the magnetic interference during welding, all steel/ferrous metals
must be at least 10 inches away from the weld zone.
E. Typical weld head dimensions and mounting hole locations are shown in Figures 6 and
7.
Contact Stanley Application Engineering department for aluminum stud weld head model
that can be used in robot simulation to determine weld head accessibility.
36
6.3 Weld Head Teaching and Tooling Set-up
A. The following distances must be observed when teaching a robot or tooling a fixture.
1. Minimum stroke of the weld head slide rail: fastener length + 10mm tolerance. This
tolerance must be observed to guarantee that the weld head correctly disengages
from the welded fastener after the welding has been performed.
2. Maximum usable stroke of the weld head slide rail must be limited to 45mm.
A. The following distances must be observed when teaching a robot or tooling a fixture.
1. Minimum stroke of the weld head slide rail: fastener length + 15mm tolerance. This
tolerance must be observed to guarantee that the weld head correctly disengages
from the welded fastener after the welding and clears the bellows on the flash
shield.
2. Studs greater than 30mm in length will need to have an additional step back taught
in the robot after welding to provide proper clearance.
3. Maximum usable stroke of the weld head slide rail must be limited to 45mm.
6.4 Weld Gun
A. Suitable locating fixture is highly recommended to be used to accurately locate the

fastener and to assist in maintaining the weld gun perpendicular to the work piece.
B. Bushings for weld guns must be 0.25mm (≈0.01”) over flash shield diameter and easily
removable for replacement. Obtain the actual flash shield diameter from Stanley
Engineered Fastening application engineering.
C. Bushings should be mounted a recommended 5mm off of the work piece.
D. Bushings must be made of a non-ferrous material, to not develop a magnetic field,

which can have an effect on weld quality.
37
E. Balancer cables may be helpful in supporting auto feed weld guns. The approximate
weights are listed in the table below. This product can be purchased separately through
Stanley Engineered Fastening.
Gun Style Approx. Weight

PLM200 8 lbs.
PK600 8 lbs.
PK560 3 lbs.
38
F. Typical weld gun dimensions are shown in Figure 9.
Figure 9
Weld Guns PLM200 Weld Gun
Dimensions
PLM200 Weld Gun

with Gas Dimensions
39
PLM200 Weld Gun with Gas

Non-Contact Nozzle Dimensions
PK600
Weld Gun
40
PK560
Weld Gun
41
6.5 Fixture Requirements
CAUTION: Use of a ferrous metal must not be used within 2 inches of the weld zone! This can
develop a magnetic field which will have an effect on weld quality.
6.5.1 Part Location and Clamping
A. The workpiece must be clamped rigidly to prevent movement during welding.
B. The weld head exerts ≈ 200 N (≈ 45 lbs) of force when advanced. A pneumatic
regulator is factory set to 45 psi inside the JIC box of the feeder.
6.5.2 Part Deflection
A. The workpiece must have adequate support to prevent deflection during welding.
B. Workpiece deflection will negatively affect weld quality, and under no circumstances
must it exceed the maximum deflection in a direction parallel to weld head travel (see
table below).
Fastener Type Tool Type Maximum Deflection

Stud Std. Head or Gun 2.5mm (≈ .100”)
Ring Stud Std. Head or Gun 1.0mm (≈ .039”)
Nut Std. Head or Gun 1.0mm (≈ .039”)
Caution: Angular deflection must be minimized in order to maintain weld quality and
prevent collet breakage.
C. A backside support to prevent deflection can be located directly behind a weld zone. It
must have an inside clearance of 2 times the fasteners maximum diameter and must be
made from a non-magnetic and non-conductive material.
D. Solid backside support “must not be” located directly behind the weld zone in order to
prevent heat sinking. The only allowable exceptions are when welding on laminated or
aluminum material.
E. For laminate material, circular backside support and solid support must be made from
a non-magnetic and non-conductive material.
42
A. Solid copper backup will be required if base material is too thin or flimsy. Consult
your Stanley Engineered Fastening application engineering for assistance.
B. All ferrous materials should be 10 inches or further from the weld zone.
6.5.4 Nut Welding Specific Tooling
A. When welding provide enough relief in the backside support to allow for debris to fall
and not be accumulated. The nut welding process blows the slag away from the nut and
if the relief is not sufficient, preventative maintenance will have to be increased to
prevent slag build up.
B. For optimum weld quality be sure the hole size in the workpiece is within the tolerance
(see table below).
Nut Size Minimum Recommended Maximum

M5 7.25mm 7.45mm 7.65mm
M6 8.00mm 8.20mm 8.40mm
M8 10.00mm 10.20mm 10.40mm
6.6 Attaching the Weld Head to a Stationary Unit
A. The weld head must be installed into a stationary unit with a flat adapter plate, which
can be purchased from Stanley Engineered Fastening or can be fabricated (Refer to
Figure 10). Consult with your Stanley Engineered Fastening application engineer
to determine the proper adapter plate for your application.
B. The two mounting rails of the Dovetail wedge are to be fixed with two, M8 inside hex
socket screws at the adapter plate.
6.7 Attaching the Weld Head to the Robot
A. For attaching the weld head to the robot, an adapter plate is required. It may be obtained
from Stanley Engineered Fastening or can be fabricated (Refer to Figure 10). Consult
with your Stanley Engineered Fastening application engineer to determine the
proper adapter plate for your application.
B. The two mounting rails of the Dovetail wedge are to be fixed with two, M8 inside hex
socket screws at the adapter plate.
43
Figure 10
44
7. Safety
A. Reference the welder control-operating manual for safety information.
8. Design / Installation Buyoff
A. Stanley Engineered Fastening requires an equipment buyoff at different stages of the

project build. Refer to the Design / Installation Buyoff Checklist for details of the
buyoff procedure.
B. Contact the appropriate person in the table below for equipment buyoff.
GM/GM Tiers Mark Schweihofer / Mark.Schweihofer@sbdinc.com / 586.405.3910

Chrysler / Tiers Charles Lashbrook / Charles.Lashbrook@sbdinc.com / 586.615.1294
Honda / Toyota Eric Olevenick / Eric.Olevenick@sbdinc.com / 586.549.9051
Ford / Tiers Robert Balma / Robert.Balma@sbdinc.com / 248.416.2993
Applications Keegan Dillon / Keegan.Dillon@sbdinc.com / 269.967.7914
Service Joe Randazzo / Joe.Randazzo@sbdinc.com / 586.615.0425
45

Emhart Installation Requirements Rev K

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Emhart Installation Requirements Rev K

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I nstallation Requirements

For N orth American

Stanley Engineered Fastening, 2400 Meijer Dr., Troy,MI. 48084

Release Date: 5/25/16 Revision K

Release Revision Released By Description

System Layout with Gas (i.e.: Aluminum)

1.2 Equipment Identification

Weld Head Styles

Weld Gun Styles

1.3 General Information

Operating temperature: 40°F – 104°F ; 4°C − 40°C

1.4 Welder Control

C. The welder control dimensions are shown in Figure 1.

Cabinet Dimensions Control Terminal Add-on XFMR

All dimensions are metric

A. Feeder base: 750mm x 620mm (29.5” x 24.4”) minimum.

Standard dimensions in brackets

Standard dimensions in brackets

2.1. Power Supply

Welder Type: Equipped Fuse Protection:

Input Voltage: 3/Phase AC 480V (575V w/transformer)

Power Feed Length for Maximum Output

Length (ft) AWG Length (ft) AWG

If maximum current output (1500A for DCE1500, DCE15AC or DCEMAX series

2.2. Compressed Air Supply

Feeder Min. Air Pressure Max. Air Pressure

ETF12 & 13 5.5 bar (80 psi) 7 bar (100 psi)

ETF20 5.5 bar (80 psi) 8 bar (116 psi)

ETF52 5.5 bar (80 psi) 7.8 bar (113 psi)

2.2.1 Air Blow Requirements for Nut Welding

2.2.2 Protective Gas Requirement for Drawn Arc Welding

3. The Welding and Grounding Circuit

3.1 General Welding/Grounding

A. Consult with your Stanley Engineered Fastening Application Engineer for

K. Grounding connections must be made through clean non-painted connections. They

3.1.1 Aluminum Welding Specific

A. Consult with your Stanley Engineered Fastening Application Engineer for

F. Components consisting of multiple panels and being connected to each other by

3.2 Sample Groundings

A. Consult with your Stanley Engineered Fastening application engineer for

3.2.1a Standard Fixture Grounding

Figure 3a Standard Fixture Grounding

3.2.1b Robot End Effector Grounding

Figure 3b Robot End Effector Grounding

3.2.1c Multiple Controls Grounding

3.2.1d Multiple Fixtures Single Control Grounding

3.2.1e Narrow Part and Laminate Grounding

Figure 3e Multiple Ground Blocks for Narrow

3.2.1f Aluminum Grounding Basics

3.2.1g Aluminum Grounding Multiple (DCE15AC)

3.2.1h Aluminum Grounding (Combined AC and DC welding)

Figure 3h Aluminum Grounding

3.3 Weld Cable Length and Conductor Size

4. Interfacing and External Control Cables

A. Logic must be written according to Stanley Engineered Fastening system requirements.

Interface Connector Type

E. Refer to interface documentation for control cable connections.

F. Emergency Stop and Operation Stop: Han 10B modular connector.

5. Welding Unit - System Cables

BOTTOM FEED ROBOT DRESS

5.1 Welding Cables Routing and Dress

B. Weld return and common measurement line must be run together.

5.2 Feed Tube Routing and Dress