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Weld334m

1. Code 33035100 4 F351 BUS Interconnection card BUS interconnection card for signals and power supply 12 connector takes 24V supply for the 1 power supply 1 connector takes 5V supply for the cards and V for programming unit HHT JP1 connector is used to power the programming keycard via CPU The connectors 2 3 4 5 6 distribute 24VI and 24VE supply for the 1 0 points Connectors P1 6 form the digital BUS Power supply HHT4300 Bus 24V 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 19 GF Technical Manual Code 33038400 5 F384 CPU Microprocessor card 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 F384 CPU CPU status Led indicators LOWBATT Red illuminated during power reset when switching on the Control device and when the reset is given via the push button P If it stays On during the operation RUN led indicator illumin
2. Internal power feeder PS 24V I O 24V PULS Com IMP External power feeder BUS W334m module The modules using 24Vdc supply have 2 jumpers J1 for 24V of J2 for 24V supply used for the pulse control 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 for these 2 jumpers GF Technical Manual 24V 1 can be managed in the following ways 0 Direct 24VI supply with pins 5 6 of PS being free see paragraph 3 2 2 figure a 1 connector jumpers of O and ADC cards to be made in position 1 2 0 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 24 line 0 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 1 jumpers of cards Where present 3 2 2 24V connections for discrete 1 Figure a Use of 24VI supply in direct way Power supply External sync Power supply 4 External sync
3. Eid uiri 0 0 0 PI nis 9 o g 0 0 0 0 1 15 maximum of 127 controls 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 15 GF Technical Manual InterBus S Example of network architecture 4221 5 Connection 1 24V REMOTE IN REMOTE OUT REMOTE IN REMOTE OUT REMOTE IN 16 APPENDIX C Weld334m Application diagram Dwg 33033323 01 Dwg 33033324 01 Dwg 33033339 02 Dwg 33033340 00 17 Main ground connection by faston POWER 80VA Main power supply 380 440 500V 60Hz TRF WELDING TRANSFORMER P4 ADC TA 9 pins F P3 Primary voltage detection _ 9 pins F 9 pins F353 Pad fex _ _ Exter
4. supply 1 2 Power supply 380Vac line PS Insula 12 33Vac sync iri 1 Pulse Firing device 2 control Welding transformer 21 WELD334m SCR 13 14 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 used Consumption Power feeder Power supply type 24V Internal 24V External F350 370 Vac Transformer recommended 110VA 62VA F350 370 Vdc Power feeder recommended 80W 45W 3 2 Useof 24V 1 0 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 3 2 1 Selecting 24V internal or external 24V supply for 1 0 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 J P2 3 4 5 6 see figure 1 Figure 1 24VI
5. WELDING CYCLE ALARM 1 if pressure is not E015 Process in WAI T mode The welding pulse is only given when the nominal value P1 has been reached Tmax WAIT e ACC PRE P1 15Kn Pressure OK WELDING CYCLE NOTE When the parameter T Prs 0 the function is disabled 13 14 Technical Manual 1 nterbus S general architecture of 1 communications Welding 4 4 cabin Ove Paramete 1 signals 0 0 00 a _ Gel 5 L2 rt FENI 1 0 Signals 104 2164 7 Power supply SCR control SCR temperature Welding transformer Set variables Current voltage guns pressure Guns Ethernet Tcp Ip Example of network architecture HUB Ethernet SSS BOSSES EG 10Base T
6. Pins connected 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 5 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 0 with PSM type F367 compatibility with old module F368 27 Technical Manual Code 33039200 8 F392 IOB Basic Card Basic card of the 1 0 connections towards the system characterized by a two position selector and linear connectors P20 P44 P22 with corresponding leds 8 1 Weld YES NO selector Enables disables the welding current F392 10B i Weld Yes No must also be enabled the Setup x x NG UU Weld YES Turned to welding current is enabled P20 24V O Weld NO Turned to t welding current is disabled See programming manual oy P44 I O O1 8 2 P20 Power supply 02 4 p 3 5 disconnectable terminal linear connector es 24V power supply output devices external to the control The 24V source depends the type of connection used on the PS connector of 2 the power supply unit see power supply technical section O10
7. 2 START recognition with use in manual environment Program code Program parity Call recognition AT 40 5 60 5 since Start 1 Start and Program Code must stay stable Technical Manual 3 EMERGENCY STOP condition general diagram NOTE The Emergency stop signal is active at OV not considered still hold Pgm 1 7 2 Now Start START PROGRAM CODE WELD HOT TI ME 24 Closed EMERGENCY 0 FK 0 CHANGE 2 SERVOVALVE CHANGE TO 1 Given by robot 4 EMERGENCY STOP condition during or outside the welding pulse NOTE The Emergency stop signal is active at OV PRE SQUEEZE SQUEEZE CYCLE CURRENT 24 Closed EMERGENCY SIGNAL NO SPOT 24 ALARM happens 0 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 f 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 Technical Manual 5 EMERGENCY STOP excluded with START stil
8. Technical Manual 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 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 manufacturer 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 dev
9. 46 Technical Manual Bit Signal Function 10 RESET COUNTER Bit 1 Stepper 0 counter is reset see electrode selection 0 AFTER TI P after electrode dressing DRESS A signal is sent to the control that the requested dressing operation has been completed The signal must be active for at least 100 ms 11 RESET COUNTER Bit 1 Stepper 1 counter reset see electrode selection after 1 AFTER TIP electrode dressing DRESS A signal is sent to the control that the requested dressing has been completed The signal must be active for at least 100 ms 12 13 Not used 14 SELECT Select the stepper electrode pair on which the commands are to ELECTRODE 2 act Control Word 1 and whose status is communicated Status Word 1 See next table 15 SELECT Select the stepper electrode pair on which the commands are to ELECTRODE 4 act Control Word 1 and whose status is communicated Status Word 1 See next table Alarm reset mode Functional description EET Alarm Reset All active error messages are reset Reset alarm with active alarms are reset If the START signal is still present Sequence End the Sequence End signal is activated Reset alarm with active alarms are reset If the START signal is still present sequence repeat the sequence is repeated i E Electrode selection Functional description Electrode selection enables one of the eight different Electrode Stepper pairs to be selected a dif
10. 0 0 2 na ansa nasa 35 92 1 Program selection code tble esr i erit 38 10 F359 MCP MEMORY CARD AND PRINTER e eene seen aser eaa 39 11 F397 PDP 40 11 1 CCHARAGTERISTICS 40 11 2 PROFIBUS DP ert te Meu 40 11 2 1 PIA senal M RP Em 40 11 2 2 EDD UBER 40 11 2 3 ADDRESS 40 11 3 CARD LAYOUT 41 12 F381 ETHERNET MODULE WITH 4 0 1222 2 020 1 8424 2 4 7 14 44 4040 04 0000 41404001 42 121 P10 ETHERNET 10 2 2 21 0 00 000000000000000000000000 43 12 2 CONNECTION 5 2 21 0 111000 0 0000000000000000000000 43 12 2 1 MPO UN 43 12 2 2 Type of usi ec dedico tite Tere Re EE de NE uS E SER one e dev EE du 43 13 PROFIBUS DP PROFIL F PDP I cuneos nae e 44 13 1 GENERAL DESCRIPTION trit tren CET Ee EFE HERE EE Lave ek Dec Ve ER CA be b FE
11. Characteristics Transmission speed 10Mbyte s Connection RJ45 8 pin connector Ki O C42 19 6 _ Pr 1 04 02 as C38 PF1 GF Technical Manual 12 1 P10 Ethernet 10Base T connector Type RJ45 8 pole female shielded type MDI connection Pin Signal Function 1 TD Positive data transmission 2 TD Negative data transmission 3 RD Positive data reception 6 RD Negative data reception 4 5 7 8 not connected Shield Connected to PE RJ 45 connector pinning 12 2 Connection cables 12 2 1 Characteristics Twisted commercial cable for Ethernet 10 BaseT network 12 2 2 Type of connection The signal connection depends on the type of connection of the HUB input port used It may be a HUB with MDI connection or a HUB with MDI X connection Before making the cable check the type of port present on the HUB Connection for HUB with MDI X port The connection between the two connectors is Pin to Pin Remote HUB with MDI X type port 3 0 NJ H Connectio
12. 11 3 POWER SUPPLY AND 24V FOR 00 414 4 0 4 eene tasto senses sosta 12 3 1 CONTROL DEVICE POWER SUPPLY RIP RIGHE GRE P RR DE e idees 12 3 1 1 PS Description of signals eie 12 3 1 2 Connections main power 13 2 41 3 PowerconsumptiOn iie uade ERR EE eae ine Ee Ua e Due EE 14 22 JUSEOP2AV eter eI es les anaes Gee decet fetten 14 3 2 1 Selecting 24V internal or external eese eene nennen een rennen 14 2 22 24V Jor discrete et o BR HARI E 15 3 3 GENERAL PROTECTIVE DEVICES ON POWER SUPPLY isses eere 17 3 4 5 17 4 F351 BUS INTERCONNECTION 44 0 sensn sn 19 5 F384 CPU MICROPROCESSOR CARD eese teens tatnen senta sesto sees suse ta sensn sn 20 6 F353 ADC ANALOGUE 9 sesso sets 22 6 1 4 DESCRIPTION OF THE ANALOGUE 5 en enne 22 6 2 P2 DESCRIPTION OF THE SIGNALS FOR THE SOLENOID VALVE AND THE TFE sss 23 7 F364
13. a y 24 Code 33036400 33038500 7 F364 SEV F385 SEV Proportional Servovalve Modules 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
14. 2 5 5 U1 3 P44 RLB2 ong re 24 JP3 1 RLB3 o 22 RLS o 20 LC Ut 12 1 31 GF Technical Manual Code 33039300 9 F393 IOE 1 Expansion card 24V discrete 1 0 signal expansion card Characterized by two terminal type connectors P43 and P42 for field connections that support 18 inputs and 16 outputs 4 of which are dedicated to control of the additional opening solenoid valves and protected via relay contact against accidental calls RESIDE All the outputs are protected against short circuits O1 9 1 P42 Description of the output signals 2 16 pin p 3 5 disconnectable terminal linear connector 55 o8 Pin Signal Description Typology Type M m 5 4 RICHRAVB Dressingrequest B 7 Electrode wear function type 0 5 e 6 RICHELA Electrode change request B Electrode wear function type 0 5 02 8 ALARM2 Hardwarealam Machinefault_ 0 5 oe 9 RICHSALD Weldingrequest typeO5 4 06 10 FINASALD welding Status type 0 5 3 2 0 i N 019 opening contact i 013 closing contact 5a 15 EVASB1 Additional opening ch
15. All alarms in course are reset If the START signal is still present the END SEQUENCE signal is activated Reset hardware alarm with Repeat Active at 24 All alarms in course are reset and if the START signal is still present the sequence is repeated Control of additional opening A solenoid valve Active at 24V Start of electrode pre approach is enabled and disabled with a rising edge 0 24V impulse type Signal read time 100ms If it is not used this input must be connected directly to the 24 Control of additional opening B solenoid valve Active at 24 As for CEVASA but for channel B Selection of dressing program channel A Active at 24 The next sequence will be performed with the predefined welding program for dressing RICHRAVA O the output is made to flash at an interval of 0 55 The signal must be active for at least 10015 Selection of dressing program channel B Active at 24 The next sequence will be performed with the predefined welding program for dressing If RICHRAVB O the output is made to flash at an interval of 0 55 The signal must be active for at least 100105 Confirmation of dressing performed on channel A Active at 24V Inhibits the alarm warnings resets the welding spot counter and increases the dressing counter in the electrode wear program by 1 This operation can also be performed from the programming keypad using the stepper menu see programming manual
16. oll The 24V is protected against short circuits by an auto reset fuse located on the ol2 power supply unit The green 24V present led is located to the side of pin 1 2 Output for 1 0 power supply 2 COM Output for 1 0 power supply al lee Ground for 1 0 power supply 4 0 Ground for 1 0 power supply 8 3 P22 HSA Circuit breaker release 3 pin p 5 08mm disconnectable terminal linear connector Relay contacts for tripping of the release coil of the main circuit breaker of the machine It is activated by the control in the case of a serious fault in the power section of the machine e g SCR conducting except during welding and by activation of the Watch dog signal of the Processor Characteristics of the contacts Max voltage 48Vdc Rated current 6A Max instantaneous current 30A P22 F392 10B Circuit breaker release For the connection refer to the application diagrams 28 Technical Manual 8 4 P44 Input Output 24Vdc discrete digital Inputs and Outputs protected against overvoltages All the 1 05 are complete with respective signal present led 16 pin p 3 5mm disconnectable termin TATUS VSB al linear connector Control of welding channel B solenoid valve 10 11 EVSA Control of welding channel A solenoid valve Relay contact R MAGEBE 16 Electrical data SALDASI Weld Yes Input type 2 SOLOPR Type 2 solid state inputs EN61
17. 15 connected to a 24V contact that is opened by the robot or in Manual mode in an emergency The control inhibits the sequence and does not permit Start until the 24V is re activated this Input See EMERGENCY diagrams in Appendix B 5 STARTA Start channel A Active at 24V The control activates the EVSA output called gun A and performs the welding program required If Start is interrupted before the pressure cycles have been performed the EVSA output is de activated and the electrodes re open After the pressure cycles Start remains latched until the end of the frequency cycles 6 STARTB As for STARTA but for channel B 7 8 CONDUZ SCR conduction detection signal input Is tapped from the secondary of a transformer connected in parallel to the SCR group in order to detect conducting of this See application diagrams 9 STATUS Enable welding current Active at 24V Indicates the Weld Yes condition when Weld Yes is enabled this output goes high see also SaldaSi 10 11 5 Output that drives the welding channel solenoid valve Relay contact closed when the output is active Activated by STARTA it is protected by a 2 relay interlock that prevents a concurrent call to channel B If the STARTA signal drops out before the pressure cycles have been completed the call is not recognized and the electrodes re open After the pressure cycles START remains automatically latched until the end of the Hold cycles Se
18. 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 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 environments 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
19. 24 I O ov 24VI1 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 15 Figure c Use of 24VE external with earth the Weld334m side Weld334m External power feeder If earthing for 24VE supply has been performed on the welding control 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 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 16 GF Technical Manual 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 Input stage Protection Self reset state type solid fuse Internal power feeder PS On the basis of the type of connection in use the pr
20. Manual 3 Power supply and 24V for I O 12 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 located 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 Description 1 2 PWR RTN Main power supply of the control device The device 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 3 4 SYNC 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 fee
21. 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 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 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 10xn Technical Manual 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 iuge deo per mnm 12 13 14 15
22. SEV AND F385 SEV PROPORTIONAL SERVOVALVE 8 404 25 74 SERVOVALVE ADJUST 25 7 1 1 Voltage outlet ch racteristiCs iiu eee REE EHE ree RT HY NER knees 26 41 2 Current outlet characteristics ae tite te Ree 26 7 2 CONNECTION OF THE F364 F385 SEV MODULE ON THE F353 ADC 26 7 2 1 Jumper function on connector eene nennen trennen ren een nennen tnn trenes 27 7 2 2 Jumper function on connector JS essent nenne ener tenente teret entren teens 27 8 F392 IOB BASIC 2 tuse ta sone ta sonata 28 Sk WELD YES NO SEEECTOR te 28 5 2 P20 POWER SUPPLY cniioeetcsasteseest eue ee sev tese aste esee eee debe eee ise eene bee eee se 28 83 P22 HSA CIRCUIT BREAKER RELEASE 28 54 P44 INPUT OUTPUT EO C RD EE ESI ENTER 29 Technical Manual 9 9 UO EXPANSION de 32 91 P42 DESCRIPTION OF THE OUTPUT 5 15 0 tte nent nnne nnn 32 9 2 P43 DESCRIPTION OF THE INPUT 6 1 85
23. 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 clip 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 Technical Manual APPENDI X 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 Program parity 0 99Cycle 20115 1 Analog pressure 1 The program code is saved Any successive changes have not effect
24. The signal must be active at least for 100ms Confirmation of dressing performed on channel B Active at 24 As for RAVOKA but for the channel B Confirmation of electrodes changed on channel A Active at 24 This input must be activated after electrode dressing following the Electrode Change Request message The following operations are performed for the Steppers active on welding channel A at the time of the command Reset dressing counter Reset weld counter The signal must be active for at least 100ms Confirmation of electrodes changed on channel B Active at 24 As for CHGEOKA but for channel B P43 Functional description of the input signals Pin 11 12 13 14 15 16 17 18 Signal CODEO CODE1 CODE2 CODE3 CODEA CODE5 CODEP CONSALD Function Active at 24V Inputs dedicated to selection in binary code of the welding program to be run at Start When Start is active the control runs the program corresponding to the binary code read see code table on page 38 Up to 64 welding programs can be used NB To select program 64 all the inputs of the program code must be at logical Parity code Active at 24 Used only on robotized lines Is used for logical checking of the CODEO 5 inputs and depends on the setting in the Setup menu see code table on page 38 Warning If it is not used it must be disabled see Setup pr
25. 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 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 daisy connection so to have only one line of transmission The cable is to comply with the relevant RS485 or Profibus specifications 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 an
26. 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 rest 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 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 medic
27. 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 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 For the correct use of the Ram Card please consult the Programming Manual chapter MEMORY CARD lt WDOEBEME P5 PRINTER N 25 way Sub d socket connector T E The parallel port allows the connection to a parallel printer for printing data concerning the programs steppers reports etc 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 39 GF Technical Manual Code 33039700 11 F397 PDP Profibus DP 40 11 1 Characteristics 11 2 Profibus DP F397 PDP The F397 PDP is a communication card complying with the Profibus DP DIN19245 part 3 standard EN 50170 fo
28. output over a range from 0 to 10V or the analogue current output over a range from 4 to 20 mA The control can enable disable the servovalve by means 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 STSERV 25 GF Technical Manual 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 Pr
29. removable ones CPU 1 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 Be upgraded with optional functions such as proportional solenoid valves or o memory card Manage a serial communication port to the welding central unit The block diagram is shown below WELD334m Basic card pack Modules Base Display Power feeder Additional cards pack I O Expansion Communication ports Drivers GF Technical Manual 2 3 Hardware configuration 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 Card order code 33037000 33035100 33036300 33038400 33035300 33036400 33039200 33039300 33035900 33039700 33038100 Card name F370 PSM F351 BUS F363 DPY F384 CPU F353 ADC F364 SEV F392 IOB F393 IOE F359 MCP F397 PDP F381 ETH Card description Order code Type Proportional solenoid
30. the 1 hazard secet te Desde t ce tss us geo 2 1 2 OBSERVATIONS ON CONNECTIONS eese ene enne ener enin entere 3 1 2 1 XVIII m 3 1 2 2 Safety criteria against short circuits eese eene 2 TL23 4 L24 5 12 5 Phasesynchronising for Welding 5 1 20 aT TET ett 1 2 7 Connecting the Weld334m with the WMS central eene nnne 6 2 CHARACTERISTICS AND GENERAL DESCRIPTION OF THE WELD334M eere 7 2 GENERAL DESCRIPTION i c ratto 7 22 BLOCK DIAGRAM OF 334M 25 62 7 23 HARDWARE 1 enne ener rnnt nr 8 ZA CHARACTERISTICS ies e IRURE ORIGO ERE EC IEEE RIED IU 9 2 4 1 Utilisation characteristics oerte EE EYE CENE Ed 10 2 42 Dimensions overall dimensions and fastening positions eese 10 2 4 3 HHT4300 programming eredi tte titer een yen e gre 11 244 Connection through esent a EHI HIE eG EH
31. valve module Ethernet card with Data Key Power supply BUS card Display 4 arrows Analogica amp SV Expansion Basic 1 Memory card printer Basic 1 0 Profibus DP C P U 33030180 Weld334m 5 33030190 Weld334m 5 33030194 Weld334m PSM X X Technical Manual 2 4 Characteristics Control power supply 24Vdc 1 total power discrete digital 1 Inputs Voltages recommended 27 10 15 1 min 14 4Vac rms max 32 4Vac rms min 18Vdc max 36Vdc self reset type 10 1 5A max 15 20 1 5A max 15 1096 self reset type Alternated current Direct current 24Vdc 20 15 1 Protection 24V internal 24V External 24V Interbus S Protection 18 30Vdc Overvoltage disturbances and peaks Voltage Protections Outputs Programming port Current sensor input TA Analogue 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 IEC 1131 2 Standard 2 3 See characteristics at paragraph 3 3 4 The value does not include the voltage ripple The external synchronism is to be used see
32. 0 15 Input Status Bit 1 24Vdc present on input Bit O0 24Vdc not present on input 53 54 Technical Manual APPENDIX GF Technical Manual APPENDI X 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 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 _____0 ____ Check on the new 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
33. 128mm 110mm 4 gt A 0 246mm 222mm 237mm 70mm v 5 0 200mm gt GF Technical Manual Cod 00793702 2 4 3 HHT4300 programming unit The unit connects to the P1 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 quit ESC 5 function keys Remote connection distance With direct connection 100m With indirect connection separate power feeder 600m 4500 HHT __ DOs Dimensions L 200mm H 90mm Pr 35mm Operating 0 to 45 C with humidity from 0 to 80 without condensation temperature Storage temperature 40 to 80 with humidity from 0 to 90 without condensation Weight 500g 9 way Sub d socket connector sumar Description 4 RXD4 _ Data reception 8 0 Data reception 9 0 Data transfer 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 11 Technical
34. 131 2 type 2 DC input Rated voltage 24Vdc Max continuous voltage 30Vdc Max non continuous voltage 36Vdc max duty cycle 8096 Max voltage for state 0 5V Min voltage for state 1 11V Min current for state 1 6mA 11V Max current max for state 1 30mA 30V 0 5 type solid state outputs IEC EN61 131 2 0 5 rated current DC output Rated voltage 24Vdc Max continuous voltage 30Vdc Max non continuous voltage 36Vdc duty cycle 12 Continuous output current state 1 0 6A Max loss current state 0 2mA Protection tripping current gt 0 7A with F370 24Vdc stabilized power supply unit with F367 power supply unit or 24Vdc non stabilized external power supply Outputs with relay contact Max voltage 30Vdc Rated current 2A Max instantaneous current 30A Min switchable current 10mA Mechanical life 2 106 fe Technical Manual 44 Functional description of the signals Pin Signal Function 1 24TRASF 24V power supply of the primary of the SCR firing transformer to be used only for this purpose 2 COMI MP SCR Fire impulse command See application diagrams 3 TSCR SCR overheating Active OFF The sensor must be of the type with N C contact In the case of overheating the TSCR signal is interrupted and the control activates the matching alarm and blocks the machine cycle 4 EMERG EMERGENCY Active OFF
35. ERV ENSERV Pin Signal 1 2 9 TFE 4 12 ISERV 3 10 VSERV 6 STSERV 7 ov 8 24SV Function Analogue voltage acquisition channel This input can be used for receiving the indication of the electrodes force through a dedicated transducer Current output Operating range 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 10096 of the pressure value which has been calibrated on the proportional valve Load resistor 470 range from 200 to 600 Voltage output Operating range from 0 to 10V Signal for piloting a voltage type solenoid valve The valve adjusts pressure on the electrodes as a function of this signal 10V correspond to 10096 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 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 OV solenoid valve power supply Solenoid valve power supply Power supply to the solenoid valv
36. GF 27275 USER S MANUAL Weld334m PSA PSC PSM Ed 1 March 2003 Doc 39000327 PEDES Technical Manual GF WELDI NG S p A Strada del Portone 18 24 10137 TORINO Italy Tel 011 3033 278 Commercial Italy 011 3033 270 279 Commercial Foreign Tel 011 3033 277 Service Italy 011 3033 274 Service Foreign 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 rights reserved to GF Welding S p A Technical Manual Table of contents 1 O 1 1 1 HAZARDS ASSOCIATED WITH THE USE OF RESISTANCE WELDING MACHINES eee 1 LAA 1 1 1 2 Conditions to be respected to reduce
37. R COUNTER 0 9 RESET STEPPER COUNTER 1 RESET COUNTER 0 AFTER DRESS 11 RESET COUNTER 1 AFTER DRESS SELECT ELECTRODE 2 SELECT ELECTRODE 4 Control Word 1 Functional description Bit Signal Function 0 START CYCLE Bit 1 Start Command The number of the welding program is acquired and the related cycle is started 1 WELD ON Bit 1 Welding cycle performed with current The welding cycle must be performed with current that is to say with command by the power group 2 FAULT RESET Bit 1 alarms no longer active will at the reset without further action by the welding control 3 ERROR RESET O Selection of alarm reset modality See next table 4 ERROR RESET 1 Selection of alarm reset modality See next table 5 ENABLE SVV Bit 1 Authorization to enable servovalve When this bit is at 1 the control activates the ENSERV signal to the servovalve 6 7 Not used 8 RESET STEPPER Bit 1 Stepper 0 counters are reset see electrode selection COUNTER O after electrode change A signal is sent to the control that the requested electrode replacement has been completed The signal must be active for at least 100 ms 9 STEPPER 1 The Stepper 1 counter is reset see electrode COUNTER 1 selection after electrode change A signal is sent to the control that the requested electrode replacement has been completed The signal must be active for at least 100 ms 45 GF
38. RRE 44 13 1 1 Control Word 45 13 1 2 _ EE 50 APPENDIX q 1 Operating diagrams 1 START recognition with use in automated 2 START recognition with use in manual 22 nene eterne nete 3 EMERGENCY STOP condition general diagram 4 EMERGENCY STOP condition during or outside the welding pulse 5 EMERGENCY STOP excluded with START still active eese nennen eterne 6 START disabled condition during the welding pulse eese nennen 7 Proportional Servovalve operating diagram sees eterne nennen tentent 8 ENABLE function Interbus s 9 Diagram of diagnostic pressure Interbus S general architecture of I O communications eee eee eterne eene ene Ethernet Tcp Ip Example of network architecture eese nennen ener InterBus S Example of network architecture eese rennen entrent APPENDIX C WELD334M APPLICATION DIAGRAM 02 0 eme nnn nnns anas nna
39. al 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 Outputs 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 GF Technical 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
40. all the conditions to perform a welding cycle are present When ALARM1 or ALARM2 occur the output is low Control of additional opening channel A solenoid valve Mono stable output active at 24 Invokes opening of gun A solenoid 1 of solenoid valve A Activated by the CEVASA command It is protected by a two relay interlock that prevents a concurrent call to channel B If the Start signal drops out before the pressure cycles have been completed the call is not recognized and the electrodes re open After the pressure cycles the start remains automatically latched until the end of the Hold cycles Control of additional opening channel A solenoid valve Mono stable output active at 24 Invokes closing of gun A solenoid 2 of solenoid valve A Activated by the CEVASA command It is protected by a two relay interlock that prevents a simultaneous call to channel B If the Start signal drops out before the pressure cycles have been completed the call is not recognized and the electrodes re open After the pressure cycles the Start remains automatically latched until the end of the Hold cycles Control of additional opening channel B solenoid valve Mono stable output active at 24V Invokes opening of gun B solenoid 1 of solenoid valve B Activated by the CEVASB command As for 5 1 but for the channel B Control of additional opening channel B solenoid valve Mono stable output active at 24 Invokes c
41. anagement program Consult the related User Manual for use of this Note After setting the address the control must be restarted using the reset button of the CPU card 11 3 Card layout Technical Manual i 1 026 U7 gps U8 eil U11 JP1 J1 J2 U3 U2 U6 7 P1 LC GF 41 GF Technical Manual Code 33038100 12 F381 Ethernet module with key 42 Serial communication card for Ethernet 10BaseT IEEE802 3 networks This module enables the welding control to be connected to a serial network of the Ethernet type for communication towards the WMS centralizer It is used as an alternative to the Profibus F354 PFB communication card or the Wmsnet F355 NET communication card To set the addresses for connection to the network please consult the programming manual The TCP IP address of the card is memorized in a DATA KEY DK device with key located on the front panel The key may be removed to enable the control device to be replaced in case of breakdown without having to set the address on the replacement control device LEDs located on the front panel LED Signal Condition LAN Lan activity ON when data transmission is in progress LINK Link status OFF when there is a line fault
42. annel B Solenoid valve command Relay H PS len commans oe 8 closing contact Electrical data Type 0 5 solid state outputs I EC EN61131 2 0 5 rated current DC output Rated voltage 24Vdc Max continuous voltage 30Vdc Max non continuous voltage 36Vdc duty cycle 12 Continuous output current state 1 0 6A Max loss current state 0 2mA Protection tripping current gt 0 7 with F370 24Vdc stabilized power supply unit with F367 power supply unit or 24Vdc non stabilized external power supply Outputs with relay contact Max voltage 30Vdc Rated current 2A Max instantaneous current 30A Min switchable current 10mA Mechanical life 2x10 32 GF Technical Manual 42 Functional description of the signals Pin 1 2 3 Signal WALLSTA WALLSTB RI CHRAVA Function Pre alarm stepper A Active at 24 This output is activated concurrently with welding in which the value set for the electrode wear pre alarm of the last Stepper used on welding channel A is reached It is switched off at the next welding operation It is non blocking and warns the operator that the counter is close to the Stop threshold of the stepper Consult the programming manual for conditions of use The message is saved in the alarm log Pre alarm stepper B Active at 24 As for WALLSTA but for channel B Dressing request c
43. ansformer For the use of the external synchronism see paragraph 3 4 The non observance of these rules will cause serious malfunctioning Technical Manual 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 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 PROFI BUS 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
44. ated this indicates that the battery is nearly down RUN Green the processor is operating correctly when illuminated This indicator is OFF during the reset or when the Watchdog indication of Fault condition intervenes Reset push button LOW RUN 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 I nternal 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 RESET Average battery life Extinction Operating condition Duration years Daily 6 working days 3 Weekly 5 working days 4 Weekly 6 working days 5 4 P1 9 way Sub d socket connector RS485 serial communication port for the connection to the HHT4300 programming unit or to a PC signal Description N C 4 RXD reception TXD Data transmission 8 RXD Data reception TXD Data transmission For maximum length of connection cable see paragraph 2 4 3 20 Technical Manual Card layout Standard setting of j
45. by Spa FASE This drawing will not be reproduced or in way utilized for the manufacture of the or herein illustrated and must not be released to other parties without written consent Any infringement will be legally pursued SALDATURA Circuit breaker command emergency main switch IAG max 110Vac 300VA 24Vdc 24Vdc 24V Firing 424TR Firing COMIMP SCR Temperature transducer 9 Start cycle A Start cycle B Firing STARTA STARTB CONDUZ CONDUZ STATUS al Output weld electrovalve A EVSA EVSB __ weld electrovalve B EVSB MAGEBE e SALDASI Pressure only SOLOPR OV at ee Changement WELD334m Terminal block Date 06 02 CONNECTIONS CARD F392 IOB 33033340 50 proprietary rights reserved by Spa FASE This drawing will not be reproduced or any utilized for 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
46. chronisation with the grid voltage A WELD PROCESS Bit 1 During the last welding cycle an anomaly in the FAULT welding process occurred The bit is set to 0 after reset alarm 5 TI MER READY Bit 1 The welding control is ready to perform a welding cycle 6 STATUS SVV Bit 1 Signals that the proportional valve has reached the requested setup value 7 Not used 8 PREWARNI NG Bit 1 The programmed number of welds has been reached STEPPER O for the electrode wear warning of the electrode assigned to Stepper 0 see electrode selection 9 PREWARNI Bit 1 The programmed to number of welds has been STEPPER 1 reached for the electrode wear warning of the electrode assigned to Stepper 1 see electrode selection 10 TI P DRESS Bit 1 The number of welds programmed for electrode REQUEST 0 dressing has been reached for the electrode assigned to 50 Stepper 0 see electrode selection The bit is set to 0 on confirming dressing has been performed GF Technical Manual Bit Signal Function 11 TI P DRESS Bit 1 The number of welds programmed for electrode REQUEST 1 dressing has been reached for the electrode assigned to Stepper 1 see electrode selection The bit is set to 0 on confirming dressing has been performed 12 END OF STEPPER 1 The programme and number of welds for electrode replacement has been reached for the electrode assigned to Stepper 0 see electrode selection The bit is set to 0 o
47. 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 DING Technical Manual 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 cable The P7 3 way connector does not take 24V 1 0 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 pu deo po or 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 co
48. d 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 memory 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 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
49. der card through 2 jumpers see paragraph 3 4 5 24 24 output internal It is used when one wants to use 24V supply internal to the device for powering the 1 0 It can be cut out for enabling 24V from a remote unit Robot For the connection refer to paragraph 3 2 2 figure b 6 24VE 24Vdc external input for discrete digital 1 0 Max Load 1 5A For the connection refer to paragraph 3 2 2 figures c and d 7 ov Input for external common for logic 1 0 For the connection refer to paragraph 3 2 2 figures c and d 8 ale Contact available for Earth connection For the connection refer to paragraph 3 2 2 Technical Manual 3 1 2 Connections for main power supply Diagrams for control device power supply are illustrated below input taken from the power line of the welding transformer 380 line Power transformer PS Power 1 supply 14 4 32 4Vac 2 3 4 Firing device 1 Pulse 2 control ransformer i 21 WELD334 Dcsupply 1 24Vdc external power 18 36Vdc feeder 2 380Vac line PS External Sync 4 Firing device 1 Pulse 2 control Welding transformer 21 WELD334m SCR Ac supply taken from a line separate from the welding transformer power supply Vac privileged power
50. e cycle time diagrams in the programming manual 44 F392 IOB EVSA 10 ial o EVSA Comune 11 12 13 5 Output that drives the welding channel B solenoid valve Relay contact closed when the output is active As for EVSA but for channel B 14 IMAGEBE 24Vdc input Dedicated signal 30 Technical Manual Pin Signal Function 15 SALDASI Weld Yes Active at 24 Enables the welding current Weld Yes must also be active in the Setup and the selector on the front edge The control activates the STATUS output 24V when Weld Yes is enabled See programming manual 16 SOLOPR Pressure only Active OFF Used for gun adjustment Normally at 24V if opened during the welding the following condition 5 the sequence is interrupted with the electrodes closed in pressure the control waits for the 24V on this Input the RICHSALD output is low If START is released the call is interrupted and the gun re opens If SOLOPR goes high the sequence is restarted the control sends the RICHSALD output high and proceeds according to the status of SALDASI and CONSALD Card layout setting of the jumpers Off J P3 Off 1 2 3 J2 1 2 1 1 5 8 923 r P20 154 ue 3 5l 5 E ifs 1 al 2
51. e is monitored with a voltage value if it falls below 22 5V 596 of 24V the ENSERV enable signal of the solenoid valve is not activated 23 Technical Manual 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 Solenoid valve power supply falls below 5 e O sequence is during cold processing cycles e CPU is in the reset status Card layout standard setting of jumpers J2 1 2 p5 Off 12 5 mM 518 n H d 5 R IN my S gt 8 m c gt to im Jur is Em 5 vin ojo 8 e o 5 5 S m 5 mm Ow 2 ER on ozn x 2 g Eee g eza vL 4
52. e 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 6 Please see the WMS programming manual Technical Manual 52 Status Word 4 Status Word 2 contains the status of the 16 inputs available the F378 IOE card These inputs are fully managed by the user The welding control does not control or protect the data contained in this Status Word in any way The maximum load values defined for the F378 IOE card must be respected If the F378 IOE card is not present in the welding control the contents of the Status Word are reset The status of the 16 inputs is updated every 10msec ee Description P36 Contact UserdefinedinpttO 4 Userdefinedinpt4 5 jUserdefinedInput5 ___ 5 O 6 Userdefinedinpt o 6 O 8 Userdefinedinptt8 9 jUserdefinedInput9 Status Word 4 Functional description Bit Signal Function
53. ferent stepper is assigned to each electrode which will be associated to the data contained in Control Word 1 and Status Word 1 where Stepper 0 Stepper 1 appear This technique enables up to eight different welding guns to be selected Bit Steppers selected 14 15 Stepper 0 Stepper 1 0 0 1 2 1 0 3 4 0 1 5 6 1 1 7 8 Technical Manual Control Word 2 Control Word 2 is used to select the welding sequence 0 WELD PROGRAMBITO 1 1 WELD PROGRAM BIT 1 2 WELD PROGRAM BIT 2 4 WELDPROGRAMBITA 5 WELD PROGRAM BIT 5 8 o Not used 12 Control Word 2 Functional description Bit Signal Function 0 7 WELD PROGRAM Select welding programme 1 255 in binary code 8 15 Not used 47 GF 48 Technical Manual Control Word 3 Control Word 3 defines the Spot Index The Spot Index is an index definable from 1 to 65535 used for the selection of a welding spot contained in a database created specifically and managed through the GF Welding WMS centraliser program In this database each Spot Index is associated with a working name generally the name of the spot to be welded and the reference to the welding program that must be used The necessary part of the database is saved in each welding control via the WMS centraliser program Welding status signals from the Weld334m welding control diagnostics pr
54. hannel A Active at 24V The number of welding operations programmed for electrode dressing of the last Stepper used on welding channel A has been reached Steady light blocking condition that can be reset only by clearing the counter of the matching stepper via the RAVOKA P43 7 input or via software reset in the Stepper menu Flashing light the machine is not blocked and input RAVEXTA is activated 42 Functional description of the output signals Pin 4 Signal RI CHRAVB RICHELA RICHELB ALARMI ALARM2 Function Dressing request channel B Active at 24 As for RICHRAVA but for channel B Counter clear input RAVOKB P43 8 Flashing light the machine is not blocked and the RAVEXTB input is activated Electrode change request channel A Active at 24 The number of welding operations programmed electrode replacement of the last Stepper used on welding channel A has been reached Steady light machine blocking condition can be reset only by clearing the counter of the matching stepper via the CHGEOKA P43 9 input or via software reset in the Stepper menu Electrode change request channel B Active at 24 As for RICHELA but for channel B Counter reset input CHGEOKB P43 10 Indication Active at 24 Does not block the processing cycle Diagnostic class alarm from E001 to E050 Is normally reset automatically but can be set to blocking condition in the Setup menu See Alarms and Setup cha
55. ice the user must make sure that all requirements for safety on the work site are strictly adhere to 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 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 GF Technical Manual 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
56. ies without written consent Any infringement will be legally pursued 24 V 1 RESHWFK 2 RESHWRP Add open weld electrovalve A Add open weld electrovalve B RESHWFK RESHWRP CEVASA CEVASB RAVEXTA RAVEXTB 2 RAVEXTA 6 7 RAVOKA 8 9 RAVEXTB RAVOKA RAVOKB CHGEOKA CHGEOKB CODEO CODE1 CODE2 CODES CODE4 IN16 CODEP CONSALD RAVOKB CHGEOKA 10 CHGEOKB Bit 0 Bit 1 Bit 2 Bit 3 Bit 4 16 IN16 A C4 md imei AeA W N gt Binary code programs selection Parity code Weld enable Alert Alert Ts dressing request A Tips dressing request A S Tips dressing request B S o Tips change request A Tye change request 8 Tips change request Alarm 1 welding Alarm 2 hardware D Cycle weld request PREALA PREALB RICHRAVA RICHRAVB RICHELA RICHELB ALARM1 ALARM2 RICHSAL 10 FINESAL End of sequence 11 FINESEQ READY EVASA1 EVASA2 EVASB1 EVASB2 c DO 9 N End of welding Weld control ok 12 Additional opening electrovalve A1 13 Additional opening electrovalve A2 14 Additional opening electrovalve B1 15 Additional opening electrovalve B2 16 Short to 24Vdc when the functions are not utilized Pu __ forge _ CONNECTIONS CARD F393 IOE rawr 33033339 02 proprietary rights reserved
57. ith constant current control device addition this could cause serious malfunctioning It is recommended to use current sensors featuring 150 mV kA 1k sensitivity and with a 20 25 Q internal resistor these be ordered from GF Welding S p A The Weld334m permits using up to 6 sensors in series one at 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 power insulation transformer with earthed electrostatic shielding 1 2 5 Phase synchronising for welding To 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 mains it is sufficient for the transformer powering the device to be connected with the same power phase as SCRs If powered from power line other than that of SCRs or DC powered the sync signal must be taken from the power side through an insulation tr
58. l active NOTE The Emergency stop signal is active at OV START EMERGENCY FK if spot done since START ON same as standard condition 6 START disabled condition during the welding pulse START WELD FK a User programmable 0 99 cycles 10 7 Proportional Servovalve operating diagram Servovalve parameters description OFFSET 0 100 active only after a reset until a start cycle Stored in Setup function EV1 0 100 Nominal value during welding cycle Stored in each program Stored in each program EV2 0 100 Pressure variation value Change is done after n cycles and in mode according the 5 available profiles START CYCLE START CYCLE PROGRAM 1 EOCYCLE PROGRAM 2 EV1 75 PGM 1 1 25 EOCYCLE 2 ON WELD GUN VALVE FE t Pressure 96 100 of program 1 THE Tw 75 29 of program 2 HOLD THE VALUE 25 XXXXXX B t HARDWARE RESET OR CONTROL SWITCH ON Pressure Output air pressure percentage of input pressure Examples with 5 bar input amp Q9 50 96 servovalve output 2 5 on on 75 96 3 75 s a 100 96 5 bar servovalve drop not considered 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 c
59. losing of gun B solenoid 2 of solenoid valve B Activated by the CEVASB command As for EVASA2 but for channel B Technical Manual 9 2 P43 Description of the input signals 18 pin 3 5p linear connector for disconnectable terminals 1 RESHWFK Reset hardware alarm Signal 7 Description Type type 2 escription end of sequence RESHWRP Reset hardware alarm with repeat CEVASA Additional opening channel A command 4 CEVASB Additional opening channel B command type 2 6 RAVEXTB Selection of dressing program channel B type2 8 _ RAVOKB Confirmation dressing performed channel B type2 9 CHGEOKA Confirmation electrode change performed channel A type2 11 CODEO Program code bit 0 type 2 14 CODE3 Program code bit 3 type 2 Electrical data Type 2 solid state inputs I EN61131 2 type 2 DC input Rated voltage 24Vdc Max continuous voltage 30Vdc Max non continuous voltage 36Vdc max duty cycle 8096 Max voltage for state 0 5 Min voltage for state 1 11V Min current for state 1 6mA 11V Max current for state 1 30mA 9 30V 35 Technical Manual 36 Functional description of the input signals Pin 1 10 Signal RESHWFK RESHWRP CEVASA CEVASB RAVEXTA RAVEXTB RAVOKA RAVOKB CHGEOKA CHGEOKB Function Reset hardware alarm with End Sequence Active at 24
60. ly Characteristics of current limitation as a function of temperature Power feeder type F350 PSM Temperature C Current A Power feeder type F370 PSM Current A Characteristics refer to the operating temperature of the component itself 17 Technical Manual 3 4 Setting the external synchronism For the firing 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 PWR RTN 1 When the control device is powered from the a c mains taken directly from odi power line of the SCRs jumpers are to be set to PWR RTN standard configuration S132 2 If the synchronism signal is to be taken directly from the power group throughyn RTN an attenuation insulation transformer the jumpers are to be set on 51 52155 This configuration is compulsory when the device is powered from the ad i mains 5152 NOTE The secondary of the insulation transformer is not to be earthed Example of connection for the external synchronism WELD334m PS power supply or i n Power supply 380Vac line privileged gt Insulation tranformer External 12 33Vac hdi 4 Firing device 1 Pls control P21 18
61. n confirmation of electrode replacement 13 END OF STEPPER 1 Bit 1 The programme and number of welds for electrode replacement has been reached for the electrode assigned to Stepper 1 see electrode selection The bit is set to 0 on confirmation of electrode replacement 14 15 Not used Status Word 2 Status Word 2 defines two Bytes included between bits 0 7 and bits 8 15 to communicate the diagnostic information such as the active alarm code FAULT CODE Bit Description 0 jrFautCodebitO S O 4 jrautCodebit4 0240 6 FaultCodebit6 S OE 8 Notused o O 9 Notused 0 02 Status Word 2 Functional description Bit Signal Function 0 7 Fault Code With this byte the control communicates the active alarm code 8 15 Not used 51 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 WeldForcebito Weld Force pit 2 4 WeldForebit 000 6 Weld Force bit6 O 8 Element Thickness Element Mhickness Bit 1 11 Element Thickness bit3 o O Status Word 3 Functional description Bit Signal Function 0 7 Weld Force With this byte the control communicates th
62. n for remote with MDI port In the connection with MDI port the signals are Crossed 1 2 3 4 5 6 7 8 Remote HUB with MDI type port 3 0 NJ 43 GF Technical Manual 13 Profibus DP Profil F PDP 01 44 13 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 F366 PDP Profibus DP and F378 IOE auxiliary 24Vdc inputs and outputs 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 0 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 PDP 01 comprises 4 Control Words 1 4 and 4 Status Words 1 4 For connections specifications and ma
63. nal Synchro it s used when the power and the control are connected to different phases WELD334m Fiat type Date 02 98 or when the control is connected to the 24Vdc power supply CONNECTIONS POWER 24Vdc FIRING AND TRANSDUCERS Set n 1 fof sheet 1 Author To use the external synchro line mode is necessary position switch change pore 33053325 01 proprietary rights reserved by Spa FASE This drawing will not be reproduced or in any way utilized for CS the ufocture of the herein illustrated and must not be released to other parties without on the power supply board M m n SALDATURA Power supply Servo Valve Enable Servo Valve ENSERV ISERV ISERV VSERV D11 STSERV D9 TVE D2 TVE D1 TVESCH RS485 Y SIGNAL RS485 SIGNAL RS485 COMMON RS485 Y TERMINATOR 85485 Y TERMINATOR T 4 WMS NET ADDRESS F355 2 WMS NET ADDRESS NET 0 WMS NET ADDRESS RS485 Y SIGNAL EE emale Y RS485 Y SIGNAL 5485 COMMON XGND ADRCOM WMS NET ADDRESS COMMON OV ADRCOM ADRP PARITY WMS NET ADDRESS ADRP ADR3 3 WMS NET ADDRESS ADRS ADRI BIT 1 WMS NET ADDRESS ADRI Changement Pong joy descr ter gen F355 WMS NET proprietary rights reserved by Spa FASE This drawing will not be reproduced or in any way utilized for the manufacture of the component or herein illustrated and must not be released to other part
64. ntrol 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 24 supply is present before installing the new card How to replace the card YS SP 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 fastening 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 J1 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 Replacing the welding control device Times indicated refer to a manual welding station configuration of the new control device 1 Saving the configuration and programs of the control device to be 1 Minute 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
65. ogram called up electrode pressure etc are integrated with the Spot Index value and the name of the welding spot WARNING If there is no specific parameterization 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 Bi Description 0 SpoindexseeconbitO 4 Spot index selection bit4 5 Spot index selection bit Spot selection bit 6 T 8 Spot index selection bit8 9 jSpotindexseletionbito O For further information please see the WMS manual GF Technical Manual Control Word 4 Control Word 2 defines the command on off of the 16 outputs available on the card F378 These outputs are fully managed by the user The welding control has no type of control or protection over the data contained in this Control Word The maximum load values defined for the F378 IOE card must be respected If the F378 IOE card is not present in the welding control the contents of the Control Word are ignored Command of the 16 outputs is updated every 10msec Description P35 Contact 0 UserdefinedOutputO O 4 UserdefinedOutput 4 4 ____ 5 User defined Output5 6 jUserdefinedOutput 8 jUserdefinedOutput8 9 UserdefinedOutput9 C
66. ogramming manual Welding consent Input active a 24V The welding consent is the weld enable signal it indicates that the welding machine is ready the welding control waits for this signal after it has sent the RI CHSALD signal The control waits until the consent signal is received Card layout standard configuration of the jumpers J1 2 3 JP1 Off 20 via 1 c U13 t Ss T L att P42 014 CU U15 5 La RLA4 o 16 RLB3 o a RLB4 1 11111 P43 na P u 8 LE SO LC amp 37 9 2 1 Program selection code table The binary codes of the 64 welding programs are indicated in the table below DING Technical Manual Even cover P P PR Vol PR RR ERR P program 64 is given by the binary code 0 EE 38 Code 33035900 10 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
67. ommand output will be upgrated according the value stored in the program choosed Also without the Start signals This function is always active Pressure 96 100 2 XXXX 0 t HARDWARE RESET OR WELD PROGRM WELD PROGRM WELD PROGRM CONTROL SWITCH ON CHANGE CODE CHANGE CODE CHANGE CODE ie 2 3 i e 1 changes without start cycle command 11 8 ENABLE function I nterbus s 24V Power Signal P 2 0 10V 4 20mA ENABLE 24V servovalve activ servovalve inactive ov Inpunt Interbus Fase ENABLE Bit 2 Servovalve 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 gt pressure stays unchanged 12 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 Tu DIAG CHECK
68. ontrol Word 4 Functional description Bit Signal Function 0 15 Output command Bit 1 24Vdc present on output Bit 0 24Vdc not present on output 49 Technical Manual 13 1 2 Status Word Status Words indicate to the remote interface device the 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 Bit Description 0 TEND OF SEQUENCE 4 WELD PROCESS FAULT O O OoOO O 6 STATUSSW _______________ 8 PREWARNI NG STEPPER 0 9 __ STEPPER 1 TIP DRESS REQUEST 0 11 TIP DRESS REQUEST 1 END OF STEPPER 1 Status Word 1 Functional description Bit Signal 0 END SEQUENCE Function Bit 1 In single spot functioning this indicates the end of the sequence if the welding cycle has been completed without anomalies Bit 1 Execution of welding cycle with current enabled The welding cycle will be executed with current therefore with command by the power group Bit 0 The diagnostic controls on the welding spot being performed are not active normal welding mode or current Bit 1 The diagnostic controls on the welding spot being performed are active Monitor or Constant Current welding modes Bit 1 Signals that the control cannot detect the signal for 1 WELD ON FEEDBACK 2 KSR NOT USED 3 LINE SYNCHRO FAULT syn
69. otection against permanent short circuits Protection of VSERV outlet pin against accidental contacts up to 36V DC 7 1 2 Current outlet characteristics Range 4 20mA Single ended type with ISERV pin connected with the of the 24SV Maximum load 600 ohm Minimum load 200 ohm Converter resolution 12 bit Converter accuracy 3 156 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 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 J1 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 26 Technical Manual P3 Mounting position of the m F385 SVV Module FA F353 ADC F364 SEV Module Fixing of the module is ensured by the tight fit of the two connectors J 1 3 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 1 0
70. otections operate in the following way 0 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 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 0 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 automatical
71. paragraph 3 4 24Vdc max 0 3A 24Vdc max 0 3A 24Vdc with 10 ohm 2W resistance in series for current limitation Voltage EV EVS Pulse Ctrl Protections Short circuit Overcurrent Overvoltage disturbances and peaks Serial type for GF Welding HHT4300 unit or Laptop PC with WMS GF Welding software Serial via the WMS centralising system see optional 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 depends on the operating conditions Ethernet Tcp lp for WMS centralisation network Parallel standard PCMCIA memory card 0 10V Voltage with protection against short circuit 4 20 mA current Vdc 18Vdc GF Technical Manual 10 2 4 1 Utilisation characteristics The construction complies with the EC requirements CE marking Operating temperature 0 to 60 C humidity 0 to 8096 without condensation Storage temperature 40 to 80 humidity 0 to 9096 without condensation Weight 2 5Kg maximum depending on the configurations 2 4 2 Dimensions overall dimensions and fastening positions 138mm lt p
72. pters of the programming section Machine alarm Active at 24 Blocks the cycle Refers to faults programming errors connection errors of both the control and machine Can be cleared through reset from HHT or from the dedicated inputs RESHWFK and RESHWRP Remains active until the cause has been eliminated 33 Technical Manual 42 Functional description of the output signals Pin 9 10 11 12 13 14 15 16 34 Signal RI CHSALD FINESALD FINESEQ READY EVASA1 EVASA2 EVASB1 EVASB2 Function Welding request Active at 24V At the end of the pressure cycles the control ready to perform the welding impulse activates the welding requests and waits for consent CONSALD P43 18 End Welding Active at 24V At the end of the welding cycles the control activates this message and continues the sequence until opening of the electrodes according to the cycle programmed End of Sequence Active at 24 At the end of the frequency cycles opening of electrodes the control activates this output and terminates the sequence It is cleared at the end of the frequency cycles with the START 0 signal If Repeat is enabled End of Sequence is not performed and the control continues restarting from the pressure cycles see programming manual cycle time diagrams Control ready message output Active at 24 This output is activated when the control is ready i e when
73. r communication of welding 1 0 information The SUB D P14 connector permits connection with the Profibus network An 8 way selector for the Profibus network DP address is provided on the front edge The quantity and type of data exchanged depend on the communication Profile defined for the specific application where Profile is a descriptive document of the data exchanged The F PDPO1 type Profile is associated to the F397 PDP card 11 2 1 14 serial port PROFIBUS DP Sub d 9 pin female connector Pin Funtion 0 9 NC O ____4 INC connected O 8 RXD TXD N DataNreception transmission 2 ox M 6 VRB Characteristics PROFI BUS DP DIN 19245 Part3 standard 50170 Data transfer speed from 9 6kBits to 12Mbit s Distance from 1200m to 100m Recommended components Cable Siemens 6XV1 830 0AH10 Connector Siemens 6ES5 762 2 12 For network wiring refer to the instructions provided in the connector assembly kit 11 2 2 TXD RXD led Two green TXD and RXD leds for serial port monitoring are provided on the front edge These indicate communication activity on the Profibus network DP Communication conditions are normal when both leds flash 11 2 3 ADDRESS selector The eight position selector numbered from 0 to 7 makes it possible to assign an address in binary code for recognition of the device the network by the serial 1 0 m
74. s 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 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 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 effects 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 w
75. t a 150mV kA 3 Rowgowsky type sensor with 20 CURR SENSOR 25ohm internal resistance Sensitivity adjustable 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 pin suma Description 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 22 Technical Manual 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 1 TFEsch Screening of analogue voltage input 4 4 20mA current output for solenoid valve 6 STSERV Semovavestausinut 8 245 Solenoid valve power supply 9 Tre Analogue voltage input 0 10V voltage output for solenoid valve Schield Screening for ISERV or VSERV signal 15 ENSERV Solenoid valve Enable Output P2 Functional description of signals w gt 5 R V V A L V E STS
76. terials please see the documentation Profibus DP DIN 19245 Part 3 m USE Reference module 1 Welding commands towards the control F366 PDP 2 Selection of welding sequence F366 PDP 3 Selection of welding spot Spot Index F366 PDP 4 Commands towards the outputs of the F378 IOE 1 0 module F366 PDP F378 IOE pine USE Reference module 1 Signals from control F366 PDP 2 Diagnostic information from welding control F366 PDP 3 Electrode force and sheet metal thickness values F366 PDP 4 Status of inputs of F378 IOE 1 0 module F366 PDP F378 IOE The modules used to have the following functions Module F366 PDP has a serial port enabling management of data communication in conformity with the specifications of Profibus see chapter F366 PDP for the characteristics Module F378 IOE is I O interface of generic use where the functions of the 1 0 defined by the user through the network Profibus to obtain specific applications of the working cycle for example control and command of guns dressing tools see chapter F378 IOE for the characteristics Technical Manual 13 1 1 Control Word GF The Control 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 Bit Description O0 8 RESET STEPPE
77. umpers J P4 5 8 9 Off P1 JP3 3 4 6 7 J P6 On H aw 2 5 L CES SNY 2 o kis ah u oc x P 08 A JP6 0N INY 5 11 p 1 JP3 20 _ 3 3 4 6 7 21 GF Technical Manual 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 F353 ADC 6 1 P3eP4 Description of the analogue inputs a 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 7 TV Positive signal Negative signal dud 5 R L E P4 TA 9 way Sub d plug connector p Input for acquiring analogue signals 3 It is used for connecting the current sensor The acquisition of this signal when welding current is constant permits the real O time check on the current trend during the welding pulse Input is so arranged to accep
78. urrent 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 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 welding transformer must 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 GF Technical Manual The lead run through by current is to be placed in the middle of the thoroid The sensor i
79. 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 e On a Robot or an automatic installation the destruction of parts onto which the short circuit current is discharged e 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 ER 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 mm 380 500 Differential 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 3 Voltage sensor 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 c

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