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WELD334M W334MHIC33030112REL2.05A50HZ WELDING

1. JP3 3 4 6 7 JP6 On E a a sm 5 O LJ Be SNS 3 1 sH E a eds Sab Sar Aa f 5 E p 03 m SP6 ON Das o INS EE 5 O on o Or Ne INS FF td 1 JP3 So TI _ JP3 3 4 6 7 26 WELDING Weld334m User s manual Cla one F353 ADC Analogue Card Code 33035300 6 F353 ADC Analogue Card This card includes 3 analogue inputs for acquiring signals from connectors P2 P3 P4 and the internal arrangement for housing the SEV module optional extra with output on the P2 for the electrode pressure adjustment proportional solenoid valve 6 1 P3 e P4 Description of the analogue inputs F353 ADC P3 TV 9 way Sub d plug connector Input for acquiring analogue signals optional extra Generally it is not used and is reserved for special applications Sensitivity 36V max Pim Signal Description TV Positive signal S E R v o Vv A L v E STSERV ENSERV ANALOG IN P4 TA 9 way Sub d plug connector O Input for acquiring analogue signals P It is used for connecting the current sensor 3 The acquisition of this signal when welding current is constant permits the real time check on the current trend during the welding pulse O Input is so arranged to accept a 150mV kA 3 Rowgowsky type s
2. REMOTE IN REMOTE OUT REMOTE IN REMOTE OUT REMOTE IN 83 GEES Weld334m User s manual WHITE PAGE 84 Weld334m User s manual APPENDIX C Weld334m Application diagram Dwg 33033311 02 Dwg 33033315 02 Dwg 33033316 02 GEES 85 WELD334m power transformer POWER 30VA 27V Secondary Main power supply 380 440 500V aes 0 25 0 4A TRF WELDING TRANSFORMER Pep oy ba he fio hom Jom CONNECTIONS POWER 27V 24Vdc etn 1 lots 1 fw All proprietary rights reserved by Spa FASE This drawing will not be reproduced or in any way utilized for SS ANSS the manufacture of the component or herein illustrated and must not be released to other parties without written consent Any infringement will be legally pursued SALDATURA FASTON1 Size 16 AWG min Main ground connection by faston CARD P21 P41 F360 F389 IOB P3 W 9 pine F a pins P am F353 P4 ADC Welding current transducer l TA 9 pins F Power supply Servo Valve ENSERV ISERV ISERV VSERV
3. GEES Weld334m User s manual F386 Ethernet 100Base T and CANbus module Code 33038600 12 F386 Ethernet 100Base T and CANbus communication module Serial and CANbus communication card for Ethernet 10 100Base T IEEE802 3 nets This module enables the welding control to be connected to a serial network of the Ethernet type for communication towards the WMS centralizer It can be used as an alternative to Profibus F354 PBS communication card to the WMSNET F355 NET communication card or to the previous Ethernet 10Base T F372 ETH e F381 ETH cards The CANbus port is a serial connection which allows the remote management of I O signals The communication protocol is settled by the user The TCP IP address of the Ethernet section is memorised in a DATA KEY DK device with removable key accessible from the front panel The key can be removed to enable the control device to be replaced in case of breakdown without having to carry out manual net configuration operations on the replacement control device To set the addresses for connection to the network please consult the programming manual 12 1 Technical features 12 1 1 Ethernet section O e Compatibility IEEE 802 3 802 3u standards i e Transmission speed 10 100Base T e Connector RJ 45 8 pole 12 1 2 CANbus section O e Bus type according to ISO 11898 1 ISO 11898 2 High Speed CAN e Connector Sub D 9 pole according to CiA D
4. PFA 58 WELDING Weld334m User s manual Cla one InterBus S Profil F IBS 03 14 InterBus S Profil F IBS 03 14 1 General description A specific data communication Profile has been integrated into the firmware of the modular control Weld334m which is automatically activated in the versions with Interbus S type serial Fieldbus communication module This Profile was developed for applications in the field of resistance welding The complete range of functions may be used by inserting modules F376 OPC Interbus S connections with fibre optics OPC controller chip into the control 334m The profile is a document describing data exchange with the peripheral in question defining their interpretation in detail The reference unit for data exchange is the WORD Each WORD is made up of 16 bits numbered from O to 15 The data are subdivided into two categories data from remote devices towards the welding control identified as Control Words data from the welding control towards the remote devices identified as Status Words It should be remembered that these words are specific to this application and are not compatible with applications other than those described in this chapter The Profile F IBS 03 comprises 3 Control Words 1 3 and 3 Status Words 1 3 For connections specifications and materials please see the documentation InterBus S DIN 19258 WELD COM PROFILE CO 14 1 1 Control Words C
5. 5 RICHRAV Request for Dressing Active at 24V This output is activated as a function of the programming of the stepper concerned Consult the programming manual for the activation reset of this function In the machine shutdown condition the signal can be reset only by setting the counter of the relevant stepper to zero This can be made via the RAVOK P24 9 input or through the software reset in the Stepper menu 6 RICHEL Request for electrodes change Active at 24V Led indicator illuminated Same as for request for dressing but it devoted to the electrodes change The validation is to be carried out with the CHGEOK P24 10 input 7 ALARM1 Signalling Active at 24V It does not interrupt the processing cycle Diagnostic alarm from E001 to E050 Generally it is reset automatically but it can be fitted with a shutdown function in the Setup menu See chapters on Alarms and Setup in the programming section 8 ALARM2 Machine alarm Active at 24V It shuts down the cycle It concerns faults errors in programming and errors in wiring of both the control device and the machine It can be reset by pressing the reset key on the small keyboard or from the RESAH dedicated input It is active until the cause has not been removed 9 UNDCURR Undercurrent Diagnostics Active at 24V It does not shut down the cycle It is always activated together with the alarm 1 when the current value read by the sensor is lower than the programme
6. Hardware configuration 2 3 Every function has been housed on a dedicated card in addition to this 24Vdc discrete inputs and outputs are divided into Base and Expansion types The first position on the BUS near connectors P1 and JP1 is to be compulsorily dedicated to the card CPU List of available cards Kay 27ed YM VAW OOT OT PUY NYD 0098 0 HII 98 A4 x x x x 00T8 0 HII T8EA Kay 27ed YM p120 UIA gt x x x 0065 0 dOW 6SE4 Jaqulid pes AiowaW x x x x 009 0 DdO 9 A DdO eondo S snqusur x x 0095 0 JOI 9S 4 jus O I UolsuedxI x x 0009 0 gol 09 4 joules O T seg x x x x 00 9 0 AAS 49 4 jnpow SAJCAOAJAS puoguodold x x xe x OOESENEE Dav Esed pJeo anbojeuy x x x x OOV8EN0EE Ndo vs8Es NdO x xxx 00 9 0 Ada 9 4 fejdsia VIP x xl x x OOTSEOEE sng TSE4 p429 uolq eUUOdIAIU SNE x x x x OOOLENEE WSd 0 4 Ajddns Jomod x x x x apoo dJapio pues weu pied uondos p pied ollel E E de a EIEIEIE tititi t LOL o Mmmm a gt oO U oO U e i Z2 Z z oO 3 als als rs ri T E O 0 0 O0 9 S 600 v mim a a fo MIMIMIM L alternative 11 GEES 2 4 Characteristics Control power supply 24Vdc I O total power discrete digital I O Outputs Programming port Current sensor input TA Analog
7. The second operation is the operating software update through by a simple loading operation In addition the operating system can be transferred from one control device to another O For the correct use of the Ram Card please consult the Programming N Manual chapter MEMORY CARD TAPO lt nOEZMEZ uv P P5 PRINTER i N 25 way Sub d socket connector E The parallel port allows the connection to a parallel printer for printing data concerning the programs steppers reports etc O For this function please consult the W334m Programming Manual To connect the printer a standard cable for printers is sufficient Centronics type 25 way parallel cable WARNING This port is not compatible with serial printers No setting jumpers are on the card 35 GFIEES 36 Weld334m User s manual F359 MCP Memory Card and Printer WHITE PAGE WELDIN Weld334m User s manual Cla sons F360 IOB I O Basic card Code 33036000 9 F360 IOB Card Base I O This card is used for the basic connections toward the plant and houses a 2 position selector switch and the linear connectors P20 P21 P22 9 1 Description of functions F360 IOB Salda SI NO Weld YES NO Selector switch It enables disables the welding current IO The following components must also be enabled Weld Yes No selector switch in the Setup stage and P30 14 input on the F356 IOE card TAMTA Salda SI Weld YES Oriented to welding c
8. VSERV VSCH STSERV TVE TVE TVESCH Circuit breaker command emergency main switch IAG max 110Vac 300VA 24Vdc 24V Firing 424TR Firing COMIMP SCR Temperature transducer e EMERG SPIN1 SPIN2 SPOUT2 SPOUT1 Firing Stepper reset done pe eta 10 RICHSALD Ly Cycle weld request NBS 11 RICHSALD Weld enable NBS 12 CONSALD 24Vde OV Pong Toy bese fie oeng fotor gen changement WELD334m Terminal block Date 02 98 CONNECTIONS CARD F360A IOB AND F364 SERVO VALVE Sheet n 1 Do rima 33033315 02 All proprietary rights reserved by Spa FASE This drawing will not be reproduced or in any way utilized for L E AN the manufacture of the component or herein illustrated and must not be released to other parties without ee A written consent Any infringement will be legally pursued SALDATURA 24Vdc From card F360 connector P3 V Start cycle A Start cycle B Add open weld electrovalve A Add open weld electrovalve B STARTA STARTB CEVASA CEVASB Weld SALDASI Pressure onl SOLOPR Reset alarm stepper A RESASA Reset alarm stepper B RESASB Tips dressing RAVOK CHGEOK CODEO CODE1 Binary code we programs selection CODES CODE4 CODES CODEP RESAH Tips change done Reset alarm hardware SWITCH SALDASI SWITCH SOLOPR E Cem of rn rs Px P fe Tr eC eT Fr From card F360 connector P3 OV 2 Warning stepper A WALLSTA VALLST
9. quit ESC 5 function keys Remote connection distance With direct connection 100m With indirect connection separate power feeder 600m rm HCM4300 HHT i Lo E OBD Dos Dimensions L 200mm H 90mm Pr 35mm Operating 0 to 45 C with humidity from O to 80 without temperature condensation Storage temperature 40 to 80 with humidity from O to 90 without condensation Weight 500g 9 way Sub d socket connector in signal Description 4 rxD Datareception 8 RxD Data reception 9 TxD Datatransfer O 2 4 4 Connection through Laptop The Laptop connects to the P1 connector of the control device and communicates through an RS485 Full duplex serial port with WMS rel 2 61 and upgrades Cable for connection between Weld334m and PC laptop F2118 Order code 32102110 With converter RS485 RS232 L 2 5mt WELDING Weld334m User s manual fe eins 3 Power supply and 24V for I O 3 1 Control device power supply The power supply section resides on the PS 8way 5 08mm pitch connector for disconnectable terminals which are located on the front Also housed on this connector is the input for the external synchronism Either incoming direct current or alternated current is accepted by the control device see characteristics at paragraph 2 4 The control device earthing is to be carried out by means of the faston terminal loca
10. 2 Robot directives update Use of Status and Control Word 2 within robot communication Within the FASE control device only 334m the 2 Interbus Word is for the communication extended between the device and the robot for the information exchange concerning the already reset counter after activating the reset counter with the number of the program Bit 0 7 output Fase Reset gun 1 8 indicates that counter has already been reset The information is confirmed by the robot via the inputs Bit 0 7 Reset gun confirmation The detailed description of this function is given in the Programming Manual of the Weld 334m Reset gun 1 Reset gun2 program Reset gun 8 The gun selected by the program is reset by Word 2 and this selection is transmitted in parallel on the gun outputs 1 8 and controlled by the Reset Counter Interbus and by the number of the selected program Weld334 in out control Bit 0 Bit 0 Reset gun 1 1 Reset gun 2 Reset 2 gun 1 8 4 confirmation 7 Reset gun 8 The selected gun outputs are confirmed via the Reset Gun Confirmation Control 66 Weld334m User s manual APPENDIX GEES 67 CFS Weld334m User s manual 68 WELDING Weld334m User s manual Cias one APPENDIX A Maintenance Maintenance operations Replacing the cards is a very simple task which poses no problems The wiring connections with the welding machine cannot be exchanged between one another and
11. Description 1 2 Power supply to SEV from internal 24Vdc 2 3 Power supply to SEV indirect from internal 24Vdc or from external 24Vdc 7 2 2 Jumper function on connector J5 Pins connected Description 1 2 24Vdc limiter SEV power supply OFF Position required when Default stabilized 24Vdc is available e g with PSM type F370 2 3 24Vdc limiter SEV power supply ON Position required when Only for F364 for non stabilized 24Vdc is available e g with PSM type F367 compatibility with old module F368 33 GFIEES 34 Weld334m User s manual F364 SEV and F385 SEV Proportional Servovalve Modules WHITE PAGE WELDING Weld334m User s manual Cla sons F359 MCP Memory Card and Printer Code 33035900 8 F359 MCP Memory Card and Printer The F359 MCP card supports a PCMCIA type memory card Ram Card and the parallel port for connection to a printer F359 MDP MEMORY CARD Standard connector for the PCMCIA card The memory card allows saving the configuration as well as all the welding programs of a control device or memorising the operating software Thus you are given the facility to perform two maintenance operations quickly and in an easy way The first operation concerns the immediate replacement of a welding control device Thanks to the Ram Card all data is quickly transferred from one device to another with no need to configure and hand copy all the programs to the new control device
12. F376 OPC 11 2 Optical connectors InterBus S The connectors used for the optical fibers are of the F SMA type in I nt A accordance with the InterBus S DIN 19258 standard Please refer to this specification for the connection topology and the optical fiber type to be used DI2 REMOTE IN REMOTE OUT Remote communication connections towards the preceding device Be DI1 Output DO1 Input REMOTE OUT Remote communication connections towards the following device DI2 Output DO2 Input und When not in use the closing cap must always be placed on the optical WARNING connectors 49 WELDING Cla Sons Weld334m User s manual F376 OPC Field Bus InterBus S Card 11 3 InterBus S interface power supply There is a P25 connector on the front panel to supply the InterBus S interface Connector type 2 way 5 08 pitch disconnectable terminals Power supply input characteristics Acceptable Input voltage 24Vdc 15 10 Max Absorption 125mA The OVIB return signal is not connected to the ground PE Pin Signal Description 1 24VIB Power OVIB Return 11 4 Description of status LEDs There are 2 groups of LEDs on the front panel indicating the status of some I O signals and of the InterBus S port sTOOF MS OBE ST FK MS BE leds TR S P These LEDs indicate I O functions dedicated to the welding process ST START Welding sequence start Control Word 1 Bi
13. F385 SEV MODULE ON THE F353 ADC CARD cscccssssesseecsseeeseeecsseeeeees 32 7 2 1 Jumper function on connector J4 rr rieea care e nara eraeaa aee ea nana ra aera en araaanac aa nana ca nara ea aaraceaaa 33 7 2 2 Jumper function on connector TS ieccccesccccecseeserseesecsseescnseesceseseecuceesceceeseesecseeeseseeeneeeseeseeseeeeeeeentes 33 8 F359 MCP MEMORY CARD AND PRINTER sssccssssscccsssscceessccccessscccesscccscssccecessacccessseececssceeeesss 35 WELDING GFLES Weld334m User s manual 9 F360 IOB CARD BASE I O sasesssseenistenoeuasos sous dete cb ssceteausscuseets sbaueeee esa desse Gonesbecuoseesescesesoastesdedectssvesecessecees 37 9 DESCRIPTION OF FUNCTIONS S oieee reana edi caad Spade nado EUEVS STA ge a da susus 0500 da EIA sas PEA EEEE EAE dt ssa gb ando 37 0 2 P20 DAVDCS NO e be sactes lezen bb cad RARAS E adaa ini abun 2 aceasta sis is ates ee 37 9 3 P22 HSA CIRCUIT BREAKER TRIP cssccccccccsesessssecececeesessssececececsesaueceeececsesnsaeeeeeceeseneaeaeeeeseeeesensaaeas 37 9 4 P2 DESCRIPTION OF SIGNALS coreeana rE E erT E AEA EEr EEEE EARE 38 10 F356 IOE I O EXPANSION CARD cccccscsssssssccsscccsssssscveccscsesssssececcessesssscocecesesssssssececcecssssescsecsecees 41 10 1 P23 DESCRIPTION OF OUTPUT SIGNALS ccccccccecessessscecececsessneceeecccseneseeesecscseseseaaeeeeeceeserseaeeeeeeeenenees 41 10 2 P24 gt DESCRIPTION OF INPUT SIGNAT S ot aaner E EE 44 10 2 1 List of
14. O For the connection refer to paragraph 3 2 2 figures c and d Contact available for Earth connection For the connection refer to paragraph 3 2 2 GEES Weld334m User s manual 3 1 2 Connections for main power supply Diagrams for control device power supply are illustrated below e Ac input taken from the power line of the welding transformer 380Vac line Power transformer PS Power supply 14 4 32 4Vac Firing device 1 Pulse 2 control P21 WELD334 e Dc supply 1 24Vdc external power 18 36Vdc pi feeder 2 380Vac line ps 3 External Sync 4 Firing device 1 Pulse 2 control P21 WELD334m SCR e Ac supply taken from a line separate from the welding transformer power supply Vac privileged power supply Power supply transformer i ill 14 4 32 4Vac gt Power supply 380Vac line PS Insulation transformer i External 12 33Vac 4 syne E 1 Pulse Firing device gt control Welding transformer P21 WELD334m SCR 16 Weld334m User s manual GrLES 3 1 3 Power consumption Power used is dependent on the type of application carried out on the machine Table below lists the minimum power to apply to the control device in its full configuration depending on the type of power supply being
15. Vdc External J2 1 2 24Vdc Internal F360 IOB I O Basic card O Ji_ J2 Se F vio sw fis Er E Mm ia 7 Ws S us c4 P3 C2 4 afp us NM 4 6 Re cio 3 c17 E w Ss 1 12 oe Fa Di 04 z LOS ug TE c5 p 2 Um C3 LD8 LAS LDO H2 U12 Di v16 2 107 UI LAS 12 Ou c UI app LAS vI Spa us Epa ofh E nos RLS RLZ 1 p2 E 3 ai gd 20 LC x a 40 WELDIN Weld334m User s manual Cla sons F356 IOE I O Expansion Card Code 33035600 10 F356 IOE I O Expansion Card This card houses two terminal type connectors a 18 way connector P24 and a 16 way connector P23 for the connection to the field They support 18 off 14V inputs 20 30V 10mA and 16 off 24V 0 3A inputs four of which dedicated to the welding solenoid valves are protected against the simultaneous clamping of guns through a relay interlocking All outputs are protected against short circuit TEASE 01 O2 10 1 P23 Description of output signals sa os 3 o 16 way 3 5 mm pitch linear connector for disconnectable terminals eo oO O Pim sinai Description fve J E 6 WALLSTA Stepper A pre alarm Electrodes wear function
16. control device 1 When the control device is still OFF and the F376 OPC card is powered 24V on P25 by starting the communication on the InterBus S line the F376 card generates the ID38hex UP Not Ready identification code on the bus to tell the Bus Master that the device has not been initialized 2 Under normal operating conditions of the InterBus S Bus if the control device is switched OFF the F376 OPC card generates a Module error type error and sends a Peripheral error indication signal to the Bus Master 11 6 Optical power regulation The SUPI 3 OPC expands the data transmission functionality thanks to the help of the optical transmission techniques This device is able to autonomously regulate the optical power transmitted by the optical fiber cables FOC thus compensating the thermal effects and the component aging The automatic regulation is only possible in the case of a communication occurring through a device with this same functionality In other cases the optical intensity is kept to a standard level which is settled by the JP23 JP24 JP25 JP26 JP27 bridge configuration and is determined through a particular procedure carried out while producing the card WARNING It is in any case forbidden to change the JP23 JP27 bridge configuration during the card setup and or replacement 51 GEES 52 Weld334m User s manual F376 OPC Field Bus InterBus S Card Card layout
17. entity of the change If only one parameter is to be modified for instance the welding current value the operation will take about 45 via the HCM4300 programming unit By contrast if more parameters are to be modified time can be calculated averagely by adding approx 30 for opening the menu concerned to approximately 10 for each modified parameter Time for modifying 1 parameter 45 Time for modifying n parameters 30 10 xn 71 WELDING Cla Sons Weld334m User s manual 72 Replacing the battery 3 6V CR2477N type lithium battery The battery is housed on the F384 CPU card in an adequate seat which allows the battery to be replaced easily with no need for special operations When replacing the battery data stored on the RAM are not lost A Supercap type capacitor powers RAMs during the replacement Check that the new battery provides the correct voltage before mounting it onto the card To do this use a tester How to replace the battery poe OO OY ee Re N mom m o om LN 14 15 Switch off the machine and disconnect wiring Disassemble the control device from the machine support Remove the front part by undoing the 3 fastening screws Draw out the card located sideways the CPU card Disconnect the F384 CPU card and draw it out tilting it sideways Disconnect the small cable of the display Remove the battery clip Draw out the down battery Insert the new battery Mount the cli
18. program selection codes cccccceccecesssesesseeeecnseesceseeseeseceesecueeesensecseesecieenesuseesensesseeaeeeeaeenaes 47 11 F376 OPC FIELD BUS INTERBUS S CARD PROFILE F IBS 03 ssesssescsesccssesssesssesecoesccesccssesee 49 11 1 CHARACTERISTICS cuco saias erene aa EE EAEE EEE R RE E EA E EER E E ARRE a 49 11 2 OPTICAL CONNECTORS INTERBUS S cccccsesceceesececeescececsseeececsueeecessececsseeeceeseeeceesueecensneseecsneeecseaes 49 11 3 INTERBUS S INTERFACE POWER SUPPLY cccccccecsssesssceeececeesssececececseneaeeeeececsesenseaesececeesesseaeeeeeeeeeenees 50 11 4 DESCRIPTION OF STATUS LEDS csssssnersecccecsssssenccescecsscsnaesetececsensaeuaesececeesseeueesscsceesseeeaensessceseeees 50 IDENTIFICATION CODE ID CODE cet secs sessed tnia eE A saecs seca cue E EE saudeunde Ra abc EIS venta seas 51 11 5 ERROR CONDITIONS WITH THE CONTROL DEVICE SHUT DOWN ccccccscsessssscsseceseeeeeseeeseeeseeeeeeauenenenees 51 11 6 OPTICAL POWER REGULATION c cccccccecsessssscecececsessseceeececsessesesececsenesseeeeeseseseaeaeeeeeceeseeneasaeeeeeceenes 51 12 F386 ETHERNET 100BASE T AND CANBUS COMMUNICATION MODULE 53 12 1 TECHNICAL FEATURES cc cccccccecssssssecceececsessnseeecececeeseaueceeececsesaaeeececscseseaeseeececsesesaeaeeeesecesecseaeeeeeeeeeeees 53 12 1 1 Ethernet sechOM snarere EE E E a a E a 53 12 1 2 CAN DUS SCCHOM wdc doi suerte DUDA E A ovhan RETIRA edd oss osdeuhdea de Udo DEST Ade de EO
19. switch unit 3 Use a safety device to monitor the value of voltage on the welding guns with respect to earth This device should be linked to circuit breaker trip Switch 380 500V N Voltage sensor E 1 2 3 Current sensor The current sensor also known as current coil or Rogowsky coil thoroid or sometimes more improperly CT current transformer is the device by which the control device measures and adjusts the welding current during the welding process Irrespective of the specifications and standards of the electric transducer characteristics a few fundamental rules are however to be applied concerning the position of the transducer and its relevant wiring This to minimise errors due to electric and mainly magnetic disturbances The reliability and accuracy of the ammeter directly depend on the correct positioning as well as on the adequate protection against external disturbances If the sensor is built into the welding transformer problems concerning the respect of a few of the Standards have already been solved in the transformer design phase As for sensor positioning the following requirements are to be adhered to The sensor is to be located in the welding secondary circuit The plane to which the sensor is mounted must be orthogonal to the lead run through by current it measures that is 90 The sensor if external to the we
20. the connector ID code is also recalled on the front panel To avoid doing wrong connections with similar connectors DO NOT REMOVE the polarising device which is fitted to several connectors of the cards To make the connection of the card on the bus easier it is better to strip the card pack from the container Always check whether jumpers are present on the card If so check they are done correctly Replacing the modular cards 1 2 3 4 10 Switch off the machine and disconnect wiring Disassemble the control device from the machine support Remove the front panel by undoing the 3 fastening screws Disconnect the card to be replaced paying utmost care in doing this operation Front part fastening screws Check on the new card for the presence of jumpers and if need be set them in the correct way Fit the new card into the rack and make sure that the P7 3 way connector fits correctly into the bus Put the card pack in place again in the container and fasten it by using its screws Re install the front part making sure that the PS connector fits properly into the window then screw down the front part Re install the control device onto the machine Connect wiring again 69 WELDING Cla Sons Weld334m User s manual 70 Replacing the CPU card The CPU card has its own compulsory position on the P1 of the bus and is connected to the display module via a 10 way flat cabl
21. the indication of the signal presence 12 way 3 5mm pitch linear connector with disconnectable terminals Pim signa Description signat Rating 2 ria comme scr trigger contr a 6 input free fimput fuma E Joutput free output Jon o FINesEg end of Sequence ouput fosa In the case of a Weld334m IMF integrated inverter the function becomes Welding starting time with current 10mA In the case of a Weld334m IMF integrated inverter the function becomes Inverter Ready P21 Functional description of signals Pin Signal Function 1 24TRASF 24V power supply to SCR trigger transformer primary to be used for this purpose only 2 COM IMP SCR trigger Pulse control See application diagrams 3 TSCR SCR over temperature OFF active The sensor is to be of NC contact type In the event of over temperature the TSCR signal is interrupted and the control device generates the relevant alarm and shuts down the machine cycle 4 EMERG EMERGENCY STOP OFF active It is connected to 24V supply through an N C contact which is broken by robot or in manual mode in case of emergency stop The control device inhibits the sequence and hampers the start function as long as 24V is not reactivated on this input See EMERGENCY STOP diagrams in Appendix B 5 INPUT 24V discrete min max20 30V 6 INPUT 24V discrete min max20 30V 7 OUTPUT 24V 0 3A discrete 8 OUTPUT 24V 0 3A discrete 38 WELDING Weld334m Us
22. 2 Current outlet characteristics Range 4 20mA Single ended type with ISERV pin connected with the OV of the 24SV Maximum load 600 ohm Minimum load 200 ohm Converter resolution 12 bit Converter accuracy 3 Isb Protection against permanent short circuits Protection of ISERV outlet pin against accidental contacts up to 36V DC Test on open current loop 7 2 Connection of the F364 F385 SEV module on the F353 ADC card The F364 F385 SEV module houses the whole electronic circuit for the servovalve management Its mounting on the F353 ADC card poses no problems this can be easily made through the two connectors Ji and J3 The J3 connector is polarised contacts 9 and 10 are not present to prevent incorrect mounting of the module F385 SEV Module Components side view WELDING Weld334m User s manual Cias one F364 SEV and F385 SEV Proportional Servovalve Modules P3 Mounting position of the E F385 SVV Module F353 ADC F364 SEV Module U P4 Fixing of the module is ensured by the tight fit of the two connectors J1 J3 Make sure that the module is properly fitted into the card For the SEV pin out refer to the chapter P2 Description of the signals for the Solenoid valve and the TFE 7 2 1 Jumper function on connector J4 For further information consult the chapter Use of 24V I O Pins connected
23. A sins EEE E TAERE 12 2 4 1 Utilis tion characteristics cscc ciccvacsvscvsescevscedcestesssstesedsecssvenseieccdsbesvusseacsecsesdovelvescesseedsotvenees Sosdeuevecees 13 2 4 2 Dimensions overall dimensions and fastening positions ccsccccecesesseetetseeeecnseeecnseeseeeeeecnsenseens 13 234 3 HHT4300 progr mmine Unit sisiciirisrsieirerire ole caw cab ee ioie A E EE ERSA EEA EAEE 14 2 44 Connection through Laptop scviccccssvsccioscascsssvssioesenesscviousevntscedonesd cntsvecioateneascadeaseonssigdonsadcntavsodoaseneese 14 3 POWER SUPPLY AND 24V FOR O cccosssssessscossesssscosesnoseesesocserauscesesncsocsescesersusossessocasseesectssesseoseonsie 15 31 CONTROL DEVICE POWER SUPPLY cics rear isnteama so eE REEE ERA ion ada dA EE E E EEEE is 15 3 11 PS Description of signals cccccccccccsccesceseesseeseeessceseceseecuseesceseeseeeseececeesesaeeaeeseseesceesesenaeeseeaeeneeets 15 3 1 2 Connections for main power Supply cccccecccccseecsseeecesesseeseceecnseeseesecseeeceeeecesecseeseceesesesensesseeeeeeets 16 31 3 POWF CONSUINDTION asus osuthniy yisces cgrsSads iba COL able sey AE e Dhsnoad cob ays dh NE US ini Eo REA 17 3 2 USROR24V DO iissa a E E R A AR qa CLA san CCE gaia aime dim RERE 17 3 2 1 Selecting 24V internal or external cc eccccccccecccceeecseesceseeseesecseenecuseeecnceeseeseeeeesecueeescneseseeseeseeaeeeeats 17 3 2 2 24V connections for discrete 1 0 ccccccccccsccesesssesecsseescuseescusecseesecesecac
24. ART PROGRAM CODE Cem 5 WELD HOT TIME 24 Closed EMERGENCY o i Open FK 0 CHANGE TO 2 SERVOVALVE CHANGE TO 1 Given by robot 75 WELDING Cla Sons Weld334m User s manual 4 EMERGENCY STOP condition during or outside the welding pulse NOTE The Emergency stop signal is active at OV PRE SQUEEZE SQUEEZE WELD HOLD CYCLE CURRENT Closed sPOTDONE NO FK EMERGENCY a SIGNAL NO SPOT ALARM If it happens During emergency time period situation the welding control behaviour will be A started spot must be ended In case of bad quality spot with retry function programmed all required retry spots must be done If a quality spot alarm occurs it can be reset by PC or HHT NO dedicated message is generated stored to indicate the situation This situation is not to be considered an emergency but just a standard cycle operation during that all process have to be suspended 76 WELDIN Weld334m User s manual cF 5 EMERGENCY STOP excluded with START still active NOTE The Emergency stop signal is active at OV 24V START 0 24V Closed EMERGENCY 0 24V FK if spot done since START ON same as standard condition 6 START disabled condition during the welding pulse START WELD FK User programmable 0 99 cycles 77 Weld334m User s ac manual 7 Proportional Servovalve operating diagram Servo
25. E ALLSTA ALLSTB RICHRAY RICHEL ALARMI i Alarm 2 hora ALARM OO lor a O Undercurrent limit alarm UNDCURR OVRCURR READY STATUS EVSA EVASA EVSB Additional opening electrovalve B EVASB xx Short to 24Vdc when the functions are not utilized Pog oly pes Mater S Tengo for gen Changoment WELD334m Terminal block Date 02 98 CONNECTIONS CARD F356A IOE ESSE SDS All proprietary rights reserved by Spa FASE This drawing will not be reproduced or in any way utilized for SS ANS S the manufacture of the component or herein illustrated and must not be released to other parties without written consent Any infringement will be legally pursued SALDATURA
26. EEEE EEEE EEEE IV WELDING Weld334m User s manual cF 9 Diagram of diagnostic pressure control Interbus S general architecture of I O communications csser 81 Ethernet Tcp Ip Example of network architecture InterBus S Example of network architecture cccccescceseesceesseseccecseesecesecnsecseesecaeceaecsessecaecaaecaeeseseaecaaecaeeeeeeaeenaeeas WHITE PAGE APPENDIX C WELD334M APPLICATION DIAGRAM GEES VI Weld334m User s manual WHITE PAGE WELDING Weld334m User s manual cF 1 Safety To insure correct installation and operation of the WELD334m welding control device it is necessary to carefully read this chapter Each operation on the machine is to be carried out only by qualified personnel with good understanding of the information contained in this manual should the documentation not be perfectly legible and or incomplete of any further information required please consult GF WELDING S p A before undertaking any work on the machine Inside the welding control signals are generated which set parts of the machine in motion therefore it is prohibited to open and tamper with the control and safety circuits Live metal parts such as screws or similar parts penetrating into the electric circuit may cause malfunctioning as well as the generation of incorrect and hazardous conditions and events It should be remembered that any changes and or modifications not expressly authorised by the manufact
27. G Weld334m User s manual Cla sons 8 ENABLE function Interbus s 24V Power p PEPPE APN SRI ES EAR P RES N AAT RASA AAE EESE E E T Signal P 2 0 10V 4 20mA ENABLE 24V servovalve activ servovalve inactive Ov Pressure PA Inpunt Interbus Fase ENABLE Bit 2 Servovalv Control Signal behaviour ENABLE 24V This function allows the valve control when voltage power supply interrupts Fail save the output current pressure is not modified Servovalve control Interbus input This function allows the servovalve piloting to be done through the Interbus control input Active High ENABLE goes to OV gt pressure stays unchanged 79 GEES Weld334m User s manual 9 Diagram of diagnostic pressure control Mode of operation relates to the status of the programming parameter PROC WAIT see programming Manual paragraph Electrode Force Diagnostic Mode Process in PROC mode The control executes the sequence respecting the set timings The diagnostic function signals any pressure errors Te DIAG CHECK WELDING CYCLE ALARM 1 if pressure is not OK E015 Process in WAIT mode The welding pulse is only given when the nominal value P1 has been reached Tmax WAIT Pressure OK P1 15Kn WELDING CYCLE NOTE When the parameter T Prs 0 the function is disabled 80 Interbus S general architecture of I O communicatio
28. Gri USER S MANUAL Weld334m HC HCM HIC HIM Ed 5 December 2004 Doc 39000326 WELDING Cla Sons Weld334m User s manual GF WELDING S p A Strada del Portone 18 24 10137 TORINO Italia Tel 011 3033 278 Italy Sales dept 011 3033 270 279 Foreign Sales dept Tel 011 3033 277 Italy After Sales 011 3033 274 Foreign After Sales Fax 011 3092046 e mail mail gf welding it web www gf welding it The information contained in this manual may be changed at any time without prior notice in this case GF WELDING S p A is relieved of any responsibility The information on the software and hardware tools contained herein are confidential and are released in conformity with a licence contract It is absolutely prohibited to distribute or circulate the hardware and software documentation of this product to third parties The purchaser is allowed to prepare the software safety backup copy in the quantity of one copy only No part of this manual may be reproduced or distributed in any form or by any means or stored in a database or retrieval system without the prior written permission of GF WELDING S p A All rights reserved to GF WELDING S p A II WELDING Weld334m User s manual cF Table of contents WELLER PAGE ane e O oa a do ee E a E OEA VI Ty SAFETY oeae e EE aE a E EE a E E EE ASEE ENESES 1 1 1 HAZARDS ASSOCIATED WITH THE USE OF RESISTANCE WELDING MACHINES cssscecesseeceeseee
29. S102 e CAN interface galvanic isolation e Transmission speed max 1 MByte s 12 2 Front panel 12 2 1 P28 CANbus connector Sub D 9 pole male type Pin Signal Function 1 Reserve 6 GND CAN Ground 2 CAN_L CAN_L bus line dominant low 7 CAN_H CAN_H bus line dominant high 3 CAN_GND CAN Ground optional 8 Reserve 4 Reserve 9 CAN_V CAN external positive supply optional line 5 CAN_SHLD CAN Shield optional Shield PE Pins 3 and 6 are interconnected to each other 12 2 2 CANbus status LED s LED Colour Meaning Condition RUN Green CAN peripheral status On active ERR Red Anomaly On generic anomaly GEES Weld334m User s manual F386 Ethernet 100Base T and CANbus module 12 2 3 P10 Ethernet 100Base T connector R345 8 pole female shielded type MDI configuration Pin Signal Function 1 TD Positive data transmission 2 TD Negative data transmission 3 RD Positive data reception 4 Not used 5 Not used 6 RD Negative data reception 7 E Not used 8 Not used Shield PE 12 2 4 Ethernet status LED s ANANAWNE P10 connector pinning front view LED Colour Meaning LAN Green ON when data transmission is in progress LINK Yellow OFF when there is a line fault 12 3 Ethernet connection cable 12 3 1 Features e Cable t
30. SS 53 12 2 FRONT PANEL 633325506060 s3sec5cnciuessssuteenedscauesazacnuensessedeveeneencsa dasudasicoatece ex suuuesdeddacsesepueeueescdevsvegedeus Gouteetesese 53 12 2 1 P28 CANbus connector ccccccccccccecececececececececececececeeececeeececuuasauaaasaaasaauaasanesaaeaenenaneneness 53 12 2 2 CANbus status LEEDS EAA EE A stds cavsiwis cavstaesiavbteecaskstaetiadseseliavstaesiaxs 53 12 2 3 P10 Ethernet 100Base T connector aaa aeee nana 54 12 2 4 Ethernet status LED S ccccscsiscsciavanesesesevess sasiveossasavens sasanevssavevens sass NORA MOS ECOS sa eneoe ouor as sasevesesanevers SATO 54 12 3 ETHERNET CONNECTION CABLE ccccccsssscscscecceeeeeeeeeeeeeeeceeeseeeeeesueeseeeauaeeuaeauaeseeeaeaeauaeauaeauaeauaeasaeeanenes 54 12 3 1 COUP OS a onte a a a a da a a codecs e aa a 54 12 3 2 Cotinection type sadssiza ss otimas chaos Sede ide eae bico dba ads amassado Dentes anais bau E E E 54 13 F383 COM RS422 SERIAL COMMUNICATION CARD uuuu ccsssessscccesssscccrcccecessssssececcesesssssceseeses 57 13 1 P15 CONNECTION PORT sic sees ciassededs sessed OEE EE E AEEA rE EET EEEE EE EIEEE aaa 57 14 INTERBUS S PROFIL F IBS 03 so00000000soo0soseossosoosoessesssososoeossoooseseossossososssesssossseeosssosseoessssssoeossss 59 14 1 GENERAL DESCRIPTION PRP 59 14 1 1 01110 BA A t ETA EE OT E E E ENO E AE E E 59 14 1 2 SLOTS WY OVS ARETE EEE ATE ASIEI ENES EATA AES I E AEE 63 14 2 ROBOT DIRECTIVES UPDATE ccsessssccececsesssseeecececeeseu
31. System All control devices installed in a given welding zone can be accessed directly through a serial line linked to a PC The program permits interacting with all control devices and at the same time controlling the whole welding process of the zone concerned Communication is performed through the WMSNet associated to an RS485 multidrop network or PROFIBUS FMS or ETHERNET TCP IP The serial port of the device has been designed to operate in industrial environment where a number of pulse and electric disturbances are present To protect the input stages these are fitted with disturbance suppression circuits whereas the output stages provide signals ensuring nearly disturbance free level For the application of the welding control devices in the WMSNet PROFIBUS FMS or ETHERNET TCP IP centralising network refer to the relevant specifications While implementing the line a few practical requirements are to be observed by the user Avoid long common paths of line cables with power cables Do not forget this warning specially when planning the lines and the network Limit the network cable length to the minimum required Respect the RS485 PROFIBUS or ETHERNET requirements for length In addition the best results are achieved if the following is taken into consideration Terminate the line as specified in the installation manual of the network card Connect all controls with the network interface card daisy connection so
32. a e WALLSTB Stepper B pre alarm Electrodes wear function A o Cis o 5 7 AND 00000000 INT EU 10 11 12 13 a 14 EVASA Channel A addit Opening solen Solen Valve control On Valve Be 09 nsdovzm 15 EVSB Channel B welding solen Valve Solen Valve control 16 EVASB Channel B addit Opening solen Solen Valve control Valve P23 Functional description of signals Pin Signal Function 1 WALLSTA Stepper A pre alarm Active at 24V This output is activated as a function of the programming of the stepper concerned It does not shut down the cycle It is an indication that the counter is approaching the Stepper Stop threshold Consult the programming manual for the activation of this function The message is memorised in the alarm history 2 WALLSTB Same as WALLSTA but for channel B 3 ALLSTA Stepper A alarm Active at 24V This output is activated as a function of the programming of the stepper concerned Consult the programming manual for the activation reset of this function In the machine shutdown condition the signal can be reset only by setting the counter of the relevant stepper to zero This can be made via the RESASA P24 7 input or through the software reset in the Stepper menu 41 WELDING Cla Sons Weld334m User s manual F356 IOE I O Expansion Card P23 Functional description of output signals Pin Signal Function 4 ALLSTB Same as ALLSTA but for channel B
33. annel A additional opening solenoid valve It is also known as pre stroke or pre approach solen Valve Activated by the CEVASA control this output is protected by an interlocking consisting of 2 relays which inhibits the simultaneous call of channel B pre stroke See cycle time diagrams for the relevant timing Piloting output of the channel B welding solenoid valve Same as EVSA but for channel B Piloting output of the channel B additional opening solenoid valve Same as EVASA but for channel B 43 WELDING Cla Sons Weld334m User s manual F356 IOE I O Expansion Card 10 2 P24 Description of input signals 18 way 3 5mm pitch linear connector for disconnectable terminals Pin Signal Description 6 SOLOPR Pressure only e resaso stepper B aterm reset Dressing done io enero electrodes change de P24 Functional description of input signals Pin Signal Function 1 STARTA Channel A Start Active at 24V The control device activates the EVSA output Gun A call and executes the welding program demanded If Start is interrupted before the pressure cycles have elapsed the EVSA output is deactivated and electrodes open When pressure cycles are got over the Start signal stays in the self holding mode up to the end of the frequency cycles 2 STARTB Same as STARTA but for channel B 3 CEVASA Control to solenoid valve for additional opening A Active at 24V Start of electrodes pre approach
34. ans of the signal ENSERV After a welding sequence has been selected the control pilots the analogue output on the basis of the parameters P1 and P2 set in the welding programme The guns close and the electrodes reach the requested closing force Before carrying out the welding operation the control device waits for the STSERV signal from the servovalve which confirms that the rated pressure has been attained It then imparts the welding pulse If the STSERV signal fails the cycle stops under pressure and welding is not done If the servovalve is used with the current analogue output 4 20 mA the continuity control can be enabled on the output circuit so if connection with the servovalve is interrupted the welding cycle is also interrupted present from F364 D version onwards If the servovalve is not used the PRESSURE OK Input mode parameter in the Setup menu is set to zero For the connections see application diagrams ENSERV WELD334m Analogue signal WELDING Cla Sons Weld334m User s manual 32 F364 SEV and F385 SEV Proportional Servovalve Modules 7 1 1 Voltage outlet characteristics Range 0 10V Single ended type with VSERV pin connected with the OV of the 24SV Minimum load 2k ohm Typical load 10k ohm Converter resolution 12 bit Converter accuracy 3 Isb Protection against permanent short circuits Protection of VSERV outlet pin against accidental contacts up to 36V DC 7 1
35. ard Code 33037600 11 F376 OPC Field Bus InterBus S Card Profile F IBS 03 11 1 Characteristics The F376 OPC card enables the welding I O functions towards the field to be managed as an alternative to the IOE field cards This data communication occurs by optical fiber transmission through a serial bus compatible with the InterBus S protocol InterBus S is one of the most common communication standards in the field of automation The F376 OPC card enables exchange of up to 12 words The actual amount of exchanged data depends on the communication Profile defined for any specific application The word Profile identifies a particular configuration of the exchanged data The F376 OPC card is associated to the F IBS 03 Profile type From the functional standpoint the card is divided into two separate parts the first part comprises the interface electronics towards the control device and is powered by the internal bus the second part comprises an optical interface circuit towards the field powered by an external 24Vdc through the P25 connector Thus the InterBus S serial communication as it is autonomously powered is not interrupted when the power to the control device is OFF The InterBus S interface is achieved through the IBS SUPI 3 OPC Optical Protocol Chip component that ensures a high degree of operational security and an independent diagnostics capability in the quality and level of the optical fiber based signal
36. d threshold A number of causes may generate it e g No current or limit threshold etc It can be of use when intervention on faulty welds is needed 10 OVRCURR Overcurrent Diagnostics Active at 24V It does not shut down the cycle Same as Undercurrent but the current value is in excess 11 READY Control device ready Active at 24V This output is activated when the control device is ready to execute a welding cycle When Alarm1 or Alarm2 is generated this output is low 42 P23 Pin 12 13 14 15 16 WELDING Weld334m User s manual Cla one F356 IOE I O Expansion Card Functional description of output signals Signal STATUS EVSA EVASA EVSB EVASB Function Welding current enable Active at 24V It indicates the condition for Weld Yes when this function is enabled this output is high see also WeldYes Piloting output of the channel A welding solenoid valve Active at 24V It is activated by the corresponding start and is protected through interlocking consisting of 2 relays which inhibits the simultaneous call of channel B If the Start signal is dropped before the pressure cycles are completed the call is not recognised and the electrodes go open again When the pressure cycles are completed the Start signal stays in the self holding mode up to the end of the Holding cycles See cycle time diagrams in the programming manual Active at 24V Piloting output of the ch
37. depends on the operating conditions Ethernet Tcp Ip for WMS GF WELDING centralisation network Parallel standard PCMCIA memory card 0 10V Voltage with protection against short circuit 4 20 mA current The value does not include the voltage ripple 2 3 See characteristics at paragraph 3 3 4 The external synchronism is to be used see paragraph 3 4 12 18Vde Weld334m User s manual 2 4 1 Utilisation characteristics The construction complies with the EC requirements CE marking Operating temperature Storage temperature 40 to 80 Weight 0 to 60 C condensation condensation 2 5Kg maximum depending on the configurations 2 4 2 Dimensions overall dimensions and fastening positions lt 138mm gt 110mm 246mm 237mm 222mm 200mm gt 128mm gt GF UN humidity O to 80 without humidity O to 90 without 13 WELDING Cla Sons Weld334m User s manual 14 Cod 00793702 2 4 3 HHT4300 programming unit The unit connects to the Pi connector of the control device and communicates through an RS485 Full duplex serial port It consists of a rectangular shaped 240x64 dot LCD display 8 lines 40 characters consisting of 6x8 dots Touch sensitive keyboard with integral surface bubble Keys layout 4 arrows enter ENT
38. device side then the external power feeder is not to be earthed Figure d 24VE with earth on the external power feeder side External power feeder 1 O If earthing for 24VE supply has been performed on the external power feeder side then the welding control device is not to be earthed The connection of pin 8 of the PS to the earth faston terminal is required only if the internal power feeder is of F350 type if the internal power feeder is of F370 type the link to the earth faston terminal is done internally and the connection between pin 8 of the PS and the faston terminal is not required 19 WELDING GFLES Weld334m User s manual 20 3 3 General protective devices on power supply General schematic of protective devices Protection A Voltage current limit circuit placed on the power feeder primary 24VI 24VI VE OV Input stage Protection Self reset state type solid fuse Internal power feeder PS On the basis of the type of connection in use the protections operate in the following way Protection A General overvoltage and overcurrent protective circuit This protective device trips in the following cases 1 If when switching on the device the line voltage exceeds the hazard limit of rated ranges 2 In all cases of internal short circuit on the output of the pulse control or of 24V signal of the servovalve 3 In case of
39. e The P7 3 way connector does not take 24V I O supply from the bus it takes the privileged power supply to power the programming unit from the RS485 port P1 How to replace the card Oy Se e ve 10 11 Switch off the machine and disconnect wiring Disassemble the control device from the machine support Remove the front panel by undoing the 3 fastening screws Disconnect the card to be replaced paying utmost care in doing this operation Disconnect the display connector from P3 Pay utmost attention in doing this Check if the new card is fitted with the buffer battery for the permanent memory Verify jumpers on the connectors JP3 and JP6 they must be as follows JP3 3 4 and 6 7 jumpers JP6 1 2 jumper Connect the display flat cable to P3 connector Insert the new card onto the bus making sure that the P7 connector is fitted correctly Put the front part in place again making sure that the PS connector fits correctly into the window then fasten the front panel with the screws Re install the control device onto the machine Connect wiring again Replacing the power feeder The power feeder card can be easily replaced Check that the internal 250V 1 5A fuse for 24VE supply is present before installing the new card How to replace the card 1 2 3 4 5 6 10 11 Switch off the machine and disconnect wiring Disassemble the control device from the machine support Remove the front part buy undoing the 3 fast
40. e from 4 to 20 mA Signal for piloting a current type solenoid valve The valve adjusts pressure on the electrodes as a function of this signal 20mA correspond to 100 of the pressure value which has been calibrated on the proportional valve Load resistor 470 Q range from 200 to 600 Q 3 10 VSERV Voltage output Operating range from 0 to 10V Signal for piloting a voltage type solenoid valve S E R Vv 0 Vv A L Vv E O STSERV ENSERV The valve adjusts pressure on the electrodes as a function of this signal 10V correspond to 100 of the pressure value calibrated on the proportional valve The output is protected against overcurrent and short circuit In case of tripping of the protective device outgoing voltage falls to O Volt Typical resistive load 10K Q 6 STSERV Input Electrodes pressure OK The logic condition OV or 24V can be defined in the Setup stage Before welding the control device waits for this signal produced by the solenoid valve if the logic condition is TRUE 24V the control device gives the welding pulse if it is FALSE OV the welding sequence stays idle with the electrodes closed 7 ov OV solenoid valve power supply 8 24SV Solenoid valve power supply Power supply to the solenoid valve is monitored with a voltage value if it falls below 22 5V 5 of 24V the ENSERV enable signal of the solenoid valve is not activated WELDING Weld334m User s manual Cla one F353 ADC Ana
41. e reset or when the Watchdog indication of Fault condition intervenes Reset push button The Reset push button is placed in the lower part This control has direct influence on the 68332 and is used in case of system shutdown to re start the program with no need to cut off power to the control device The Reset control is not an alarm reset and it must not be used to this end Internal battery for data backup Lithium battery with surveying circuit of the charge status and Supercap high capacity capacitor used to store data during the replacement The battery is housed in a container which facilitates the replacement To replace the battery refer to Appendix A Maintenance Average battery life Extinction Daily Weekly Weekly Operating condition Duration years 6 working days 3 5 working days 4 6 working days 5 4 Pi 9 way Sub d socket connector F384 CPU O LOW BAT RUN RESET RS485 serial communication port for the connection to the HHT4300 programming unit or to a PC pin signal Description HHT4300 unit power supply N C Pin bias 4 RXD Data reception 8 RXD Data reception 9 Tx0 Data transmission Maximum length of connection cable 100m 25 WELDING Cla Sons Weld334m User s manual F384 CPU Microprocessor card Card layout Standard setting of jumpers JP4 5 8 9 Off
42. eceeececsessuaseecececseneaeaeeeceesenesasaeeececeseeeseaeaeeeeeseeee 66 APPEND EX O A EE A A A E A EA E A E 67 APPENDIX A MAINTENANCE ccccccccsssesseceeececsessnaesesececcesesseaeeeeececeesaaaeseesceeseaeaeeeecesceesasaeseeeceesenseaeeeeseseeenees 69 Maintenanceoperations sesruro ar e vips lecevies fato 69 Replacing the modular cards saieiiimaiesraresgeas lecdsaieseuagets cvulacss yavdtodsdedes st suvdeswegved sevdiviaswedeesi dyelesstsevduets condeasnaredzeds donates 69 Replacing the CPU Card cs cacssceelensioapedssvigutan ibalecdieysteddsddeonoastecaet oh Saad uede insta edecediavassnetueteiadgusdesyeteetedavensdsoncteidbdndanedssactase 70 Operating diagramas senademi ads ad EE e gas tala vest Oa E EEEE VENAS AEEKO EIES SEPAK ANE S E AEO AEEA SATa E AER 1 START recognition with use in automated envirOnMent ee ee sceseeecreeseeeeeseeeceeesecsesscesecneeseceeaeeesaeseesaeeeeeaes 2 START recognition with use in manual environment cece eens 3 EMERGENCY STOP condition general diagram eee eeeereeeeees 4 EMERGENCY STOP condition during or outside the welding pulse 5 EMERGENCY STOP excluded with START still active 6 START disabled condition during the welding pulse 7 Proportional Servovalve operating diagram 8 ENABLE function InterbiS S sisce isvessiecs scassncaceassonsscasaxcs scasueak ine ooie iei esiin Eise RE EEE
43. eceenseeeeenneeens 2 1 1 1 E ITO EN ETEN EEE E A EAE E E T DE 2 1 1 2 Conditions to be respected to reduce the hazard 2 Liy A CAUSCS Of hazard aseet e r a a DR a a a ea ara e 2 1 2 OBSERVATIONS ON CONNECTIONS cecstaiorsonieniremdeianies EENE AE ges deudvestacsadcxevedrectessnaessaudierteiandexeenceaendhorves 4 1 2 1 Earthing ins lati omens orninan rai a aris I a EEE TO E terest SE ESEE EE 4 1 2 2 Safety criteria against short circuits ccceccceceeccecessecsseseceseeseesetseesecaseseeseesesieesecseesencesseetensseeeneeeteees 4 1 2 3 CurrentiSenSOR orsin d rdar a a a a lar d 5 L24 Power suppesa a ee DTD RREO RN ee a ae 6 1 2 5 Phase synchronising for Welding c cccccccccccccsceescessceeecececeseeeeceeeceseeeeceecesecseceaecsaecaeeaeeeseeeseeessenseensees 7 1 2 6 Programming unit essessssriesirsiroryiiiseregriotit rerio rers on r i SKKS ENEE ESE REKET EEEE EREE ENE EER E niin 7 1 2 7 Connecting the Weld334m with the WMS central network cccccccccseeceeceeeteeeceneecusecteeaeeeaseestensees 7 2 CHARACTERISTICS AND GENERAL DESCRIPTION OF THE WELD334M scccssssscessseceessseee 9 2 1 GENERAL DESCRIPTION cccscccssscesssesssecessceesseceesecsaeceseeecsaeceeeeesaeceseeecsseceseeecsaeceeeeecsaeceesecsueceaeesaeeeaees 9 22 BLOCK DIAGRAM OF 334M uciasssasress sas sealisianas Eni sco nere E ee 10 2 3 HARDWARE CONFIGURATION oiii Ea E E E AE LE amada RL COTA Ned TEUS E ENERE E ts 11 2 4 CHARACTERISTICS 2 secede veh e a a a Ea
44. ects If possible minimise the quantity of interruptions terminal boards and or plugs Do not use fuses on the current sensor conductors The rules cited above are to be observed by all users carrying out installations and wiring as well as by those who design and manufacture electric switchboards in cabinets transformers and other equipment which are someway associated or associable to current sensors The non observance of these rules entails loss of accuracy and repeatability in the welding process with constant current control device In addition this could cause serious malfunctioning It is recommended to use current sensors featuring 150 mV kA 1k Q sensitivity and with a 20 25 Q internal resistor these can be ordered from GF WELDING S p A The Weld334m permits using up to 6 sensors in series one at a time is active when welding The quantity of sensors connected is to be set on the welding device see Programming manual Setup chapter 1 2 4 Power supply Depending on the configurations the Weld334m input can be both direct current and alternated current See operating characteristics One assumes that power supplied to the system is clean meaning it is free from electrical disturbances and showing no voltage drops In case of AC it is recommended to use a power insulation transformer with earthed electrostatic shielding WELDING Weld334m User s manual fe eins 1 2 5 Phase synchronising for welding To
45. eescsesseesecaeeeeeaeeseeseeseeaeeneeats 18 3 3 GENERAL PROTECTIVE DEVICES ON POWER SUPPLY ssssccessssseeessseeecssneececaeeecsesaeeeceesaeeeseaeeecsesaeeesseneeees 20 3 4 SETTING THE EXTERNAL SYNCHRONISM csssesceceesseeecseseeceesneeecsssuececseseeceeaesecsesaeeecseeeeeesueeecsesaeeeseeeaaees 21 4 F351 BUS INTERCONNECTION CARD csssscssssccsssscccessscccscssccecsssaccsessseccecsaceecessacceessnsccscssseeeesees 23 5 F384 CPU MICROPROCESSOR CARD cssssccsssssccessnsccecsccecessscccessnscceessccececaceecesseccsessceceessscscessnsees 25 6 F353 ADC ANALOGUE CARD sscnesscoossesecastesiraroamt ince vasesoce cannons ccccopeseuscisesedecdetcecesdeuscesedsccesvsbsetooseeeeee 27 6 1 P3 E P4 DESCRIPTION OF THE ANALOGUE INPUTS cccssscessssceeesssececssseeceeseeecsesaeeeceeeaeeessaeeeeseaeeesseeeeees 27 6 2 P2 DESCRIPTION OF THE SIGNALS FOR THE SOLENOID VALVE AND THE TFE cccccccceececeessseeeesseeees 28 7 F364 SEV AND F385 SEV PROPORTIONAL SERVOVALVE MODULES 0 ssccccssseecesssrccesssees 31 Ted SERVOVALVE ADJUST weccsecsacccassczccesesccedesesecdebensecacssnsensesancstedsasceapesendsansecesaaceanndssessaassacesaesscncaiessneeaneseiesas 31 FAD Voltage Outlet Characierist es ccccetccedsceieestesan sefeasinceses tase cass theutensthas a a aaa n ad 32 7 1 2 Current outlet characteristics eee teeeereeeeea aeee rece aaa ae ceara aaa nana crer eea aaa aaa re arena 32 7 2 CONNECTION OF THE F364
46. ening screws Remove the 5 screws fastening the power feeder to the fastening brackets Disconnect the power feeder from the bus Check that network sync jumpers on the power feeder are set in the correct way internal or external see paragraph 3 4 Connect the new power feeder making sure it fits properly into the connectors Ji and J2 of the bus Screw it down Put the front part in place again making sure that the PS connector fits correctly into the window then fasten the front part with the screws Re install the control device onto the machine Connect wiring again WELDING Weld334m User s manual Cla one Replacing the welding control device Times indicated refer to a manual welding station 1 Saving the configuration and programs of the control device to 1 Minute be replaced on a Ram Card 2 Dismantling the control device to be replaced from the welding 3 Minutes machine support 3 Mounting the new control device 3 Minutes 4 Switching On the new control device and verification that no 1 Minute diagnostics alarms are On 5 Inserting the Ram Card and loading the programs and the 1 Minute configuration of the new control device Time for replacing the device totals to 9 minutes approx Modifying a welding program The operation is to be carried out by qualified personnel with optimum knowledge of the control device programming Time taken up to modify a program depends on the
47. ens F383 COM RS422 Serial communication card Code 33038300 13 F383 COM RS422 Serial communication card RS422 serial interface for the communication with a remote device The communication protocol depends on the functional goal that has to be achieved Features Data transmission speed 19 2 kBit s eee Maximum length 1000m TXD RXD LEDs The 2 green LEDs TXD and RXD on the front panel are used to monitor the serial port When the communication occurs properly both LEDs are blinking In case of an anomaly in the serial port or in the cable one or both LEDs remain switched ON or OFF 13 1 P15 Connection port Sub D 9 pin Female Connector Pin Signal Function O o nef Not connected a Rao Non inverting differential input ps ne Not connected 6 ne Noticonnected Recommended connection components e Connector Shielded male 9 pin SUB D connector e Local and remote connection cable out of the cabinet 500m max Shield connected to the connector case Serial cable features 2 twisted pair 1 wire single shield 0 35mmg minimum section E g LappKabel Unitronik Li2YCY TP 57 GEES Weld334m User s manual F383 COM RS422 Serial communication card Card layout U3O u3 U33 u30 U314 5u32 U32 P15 U34 LD2 LLX u25 u27 U23 u22
48. ensor with 20 25ohm internal resistance CURR SENSOR Sensitivity adjustable O Facility to connect up to a maximum of 6 sensors in series For correct use see setting parameters indicated in the programming manual For the connections refer to relevant application diagrams O Pin Signal Description SS Positive signal 4 TA Negative signal NOTE The control device can be operated even if the F353 ADC card is not installed but in this case only the normal welding mode is allowed This type of operation however is detrimental to the processing quality and it has now been superseded 27 WELDING Cla Sons Weld334m User s manual 28 F353 ADC Analogue Card 6 2 P2 Description of the signals for the Solenoid valve and the TFE The two green LED indicators are for the proportional solenoid valve and their function is the following ENSERV illuminated when the relevant output on P2 is active STSERV illuminated when the signal is present on the input 15 way Sub d socket connector pin signal Description Sd Analogue voltage input 6 sTSERV senovavesamsimpir Solenoid valve power supply O TFE Analogue voltage input P2 Functional description of signals Pin Signal Function 1 2 9 TFE Analogue voltage acquisition channel This input can be used for receiving the indication of the electrodes force through a dedicated transducer 4 12 ISERV Current output Operating rang
49. er s manual Cla one F360 IOB I O Basic card P21 Functional description of signals Pin 9 10 11 12 Signal FINE SEQ RICHSALD RICHSALD CONSALD Function Output active at 24V At the end of frequency cycles electrode opening the control device activates this output and terminates the sequence If Repeat Function is enabled the End of Sequence is not performed and the control device goes on starting from pressure cycles See diagrams relevant to cycle time on the programming manual Output NO relay contact At the end of the pressure cycles the control device ready to execute the welding pulse activates the request for welding and waits for the consent CONSALD CONS TO WELDING It needs a common wire contact 11 connected to 24V P21 F360 IOB RICHSALD 10 TOTO 8 RICHSALD Commun 11 all Rq for Weld For the connection refer to application diagrams Consent to welding Input active at 24V The consent to welding is the enable signal for welding it is an indication that the welding machine is ready It is tested after the Request for Welding Signal has been activated When not in use this input is to be connected to 24V p21 F360 IOB CONSALD Cons to Weld CONSALD 12 x l d 24V For the connection refer to application diagrams 39 GEES Weld334m User s manual Card layout jumpers setting JP1 Off Ji 2 3 24
50. est position of the pneumatic valves in use during the operation this situation affects the whole plant If during the welding process the cooling water flow is low or non existent it is prohibited to bypass or inhibit the tripping of thermostats or the water flow control device if installed Weld334m User s manual GrFLES High magnetic fields generating very close to the welding gun and the secondary cable represent a serious hazard to people and property e g watches cables for electric data transmission magnetic devices medical equipment and pace makers Welding is obtained through the periodical repetition of high single phase short time and low cosphi current pulses These conditions of use may cause disturbances to the power lines of the production plant and may be hazardous for other types of operating machines or machine tools Outputs of the welding control device solenoid valves are all protected by a series connected contact of the cycle start relay This to prevent any faults or disturbances of the electronic outputs from causing undesired controls The Start cycle function is equipped with a time dependant consent control at the plants and countries demanding for it In cases where local safety regulations require or prescribe such as for machine start for instance two hand cycle start controls with check of simultaneous operation these devices shall have to be implemented when installing the system Outpu
51. for these 2 jumpers 24V I O 24V PULS Com IMP BUS W334m IoB module 17 WELDING Cla Sons Weld334m User s manual 24V I O can be managed in the following ways Direct 24VI supply with pins 5 6 of PS being free see paragraph 3 2 2 figure a Ji connector jumpers of I O and ADC cards to be made in position 1 2 Indirect 24VI supply with pins 5 and 6 of the PS make jumpers or cut them out from a contact see paragraph 3 2 2 figure b 24VI supply which in this way can be cut out from the outside enabled disabled is re closed on 24VE line External with external 24V supply connected to pin 6 and pin 7 of the PS see paragraph 3 2 2 figures c and d Summary Table of 24V I O jumpers of cards Internal indirect 1 2 Where present 3 2 2 24V connections for discrete I O Figure a Use of 24VI supply in direct way Power supply External sync 24 I O ov Figure b Use of 24VI in indirect way Power supply External sync 24 I O OV 24VI is cut off on the PS between pin 5 and pin 6 Thus 24V supply of I Os can be enabled and disabled independently of the control device 18 WELDING Weld334m User s manual fe eins Figure c Use of 24VE external with earth on the Weld334m side Weld334m External power 24 feeder ESSO ed I O sabe ov If earthing for 24VE supply has been performed on the welding control
52. g pulse to the SCRs to be synchronised with the mains of the SCRs the two jumpers for the line synchronism must be set on the card F350 PSM Line synchronism selection jumpers internal external my I K I PWR RTN 1 When the control device is powered from the a c mains taken directly H from the power line of the SCRs jumpers are to be set to PWR RTN i standard configuration 2 If the synchronism signal is to be taken directly from the power group PWR RTN through an attenuation insulation transformer the jumpers are to be set ojo on S1 S2 This configuration is compulsory when the device is powered from the d c mains s1 s2 NOTE The secondary of the insulation transformer is not to be earthed Example of connection for the external synchronism WELD334m PS Vdc power supply or Vac gt 1 ivi Power supply 380Vac line privileged gt 2 Insulation tranformer External 12 33Vac synch 4 Firing device Pulse 2 control P21 21 GEES 22 Weld334m User s manual WHITE PAGE GEES Code 33035100 Weld334m User s manual F351 BUS Interconnection card 4 F351 BUS Interconnection card BUS interconnection card for signals and power supply J2 connector takes 24V supply for the I O power supply Ji connector takes 5V supply for the cards and V f
53. gnostic controls on the welding spot being performed are activated monitor welding 63 WELDING Cla Sons Weld334m User s manual 64 InterBus S Profil F IBS 03 mode or constant current 7 STATUS Bit 1 Execute welding cycle with current enabled The welding cycle will be executed with current that is to say under command of the power group 8 Danger Alarm Bit 1 Signals that the control has detected the Circuit br trip condition of current without start 9 STSERV Bit 1 Signals that the proportional valve has reached the required setup value 10 MAXPWR Bit 1 Signals that the control is operating with the minimum admissible striking angle 11 UNDERCURRENT Bit 1 Signals that the welding current measured is below the minimum tolerance admissible 12 Hardware Alarm Bit 1 Signals the presence of an alarm with ALARM 2 error code gt 50 planned alarm 13 15 Not used Status Word 2 Status Word 2 defines the commands relating to the management of supplementary stepper functions and of accessory functions or Description OC OC l o resetstepergn O OC SS 6 Resetste peron7 O C O 6 nes O DO nos TT Status Word 2 Functional description Bit Signal Function 0 7 Reset stepper Bit 1 Stepper gun no reset gun 1 8 Resetting of stepper counter no is confirmed see description of spec s at par 14 2 8 14 Not used 15 Communication Error du
54. gram 1 255 in binary code Functional description of bits 5 and 6 of Control Word 1 Description Action taken Reset alarm All active error messages are reset alarm with All active alarms are reset If the START signal is Sequence End still present the Sequence End signal will be activated Reset alarm with All active alarms are reset and if the START Sequence Repeat signal is still present the sequence is repeated 60 Weld334m User s manual GrFLES InterBus S Profil F IBS 03 Control Word 2 Control Word 2 defines the commands relating to management of the supplementary functions of the steppers and of accessory functions Bit Description S 0 JResetsteppergunt S O 6 Reset steppergun7 _ _ S OE 8 Jntused S Oe 9 Inotued o O 11 Not used Not used Start log Stop log Reset communication fault Control Word 2 Functional description Bit Signal Function 0 7 Reset gun 1 8 Bit 1 Reset gun no stepper recognized stepper Information that stepper counters no s reset is confirmed see specific description at para 14 2 8 12 Not used 13 Start Log Data storage for the protocol function for test pieces begins 14 Stop Log Data storage for the protocol function for test pieces stops 15 Reset Communication fault alarm is reset Status word 2 Communication bit 15 Fault 61 WELDING Cla Sons Weld334m User s manual 62 InterBus S Profil F IBS 03 Contro
55. have correct welding operation the device is to be synchronised with the same power phase as the SCRs it is piloting Considering the power supply features of the device synchronising may take place in a different manner depending on the following cases If powered from the Ac mains it is sufficient for the transformer powering the device to be connected with the same power phase as SCRs e If powered from a power line other than that of SCRs or DC powered the sync signal must be taken from the power side through an insulation transformer For the use of the external synchronism see paragraph 3 4 The non observance of these rules will cause serious malfunctioning 1 2 6 Programming unit Great care is to be paid to the switching on and off of the HCM 4300 HHT graphic programming unit The input port can be damaged both because of a short circuit during the connection work and further to electrostatic charges Put the HHT metal casing in touch with that of the Weld334m before installing the connector This will discharge the static charge Make sure no foreign bodies such as metal chips or slags fall inside the connector Any damage to the HCM 4300 HHT graphic programming unit and to the Weld334m resulting from tampering or deliberate disregard will void the guarantee 1 2 7 Connecting the Weld334m with the WMS central network To centralise the welding zones GF WELDING has developed a program called WMS Welding Management
56. it is enabled and disabled with O to 24V ramp up pulse type Signal reading time lt 100mS If not used this input is to be connected directly to 24V 4 CEVASB Same as CEVASA but for channel B 44 WELDING Weld334m User s manual Cla one F356 IOE I O Expansion Card P24 Functional description of input signals Pin 5 6 10 Signal SALDASI SOLOPR RESASA RESASB RAVOK CHGEOK CODEO CODE1 CODE2 CODE3 CODE4 CODE5 Function Weld Yes Active at 24V It enables the welding current Also the following functions are to be active Weld Yes in the Setup stage and the selector located on the front of IOB card The control device activates the Status output 24V when the Weld Yes function is enabled See programming manual Pressure only OFF active It is used for the gun setup Usually at 24V if it is open during the welding sequence the following occurs e The sequence is interrupted Electrodes are closed and under pressure e The control device waits for 24V signal on this input e The RICHSALD output is low If the Start signal is released the call is interrupted and the gun opens If SOLOPR goes high the sequence is resumed the control device makes the RICHSALD output go high and the process continues according to the status conditions of SALDASI WELDYES and CONSALD CONS TO WELD functions Stepper A alarm counter reset Active at 24V It clears the coun
57. l Word 3 Control Word 3 defines the Spot Index The Spot Index is an index that can be defined from 1 to 65535 used to select a welding spot contained in a database specifically created and managed through tne FASE SALDATURA WMS centralisation program Each Spot Index in this database is associated to a working name generally the name of the spot to be welded and a reference to the welding program that must be performed In each welding control the necessary part of the database is saved through the WMS centralisation program Signals sent by the Weld334m on the welding status diagnostics program called up electrode pressure etc are integrated with a Spot Index value and the name of the welding spot WARNING If there is no specific parameter setting where a program code value different from zero Control Word 1 bit 8 13 and a Spot Index value different from zero Control Word 3 bit 0 15 appear the welding control will perform the selected sequence with the program code sit Description TT o Spot index selection wto SCSCSCS S 6 Spot index selection wte 8 Spot index selection bts o lt o spotindexselecindts For further information please see the WMS manual WELDIN Weld334m User s manual Cla one InterBus S Profil F IBS 03 14 1 2 Status Words Status Words indicate to the remote interface device the
58. lding transformer must be placed as close as possible to the welding electrodes Thus maximum accuracy is achieved However this mounting position is not always possible A good compromise lies in mounting the sensors in the rear part of the guns near the cable adapter Provide for protection against shocks It can however be always placed at the transformer secondary output WELDING GFLES Weld334m User s manual The lead run through by current is to be placed in the middle of the thoroid The sensor is to be placed as far as possible away from any edges or elbows of the secondary lead As for the turn formed by the secondary circuit it is necessary to mount the sensor in a position so that the distance between the go and return conductor be the maximum possible one As for the sensor connections the following requirements are to be adhered to The connection cable is to be tightly twisted and screened and is to be run as short as possible In any case its laying is to be done as far as possible away from sources of electrical or magnetic disturbances and it must not be run in parallel with the cable for welding component primary secondary The cable screen must be bonded on only one side of the welding control whereas no sensor end is to be bonded Accurately avoid joints or provisional connections between the sensor and the connector of the welding control in order to minimise any inductive and capacitive eff
59. les The F364 SEV or F385 SEV module housed internally on the F353 ADC card is an analogue driver with two outputs a voltage output and a current output used to pilot a proportional servovalve The proportional servovalve is able to adjust the pressure inside a pneumatic circuit automatically on the basis of an analogue voltage or current signal from the welding control device The welding gun pneumatic cylinder converts the pressure in the pneumatic circuit into an electrode closing force This function is of great importance for process quality The electrode closing force the time during which current flows and the welding current are the three main parameters that determine welding quality With the proportional servovalve the electrode closing force can be kept under control For use and programming of the proportional output please see the Control Device Programming Manual 7 1 Servovalve Adjust The pressure servovalve must be adjusted for two operating conditions the first is the line pressure under machine stopped conditions the latter refers to the working pressure of the cylinder These adjustments are dependent on the settings entered in the Setup menu and in the welding program see Programming Manual On the basis of these settings the Weld334m pilots the analogue voltage output over a range from O to 10V or the analogue current output over a range from 4 to 20 mA The control can enable disable the servovalve by me
60. logue Card P2 Functional description of signals Pin Signal Function 11 Shield ISERV o VSERV servovalve signal screening 15 ENSERV Output Active at 24V Proportional solenoid valve enable Before commencing the adjustment operation the solenoid valve waits for this signal from the control device ENSERV output is deactivated when e Solenoid valve power supply falls below 5 e I O sequence is during cold processing cycles e CPU is in the reset status Card layout standard setting of jumpers J2 1 2 Jp5 Off We Ry 8 re pm J3 J1 E zs R eh ae E q 13 5 Lo E 8 z E S fo fen ee af IL FILE 9 E zn 8 5 5 stn ojlo a E E a jo 5 5 E E Ay 5 PT2 Lo ow gt Lo 5 mT o ozn als 3 8 2 E dO FEF do eai Ed 2 waa h ra 1 es F r pra ay 29 CFS 30 Weld334m User s manual F353 ADC Analogue Card WHITE PAGE WELDING Weld334m User s manual Cla sons F364 SEV and F385 SEV Proportional Servovalve Modules Code 33036400 33038500 7 F364 SEV and F385 SEV Proportional Servovalve Modu
61. ns o Jo E o 4 F 4 cabin z 81 Weld334m User s manual seles EEN D E o ie Aba K E 724 al g a o E gt Power supply A lt SCR control SCR temperature Welding transformer i Set variables Current voltage guns pressure Guns Paramete I O signals lt lt I O Signals GEES WELDING Cla Sons Weld334m User s manual Ethernet Tcp Ip Example of network architecture HUB Ethernet 10BaseT Ho DDODDODDDODO Card of o o A O oo E 00 o Ha H ul A maximum of 127 controls can be connected Signal connection depends on the type of port present on the HUB which can be of the MDI or of the MDI X type 82 Weld334m User s manual InterBus S Example of network architecture 24V 422InterBus S Connection GEES
62. on the machine equipment and the welding transformer only after breaking the connection from the mains This to be sure that no undesired switching of electrical current occurs Work on the spotgun and welding cable connections only after breaking the connection from the mains power 1 1 3 Causes of hazard The programming of the welding control is entrusted only to qualified personnel Incorrect parameter settings may cause damage or injury because of undesired molten material splashes during welding It is compulsory to wear protective goggles non flammable clothes and protective shoes Dangerous conditions may arise when for example electrodes are changed or dressed and no current re adaptation re setting takes place especially when using the stepper function stepper reset If 24V power supply is external to the machine or the control device power may be applied to the equipment even if the main switch connection is broken During mounting setting of work maintenance and or repair operations hazards may occur because of the exchange of leads air water pipes etc Unqualified personnel may be unaware of the risk that such changes modifications entail therefore all changes modifications are only to be entrusted to and or performed by qualified personnel Hazardous situations may arise because of mains voltage drops or in case of tripping of the machine emergency stop device which causes the return to r
63. onments showing electromagnetic field pollution In the design phase systems have been adopted which respect the EMC requirements with the surrounding ambient It is recommended to scrupulously observe the conditions of use meaning by this that the Weld334m cabinet is to be closed and all its earth leads must be connected In compliance with the accident prevention Standards the welding control does not act directly on the SCR block the SCR switching is operated through a special external firing circuit which is isolated from high voltage present on the power circuit 1 2 2 Safety criteria against short circuits On a welding machine the short circuit is likely to occur on the transformer primary side This may entail very serious consequences such as for example On a Robot or an automatic installation the destruction of parts onto which the short circuit current is discharged On a manual station the electrical shock of the operator and damage to the equipment The short circuit may occur between the primary and ground or between the primary and the secondary 380 500V WELDING Weld334m User s manual cF Here below are a few measures which are to be taken in order to avoid harm and damage to operators and equipment 1 Earth the welding transformer secondary 2 Install a differential on the welding transformer primary set to the minimum value of current 30mA a o 380 500V D oS Differential
64. ontrol Words are commands relating to the welding sequence sent from the remote interface device to the welding control Control Word 1 Control Word 1 defines the commands relating to the fundamental welding functions ee Depto SSCS DO START C O 4 ResetaAlame O O o y 6 Reset Alarme 8 CODEO S O 9 CODE o y 59 WELDING Cla Sons Weld334m User s manual InterBus S Profil F IBS 03 Control Word 1 Functional description Bit Signal Function 0 Start weld Bit 1 Start Command program The number of the welding program is acquired and the related cycle is started 1 RAVOK Bit 1 Electrode dressing completed The signal is sent to the control that the requested dressing has been completed The signal must be active for at least 100 ms 2 Servovalve Bit 1 Authorisation to enable the servovalvolve When this bit is at 1 the control can send the ENSERV signal to the servovalvole 3 CHELOK Bit 1 Electrode change completed The signal is sent to the control that the requested electrode change has been completed The signal must be active for at least 100 ms 4 Reset Alarm Bit 1 All alarms no longer active will be reset without further action from the welding control 5 6 Reset alarm See next table 7 WELD Bit 1 Enable cycle with current YES NO The welding cycle must be performed with current that is to say commanded by the power group 8 15 Program code Selection of welding pro
65. or programming unit HHT JP1i connector is used to power the programming keycard via CPU The connectors JP2 3 4 5 6 distribute 24VI and 24VE supply for the I O points Connectors P1 6 form the digital BUS Power supply HHT4300 Bus 24V I O F384 CPU F351 BUS The position JP1 P1 is typical for the CPU card all the remaining positions are available for the control device configuration The BUS module needs no preset 23 CFS 24 Weld334m User s manual F351 BUS Interconnection card WHITE PAGE Weld334m User s manual F384 CPU Microprocessor card 5 F384 CPU Microprocessor card GEES Code 33038400 This is the system calculation centre and it is fitted with a MCU Motorola 68332 card 20MHz clock Data and program RAM resides on flash eprom 1MB Permanent data is stored in a buffer battery The CPU has 2 ports an RS485 full duplex port for the HHT4300 programming terminal or a Laptop P1 Sub d 9 way connector located on the front part and another one for connecting the multifunctional display internal port CPU status Led indicators LOWBATT RUN Red illuminated during power reset when switching on the Control device and when the reset is given via the push button If it stays On during the operation RUN led indicator illuminated this indicates that the battery is nearly down Green the processor is operating correctly when illuminated This indicator is OFF during th
66. overcurrent if 24VI for I O points is used both in the direct connection mode see paragraph 3 2 2 figure a and in the indirect one see paragraph 3 2 2 figure b With this type of connection the protective device A which features a faster switching time prevails on the device B In order to reset the functional conditions it is necessary to cut off power and remove the cause of the short then switch on the device again after about 30 If by activating it again the device does not switch On RUN led indicator of CPU Off then check that line voltage is correct and that it complies with the characteristics indicated if not the control device will stay off due to the protection device If all these conditions are observed but the device does not switch On the power feeder is likely to be damaged Replace it Protection B current limit circuit on the external 24V supply It intervenes in case of use of the external 24V supply for the I O points see paragraph 3 2 2 figure c Once the cause has been removed the protection resets automatically Characteristics of current limitation as a function of temperature Power feeder type F350 PSM Temperature C Current A WELDING Weld334m User s manual fe eins Power feeder type F370 PSM Temperature C Current A Characteristics refer to the operating temperature of the component itself 3 4 Setting the external synchronism For the firin
67. p Connect the small cable of the display and tilting the card sideways fit it into the slot Insert the card close to the F384 CPU making sure that the P7 fits correctly Put the front part in place again checking that the PS connector fits into the window then fasten the front part by using the screws Re install the control device onto the machine Connect wiring again It is of paramount importance that the battery clip be always fitted WELDIN Weld334m User s manual Cla one APPENDIX B Diagrams and network configurations Operating diagrams This section illustrates a few operating diagrams of the control device which allow analysing timing and synchronisms referred to the Start and Emergency conditions in manual or automated environments 1 START recognition with use in automated environment Min 10mS Program code 24 Program parity EVS Analog pressure 1 The program code is saved Any successive changes have not effect 73 74 GEES Weld334m User s manual 2 START recognition with use in manual environment Ti 20mS Program code Program parity Call recognition AT Min 40mS Max 60mS since Start 1 Start and Program Code must stay stable WELDING Weld334m User s manual Cla one 3 EMERGENCY STOP condition general diagram NOTE The Emergency stop signal is active at OV not considered still hold Pgm 1 PGM 2 Now Start 7 ST
68. ring storage on network support of data Fault relating to the protocol function for test pieces WELDING Weld334m User s manual Cla one InterBus S Profil F IBS 03 Status Word 3 Status Word 3 defines two Bytes included between bits 0 7 and bits 8 15 to communicate the technological parameters necessary to manage an electric gun such as electrode closing force WELD FORCE and the thickness of the part to be welded ELEMENT THICKNESS Bit Description TT 0 weldForcebito S O 6 Weld Force bit6 S O 7 Weld Force bit7 S y O 8 Element Thickness bitO Cd 9 Element Thicknessbitt CC Status Word 3 Functional description Bit Signal Function 0 7 Weld Force With this byte the control communicates the value of the electrode force defined in the welding programme It is a parameter that replaces the analog signal for application of the proportional servovalve The field of regulation of the force is between 0 1275 daN one bit is the equivalent of 5daN 8 15 Element With this byte the control communicates the element Thickness thickness defined via WMS and assigned to the welding spot The field of regulation of the thickness is between 0 12 75 mm one bit is the equivalent of 0 05mm This parameter is located in the WMS in the User Parameters area of the welding programme fs Please see the WMS programming manual 65 WELDING Cla Sons Weld334m User s manual InterBus S Profil F IBS 03 14
69. status of the welding sequence and the status of the control and functionality of accessories in general Status Word 1 Status Word 1 defines the standard welding outputs e beca TT 0 FINESEQ o O 6 fpocessconmo O O OCC SoS e Danger Alarm arcuit breaker tripped Do E CSC s CS SCSSC d Status Word 1 Functional description Bit Signal Function 0 SEQ END Bit 1 When operating in single spot mode indicates the end of the sequence if the welding cycle has been completed without anomalies 1 RICHRAV Bit 1 The welding control requires electrode to be dressed The bit is set to O when dressing gives confirmation through the signal electrode dressing end 2 PREALARM Bit 1 One of the electrodes has reached the programmed value for warning of electrode wear 3 RICHEL Bit 1 One of the electrodes has reached the value programmed for end of electrode life The maximum electrode life has been reached The bit is set to 0 when the counter has been reset 4 READY Bit 1 The welding control is ready to perform a welding cycle 5 ALARM1 Bit 1 During the last welding cycle an anomaly occurred in the welding process The bit will be set to O after reset alarms 6 PROCESS Bit O The diagnostic controls on the welding CONTROL spot being performed are not activated normal welding mode or current sensor disabled Bit 1 Dia
70. t O FK FINESEQ Sequence end active Status Word 1 Bit 0 MS STATUS Weld YES enabled Control Word 1 Bit 7 BE READY Control device ready Status Word 1 Bit 4 TR Transmit Communication through PCP None Receive protocol active SP SPARE Not used Available for future uses uL cc RDO OBA UL RC RD BA LEDs FO1O OFO2 These LEDs indicate InterBus S port communication functions UL Green On When OFF it indicates a reset condition RC Green On when OFF it indicates InterBus S reset active Off When ON it indicates BUS IJInterBus S disabled BA Green Jon When OFF it indicates InterBus S inactive FO1 Yellow Off When ON it indicates a fault on the REMOTE IN optical interface e g reached limit level of the optical fiber signal FO2 Yellow Off When ON it indicates a fault on the REMOTE OUT optical interface e g reached limit level of the optical fiber signal 50 WELDING Weld334m User s manual Cla one F376 OPC Field Bus InterBus S Card Identification code ID Code The welding control devices are considered by the InterBus S net as digital devices belonging to the Profile conforming digital devices with I O addresses PROFILE DIO This functional category corresponds to the decimal identification code ID code 47 2f hexadecimal 11 5 Error conditions with the control device shut down During InterBus S line working the communication protocol recognizes two shut down conditions of the
71. ted at the side of PS connector 3 1 1 PS Description of signals 8 way 5 08mm pitch PS connector for disconnectable terminals Pin Signal 1 2 PWR RTN 3 4 SYNC 5 24VI 6 24VE 7 ov E E Description Main power supply of the control device The device can be powered from either d c mains from 18 to 36Vdc and a c mains from 14 4 to 32 4Vac with no need for the user to change the connections or the internal settings If powered from a d c source the pin polarity is irrespective of this status NOTE if the unit is fed from a d c supply the external synchronism must be used External synch signal Sensitivity 12 33Vac It permits the synchronisation with power supply on the power side SCR through an insulation transformer connected to the same phase This must be used when the unit is powered from a line separate than that of the welding machine or when it is powered from the d c mains If used this signal must be configured on the power feeder card through 2 jumpers see paragraph 3 4 24Vdc output internal It is used when one wants to use 24V supply internal to the device for powering the I O It can be cut out for enabling 24V from a remote unit Robot For the connection refer to paragraph 3 2 2 figure b 24Vdc external input for discrete digital I O Max Load 1 5A For the connection refer to paragraph 3 2 2 figures c and d Input for OV external common for logic I
72. ter of spots active on channel A if no dressing or electrodes change is active Same as RESASA but for channel B Validation of Dressing done Active at 24V This input is to be activated when the electrode dressing has been done further to the Request for Dressing Signaling It inhibits the alarm signaling sets the welding spot counter to zero and increments by one unit the counter for dressing operations done in the electrodes wear program Validation of electrodes change done Active at 24V This input is to be activated when the electrode dressing has been done further to the Request for Electrodes Change Signaling It inhibits the alarm signaling and sets to zero all counters of stepper concerned Active at 24V Inputs reserved for the selection with binary code of the welding program to initialise at Start When the Start function is active the control device reads the active code on these inputs and performs the relevant program see list of codes on page 47 Facility to use up to 64 welding programs IMPORTANT To select program 64 all inputs of program codes are to be OV logic 45 GEES Weld334m User s manual F356 IOE I O Expansion Card P24 Functional description of input signals Pin Signal 17 CODEP 18 RESAH Function Parity Code Active at 24V It is used only on robot operated lines It is used for the logic check of CODEO 5 inputs and is dependent on the setting done in
73. the Setup menu see list of codes on page 47 Warning If not used this input must be disabled see Setup section of programming manual Hardware alarm reset Active at 24V It inhibits the machine shutdown Alarm 2 occurred during the processing Card layout Standard setting of jumpers Ji 2 3 JP1 Off J1 K1 O ul n gt D3 Cy P7 46 ol a mm 4 Ge O L Ea ae O Eos eim a Ez 5 E LE yin o E a K S sin E 09 q S Bgg Eai 3 m e o eee z z z z a 1 L A JP1 a RA HS q 6 3 l s AG a 6 ei 0 2 D s 2 O cl Eu la FP TU 5 SI g l le 91 Ly z 2 18 Ei e E qT por gt 5 o SO ie C PF1 WELDING Weld334m User s manual ejgv one F356 IOE I O Expansion Card 10 2 1 List of program selection codes The list below shows the binary codes of the 64 welding programs Binary code Fa copep Eve 47 GFIEES 48 Weld334m User s manual F356 IOE I O Expansion Card WHITE PAGE WELDING Weld334m User s manual fe wens F376 OPC Field Bus InterBus S C
74. to have only one line of transmission The cable is to comply with the relevant RS485 Profibus or Ethernet specifications WELDING Cla Sons Weld334m User s manual WHITE PAGE WELDING Weld334m User s manual cF 2 Characteristics and general description of the Weld334m 2 1 General description The Weld334m is a control device intended for single phase AC powered resistance welding machines It is capable of managing all the operations run by the machine it is associated with the Weld334m also provides adequate diagnostics for the plant and welding process and carries out welding current regulation by chopping the voltage applied to the power transformer The Weld334m can be field programmed via the HHT4300 graphic unit or through the centralising network via a remote computer equipped with the WMS software and the adequate communication card It permits running up to a maximum of 255 welding programs and 16 different self increment programs stepper The internally mounted clock provides the correct absolute timing reference this function is also available for the stand alone utilisation meaning with independent control The HHT4300 programming unit is removable thereby preventing any interference of unauthorised personnel on the welding programs The operating frequency of the unit is 50Hz or 60Hz Facility is also provided to memorise and transfer data and programs through a commercially available PCMCIA type memor
75. ts for the pre stroke solenoid valves controlling the additional gun opening feature direct control as well as the output for the proportional solenoid valve These two outputs do not cause any movement nor do they operate the gun to close fully WELDING Cla Sons Weld334m User s manual 1 2 Observations on connections 1 2 1 Earthing insulation This paragraph deals with the earthing of the equipment please ensure that all earthing is correctly carried out The correct earthing of each part of the electric system is a compulsory precaution in order to ensure the plant workers operators safety Furthermore earthing is of paramount importance to avoid damage to the installation itself Periodically check the status of earth connection of all cables and terminal cards Special care is to be paid to connections with moving and metal parts making sure there is no oxidation of connection and that the electrical connections are made against painted areas To have correct earthing it is fundamental to avoid series connecting the whole earth installation or part of it with only one cable It is also important to check that for each machine the earth is star connected at the fixing point of the earth cable Some types of welding machines need for the earth connection of the transformer secondary to be made outside of the machine The Weld334m is a sophisticated microprocessor controlled equipment which can also be used in envir
76. ue voltage input TV Analogue voltage input TFE External sync System program No Of Programs Welding channels Storage Optional extras Serial Card Printer port Port for external memory card Proportional solenoid valve module Notes 1 IEC 1131 2 Standard Inputs Weld334m User s manual Voltages recommended 27Vac 10 15 Alternated current min 14 4Vac rms max 32 4Vac rms min 18Vdc max 36Vdc self reset type Direct current 24Vdc 20 15 Protection 24V internal 24V External 24V Interbus S Protection 10 1 5A max 15 20 1 5A max 15 10 self reset type 18 30Vdc Overvoltage disturbances and peaks Voltage Protections Voltage 24Vdc max 0 3A EV EVS 24Vdc max 0 3A Pulse Ctrl 24Vdc with 10 ohm 2W resistance in series for current limitation Protections Short circuit Overcurrent Overvoltage disturbances and peaks local Serial type for GF WELDING HHT4300 unit or Laptop PC with WMS GF WELDING software Serial via the WMS GF WELDING centralising system see optional On line type 150mV kA adjustable 36V max 36V max 12 33Vac On flash eprom it can be updated through the memory card 255 2 The storage and the internal clock are powered through a lithium battery with a surveying circuit of the battery charging status and Supercap for data holding when replacing the battery The battery life
77. urer or performed by unauthorised personnel or non GF WELDING personnel which modifies the machine operation makes the warranty void Check all cables and the relevant connections before using the welding control device in order to see if there is any mechanical damage or failing insulation Whenever a problem arises such as to compromise the safety conditions switch off the unit and cut out power Report the problem to GF WELDING After Sales Personnel To ensure the optimal performance of the device the user must make sure that all requirements for safety on the work site are strictly adhere to WELDING GFLES Weld334m User s manual 1 1 Hazards associated with the use of resistance welding machines Because of the presence of electric current and live parts in the machine mounting maintenance work and replacement of genuine parts is only to be entrusted to Qualified Personnel electricians or authorised personnel All work undertaken is to be done in safety conditions The non observance of these requirements can cause death injury to persons or damage to machine and property 1 1 1 Prohibitions It is prohibited to work on the live installation It is prohibited to remove by pass and modify the safety devices as this could cause serious risks to personnel and equipment and could lead to death 1 1 2 Conditions to be respected to reduce the hazard Always insure that the electric switchboard main switch is OFF Work
78. urrent enabled Salda NO Weld NO Oriented to AA See programming manual welding current disabled 9 2 P20 24Vdc I O 4 way 3 5mm pitch linear connector with disconnectable terminal Output of 24V power supply of devices external to the control device The source for 24V supply is dependent on the type of connection used on the PS connector of the power feeder see technical section of power supply 24V is protected against short circuit by the self resetting fuse placed on the power feeder Beside pin 1 there is the green LED indicator which indicates the presence of 24V supply P22 HSA Pin Signali Description Output N C COM N O 9 3 P22 HSA Circuit breaker trip 3 way 5 08mm pitch linear connector with disconnectable terminal Relay contacts for activating the machine main switch tripping coil It is activated by the control device in case of serious fault occurring on the power section of the machine e g SCRs in out of welding status and by the activation of the Processor Watchdog signal Voltage on contacts 48V 8A max P22 F360 IOB Sgc dsg For connection refer to the application diagrams 37 WELDING Cla Sons Weld334m User s manual F360 IOB I O Basic card 9 4 P21 Description of signals 24V discrete digital inputs and outputs protected against overvoltage Input sensitivity 20 30V All I Os are equipped with a LED indicator for
79. used Consumption Power feeder Power supply type 24V Internal 24V External F350 370 Vac Transformer recommended F350 370 Vdc Power feeder recommended 80W 45W 3 2 Useof24V I O To make use of 24V supply of I O certain rules are to be observed These rules depend on the type of application used on the machine The Weld334m is supplied by GF WELDING in a standard configuration 24V make jumpers between pin 5 and pin 6 see figure below Power supply External sync 24 I O ov 3 2 1 Selecting 24V internal or external 24V supply for I O input is distributed in such a way to have two internal separate lines These lines are alternate between one another e One line for external 24V 24VE whose input is located on pin 6 and pin 7 of PS e One for internal 24V 24VI which from the power feeder is connected directly to bus connectors JP2 3 4 5 6 see figure 1 Figure 1 24VI OV JP2 JP3 Internal power feeder PS Ext l xternal power 24V feeder The modules using 24Vdc supply have 2 jumpers J1 for 24V of I O and J2 for 24V supply used for the pulse control or the servovalve These jumpers allow 24V supply to be set toward the internal power feeder or toward an external 24V supply Each module is factory calibrated standard calibration and calibration value is shown on the layout page in the chapter concerning each module Figure 1 gives an example of setting
80. valve parameters description OFFSET 0 100 active only after a reset until a EV1 0 100 Nominal value during welding cyc EV2 0 100 Pressure variation value start cycle Stored in Setup function Stored in each program le Stored in each program Change is done after n cycles and in mode according the 5 available profiles START CYCLE START CYCLE PROGRAM 2 PROGRAM 1 EOCYCLE E EV1 75 Ra PGM 1 EV1 25 E EOCYCLE PGM 2 ON WELD GUN VALVE OFF t Pressure 100 EV1 of program 1 HOLD THE VALUE VALUE 75 Ro EV1 of program 2 HOLD THE VALUE 25 XXXXXX E t HARDWARE RESET OR CONTROL SWITCH ON Pressure Output air pressure percentage of input 5 bar input amp EV1 O 50 75 100 Examples with pressure 2 5 3 75 5 bar servovalve drop not considered servovalve output When the weld program code change at the physical discrete inputs or by serial line fielbus as Interbus S or Profibus DP or DeviceNet immediatly the servovalve command output will be upgrated according the EV1 value stored in the program choosed Also without the Start signals This function is always active Pressure Yo 100 XXXX WELD PROGRM CHANGE CODE i e 1 HARDWARE RESET OR CONTROL SWITCH ON WELD PROGRM CHANGE CODE WELD PROGRM CHANGE CODE i e 2 ie 3 All changes without start cycle command 78 WELDIN
81. y card The welding control interfaces with a number of equipment and actuators e g welding solenoid valves process controllers PLC and robots by connecting with the field or with standard wiring or through a serial line optic fiber in conformity with the Profil CO protocol of Interbus S standard WELDING GFLES Weld334m User s manual 10 2 2 Block diagram of 334m The 334m can be divided into two separate functional blocks The first block is the basic part of the system and consists of the main cards which must always be installed two internal fixed cards power feeder and BUS and three removable ones CPU I OB and ADC The second functional block consists of the additional configuration card pack I O Expansion Memory Card Printer EVS Proportional Network Through these cards the control device can e Be configured for advanced or special applications which are used in the resistance welding field e Be upgraded with optional functions such as proportional solenoid valves or o memory card e Manage a serial communication port to the welding central unit The block diagram is shown below WELD334m Basic card pack Too Modules e cru Display gt ADC e Base I O Power feeder Additional cards pack T O Expansion Communication gt ports Drivers E S WELDING Weld334m User s manual
82. ype 100Base T Category 5 or 5e UTP up to 100m e Cable type 10Base T Category 3 4 5 or 5e UTP up to 100m 12 3 2 Connection type The RJ45 connection layout depends on the type of connection of the used HUB input port It can be a HUB with MDI connection or a HUB with MDI X connection Before making the cable please check the port type on the HUB 12 3 2 1 Connection for HUB with MDI X port In this case the connection between the two connectors is Pin to Pin 12 3 2 2 Connection for remote HUB with MDI port oo NOANA WUN In the connection with MDI port the signals are crossed 1 2 3 4 5 6 7 8 AONAUNAWNEH NOW BWUNH Remote HUB with MDI X type port Remote HUB with MDI type port 54 GEES Weld334m User s manual F386 Ethernet 100Base T and CANbus module Card layout ME OT 1 6 e d g Ra KA o es amp Ic6 La O 70 com IO E O m 7 E c10 an q m g 2 P10 en As gt 2 xT2 E a C12 i 1C14 15 Ic16 RR C17 PI o o lon Ic19 p 121 GA SS ur PL re 1c23 p C24 pr oy GFIEES 56 Weld334m User s manual F386 Ethernet 100Base T and CANbus module WHITE PAGE WELDIN Weld334m User s manual fe w

WELD334M W334MHIC33030112REL2.05A50HZ WELDING

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