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CHOWEL PATC--150A-EU, Instruction Manual

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OM-PATC150A-EU_061205E

INSTRUCTION M ANUAL

FOR

RESISTANCE WELDING CONTROLLER

& TRANSFORMER

( MODEL : PATC

­

150A-EU )

CHOWEL  CORPORATION

Summary of Contents for PATC--150A-EU

Page 1: ...OM PATC150A EU_061205E I N S T R U C T I O N M A N U A L FOR RESISTANCE WELDING CONTROLLER TRANSFORMER MODEL PATC 150A EU CHOWEL CORPORATION...

Page 2: ...fore installing operating or maintaining this equipment This equipment and this manual are for use only by persons trained and experienced in the safe operation of welding equipment Do not allow untra...

Page 3: ...ten approval from CHOWEL and may not be copied used or disclosed to others without prior written approval from CHOWEL Users are cautioned that the material contained herein is subject to change by CHO...

Page 4: ...manual After the expiration of guarantee period Earthquake fire riot violence war and any other natural disaster Modification repair or adjustment is performed by unauthorized person Contact your sal...

Page 5: ...EC Directives based on its design and type as brought into circulation by us The followings are the requirements applied Comply with the following provisions applying to it Low Voltage Directive 73 23...

Page 6: ...d with high voltage electricity Turn electrical power OFF before open the door In the case the door is opened as it is not turn OFF can lead to injury by an electric shock or death of personnel WARNIN...

Page 7: ...at welding machine generate intense magnetic fields Consequently Do not approach the secondary circuit of the machine carrying on your person any article that are likely to suffer damage These include...

Page 8: ...Specification 7 3 4 T C Specification 9 4 Commissioning 4 1 Initialize the program sheet 14 4 2 Setting the turns ratio 15 4 3 Test welds in TEST mode 15 5 Installation 5 1 Caution on installing 16 5...

Page 9: ...r troubleshooting 52 8 Regular inspection Maintenance 8 1 Daily 53 8 2 Weekly 53 8 3 Monthly 53 8 4 Quarterly 54 8 5 annually 54 APPENDIX 1 Weld program sheet 55 2 Electrical connection diagram for PA...

Page 10: ...o user s convenience that enables higher quality and reliable welding Thyristor are fitted which capacity 900A 1200V at continuous load in primary circuit of welding transformer Using 8bit high perfor...

Page 11: ...se Programmable up slope Automatic reweld in the event of weld failure Fault output 2 schedule counter Each valve output Programmable 2 schedule for heat step up Remote programming Built in diagnostic...

Page 12: ...n you are ready to enter the settings into the PATC 150A EU you need simply refer to your entries in the tables The tables may also be used as a permanent record of the settings On reading Chapter 6 D...

Page 13: ...uring installation Make earth connections in accordance with EN regulations Wiring Regulations or to the standard that applies in your country Clear plastic panel cover the components operating at hig...

Page 14: ...leave the SCR box cover remove unnecessarily This may allow dirt and moisture to enter the unit Make sure the door is fully closed and the fastener is tightened Do not pour or spray water over the cas...

Page 15: ...y wire linking the runway trolley the transformer are fitted 3 2 T C Function 3 2 1 Welding Condition and Current Control Weld Schedule 15 Binary 4 bit Gun Valve Select 2 Current Control Voltage compe...

Page 16: ...ore by Lithium battery 3 3 TRANSFORMER Specifications 3 3 1 General Specification Model PATC 150A EU Rated Capacity at the 50 D C KVA 150 Rated input voltage V 380 Phase Single Rated frequency 50 60 M...

Page 17: ...80 at the water inlet Cooling water quantity 6 min for only TR Electric resistivity More than 5000 cm 3 3 3 Air supply circuit diagram Function of each part Ball Valve Check valve main air line ON OF...

Page 18: ...to partially remove foreign matter held in suspension Water manifold Cooling water device which provides multiple connection ports Water flow indicator See cooling water flowing at a controlled rate B...

Page 19: ...System Synchronous phase control by Thyristor 3 4 7 Weld current control method Constant current control Loop control by means of primary current feedback Voltage compensation control Open loop contro...

Page 20: ...CHOWEL PATC 150A EU 11 Pulsation 1 9 times...

Page 21: ...Stepper complete 1a Fault 1a Contact load voltage AC130Vrms DC170V Cont max value Contact load current 0 15A Cont max value 3 4 11 Stepper function Stepper schedule 2 On each valve output Number of st...

Page 22: ...tep number 0 5 Step weld counter 0 9999 Weld counter 0 99 999 999 Common monitor Schedule no 1 to 15 Fault code no 0 to 99 Average Firing angle 1 2 weld 20 to 150 degree Average weld current 1 2 weld...

Page 23: ...d complete output OFF ISQ SQ US WT1 CT WT2 HT OT Pulsation repetition For repeat operation ISQ Squeeze delay time CT Cool time SQ Squeeze time WT2 2 weld time US Up slop time HT Hold time WT1 1 weld t...

Page 24: ...machine will be activated Beware that the welding machine may inadvertently be activated Take precautions as given in the instructions for the welding machine and in the factory safety standard prevai...

Page 25: ...sed MODE key the mode will changed as WELD TEST and PRESS TEST Instruction of each mode operation is as under mentioned WELD Sequence is active and weld TEST Sequence is active and not weld PRESS TEST...

Page 26: ...g water and compressed air Check if cooling water and compressed air is leaking 5 2 mechanical install If you want to install the welding transformer and controller on a hook or a trolley hanger you m...

Page 27: ...tage The controller adjusts itself for 50Hz or 60Hz supply frequency The supply must always be switched by an individual isolator for each PATC 150A EU Use the table below as a guide to size of wire b...

Page 28: ...rate of welding machine s margin is 100 5 4 Control signals Refer to your system configuration table for the control signal and solenoid connection that you will need to make Fig 5 6 shows how can yo...

Page 29: ...24 Volts DC supply The 0 Volt output of the external 24 Volts supply is to be connected to connector the 24 volts output to connector The current rating of output is 0 15 Amp The supply for the solen...

Page 30: ...where the vibration occurs to impact on the equipment where the surroundings temperature is over 40 and where the corrosive and explosive gas comes 5 6 Caution on Operation Prior to power source swit...

Page 31: ...electric shock Those panel should be removed only when the electric supply has been disconnected externally Once they are removed access is gained for marking connections and for carrying out replacem...

Page 32: ...EU Timer unit controls the welding operation Welding current may be programmed under phase angle control in terms of heat or under constant current control in amps A teach facility simplifies setting...

Page 33: ...sequence will be in the self holding status Connect this signal to the weld sequence initiation signal When not used keep this signal short circuit to ON COUNT RESET When this signal is turn ON only t...

Page 34: ...nal short circuit to ON External Output signals For all the output circuits a solid state is used VALVE OUTPUT 1 This is voltage output AC100V or DC24V for solenoid valve no 1 Connect this signal to t...

Page 35: ...nal for welding result or the Timer unit When not used keep this signal open 6 6 Programming Program the operation of the welding Timer unit the weld condition and the constant of the welder to be use...

Page 36: ...1 When the GUN VALVE STEPPER select is set at 0 the stepper control is not performed Y31 PULSE PILOT If this is set at 0 the self holding of the pilot input signal will not be made until the weld init...

Page 37: ...ion after initiation Y1 SQUEEZE TIME Set the time from when the VALVE OUTPUT signal is turned ON to when the squeeze completes This is always effective including for repeat mode operation Y3 UP SLOPE...

Page 38: ...y and secondary windings of the weld transformer Y21 GUN VALVE STEPPER SELECTOR Set the valve output destination stepper condition select When this is set at 0 neither of the squeeze output is any one...

Page 39: ...e weld current rate of step 4 when the stepper is in operation Y49 STEP 2 WELD COUNT 1 TO 9999 TIMES Set the weld count of the step 4 when the stepper is in operation Y52 STEP 3 CURRENT RATE 50 to 200...

Page 40: ...is ON this indicator is ON FAULT When the FAULT OUTPUT is ON this indicator is ON TR SCR THERMO When the both SCR and the TRANSFORMER THERMO input are ON this indicator is ON READY When the READY OUTP...

Page 41: ...of the thyristor in the 1 WELD TIME Y79 1 WELD CURRENT This item indicates average value of the weld current in the 1 WELD TIME in the constant current control mode Y80 1 LINE VOLTAGE This item indic...

Page 42: ...REAK DECISION This item indicates the frequency that the test current is judged to be continuously lower than the BREAK DETECTION LEVEL 6 8 Fault detection Fault is checked for at the time of power on...

Page 43: ...power is turned on and alarmed immediately if any This fault indicates that the power has been shut OFF during the welding or the drastic voltage drop was caused Check whether the weld during the powe...

Page 44: ...e disconnection of the secondary cable is imminent The imminent disconnection is predicted based on the probability Before replacing the secondary cable Check the impedance again for the reconfirmatio...

Page 45: ...ith communication Check the communication connector and the communication cable for disconnecting 6 8 2 Fault history The faults caused are recorded according to the schedule and the fault code for us...

Page 46: ...is tells the operator the time of the electrode tip dressing or replacement SETTING PROCEDURE a Set the stepper program of the valve no to be used b Set the stepper control of the common program to on...

Page 47: ...in the following diagram set the stepper so that the weld is counted and the weld current can be gradually increased as the electrode tips wear Weld current STEP 2 COUNTS Step 4 final step Step 3 Ste...

Page 48: ...G a Check again the secondary cable to be replaced with a low resistance checker before replacing b Replace the secondary cable c Try welding a few times or set again the BREAK DETECTION to 0 NOTES a...

Page 49: ...ven if the counter has not yet counted up it will be reset in the same way 6 10 2 Repeat function As long as the pilot input is ON the sequence from the squeeze time to the off time is repeated and th...

Page 50: ...o the Low Current Limit X0 Y2 50 to 99 6 11 Current Control method The current control method has two modes constant current and voltage compensation Select suitable one according to the specification...

Page 51: ...TTING METHOD a Set the current taking the weld current at rated voltage as 100 b Setting range 20 to 130 TURNS RATIO No need to set COMPENSATION FACTORS a Power voltage compensation only b For welding...

Page 52: ...of the initiation switch or the delay and correcting the time irregularity of each pilot signal in the binary pilot mode 6 12 1 Basic operation sequence TWO TIME WELD CONTROL SEQUENCE Pilot input OFF...

Page 53: ...FF Weld current OFF Weld complete output OFF ISQ SQ US WT1 CT WT2 CT WT2 CT WT2 CT WT2 HT OT NO of PULSATION In Repeat mode ISQ Initial Squeeze Time CT Cool Time SQ Squeeze Time WT2 2 Weld Time US Up...

Page 54: ...OFF Weld current OFF Weld complete output OFF ISQ SQ US WT1 CT WT2 HT OT SQ US WT1 CT WT2 HT Repeat Unit Approx 6 cycles ISQ Initial Squeeze Time CT Cool Time SQ Squeeze Time WT2 2 Weld Time US Up Slo...

Page 55: ...in a short time When the weld sequence is used in the pulse start mode set the initiation pulse width at rather large value to have a secure initiation Pilot input Pulse signal more than 5cycles OFF...

Page 56: ...150A EU 47 6 12 2 FAULT and ALARM signal output sequence SEQUENCE WHEN DETECTION IS MADE AT THE INITIATION Pilot input OFF Valve output OFF Weld complete output OFF Fault output OFF Fault reset input...

Page 57: ...put If Weld Complete is ON in case of fault OFF Fault output OFF Fault reset input OFF ISQ SQ US WT1 CT WT2 HT ISQ Initial Squeeze Time CT Cool Time SQ Squeeze Time WT2 2 Weld Time US Up Slope Time HT...

Page 58: ...t is made by the pilot input Pilot input OFF Valve output OFF Weld current OFF Weld complete output OFF Fault output OFF ISQ SQ US WT1 CT WT2 HT OT number of pulsation repeat In repeat mode ISQ Initia...

Page 59: ...the NO CURRENT the EXTREMELY LOW CURRENT and the LOW CURRENT reweld is not made Pilot input OFF Valve output OFF Weld current OFF Weld complete output OFF ISQ SQ US WT1 CT WT2 HT US WT1 CT WT2 HT whe...

Page 60: ...ON ON f FAULT INPUT indicator OFF OFF OFF OFF The WELD NO WELD input indicator always indicates the external input signal status and therefore is not related to the WELD NO WELD mode selector at the T...

Page 61: ...whether the squeeze time is sufficient or not If the squeeze has not yet completed by the time when the weld initiation it may cause no current b When the controller is used in the VOLTAGE COMPENSATE...

Page 62: ...n the turns ratio setting result in the error in the current c Check the setting of the SPECIFIED CURRENT or the COMPENSATE CURRENT Make sure that the applicable current setting items are not the same...

Page 63: ...ine pressure Empty air line filters Check lubricators oil level Feel solenoid valves for overheating listen for hum indicating improper seating of spool 8 2 Weekly Check air supply unit circuit system...

Page 64: ...n all connections for good contact Check air gauges and regulators with pressure indicator Clean or replace airline mufflers lubricator and filter Confirm the safety by checking safety main hanger Eye...

Page 65: ...CHOWEL PATC 150A EU 56 1 Weld program sheet...

Page 66: ...0 L1 L2 01 03 SCR TH CIRCUIT DIAGRAM CEN 0611 2006 11 15 MAIN PCB PC 734 WELDING POWER SUPPLAY B6 B7 B8 B9 9S TB RB 1 9 MCCB F2 2A F1 2A CR1 CN7 14P 1 11 10 14 CN8 12P 1 11 10 12 DISPLAY PCB PC971209...

Page 67: ...CHOWEL PATC 150A EU 58 3 I O connection diagram...

Page 68: ...CHOWEL PATC 150A EU 59 4 RC 05 wiring diagram...

Page 69: ...CHOWEL PATC 150A EU 60 5 Outside view of PATC 150A EU...

Page 70: ...CHOWEL PATC 150A EU 61 6 Outside view of TB 30...

Page 71: ...CHOWEL PATC 150A EU 62 7 Outside view of RB 10...

Page 72: ...CHOWEL PATC 150A EU 63 8 Electrical connection for step down T R and SCR...

Page 73: ...CHOWEL PATC 150A EU 64 9 Connection diagram for Timer Box connector 10 Connection diagram for SCR Box connector...

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