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OM-W600P-0410(E) 

     

 

 

 

 

 

 

  RESISTANCE WELDING CONTROLLER   

  WELCOM 600P   

  USER MANUAL   

                    

 

 

 

 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

  

 

 

 

 

 

      CHOWEL CORPORATION 

 

Summary of Contents for WELCOM 600P

Page 1: ...OM W600P 0410 E RESISTANCE WELDING CONTROLLER WELCOM 600P USER MANUAL CHOWEL CORPORATION...

Page 2: ...manual can be changed also without the notice CHOWEL is registered trademark of the CHOWEL CORPORATION CHOWEL FIRST FACTORY 395 3 MOKNAE DONG DANWON GU ANSAN CITY GYEONGGI DO KOREA TEL 82 31 494 2511...

Page 3: ...instructions depends on the level of danger as follows DANGER If shows readers where people will be hurt if procedures are not followed properly WARNING If shows readers where people may be hurt if p...

Page 4: ...controller is charged 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...

Page 5: ...rne in mind that welding machine generates intense magnetic fields Consequently Do not approach the secondary circuit of the machine carrying on your person any article that are likely to suffer damag...

Page 6: ...mming 1 Common program 18 2 Program for each pilot schedule number 20 3 Stepper program for each valve schedule number 23 Chapter 3 Indicator and Monitor data 1 Panel indicator of I O signal 25 2 Moni...

Page 7: ...te sequence at reset 49 Chapter 7 DATA input and monitoring 1 The normal window 51 2 The fault window 53 3 Function select mode 53 Chapter 8 Troubleshooting 1 External I O checking 60 2 Program checki...

Page 8: ...d touch to the component of PCB 2 3 To transport use a vinyl packing paper to become a static electricity protect processing 3 Check point before operation 3 1 The each connected part must be connecte...

Page 9: ...compression air must be provided to the pressure to be determined 4 5 If temperature is lesser than 0 the factory in the winter it have the worry which cooling water system is damaged it must remove t...

Page 10: ...n shut and the door of the T C unreasonable it skew to pull did not exist in the conduit and a conduit fix is not touched at the electrode 1 4 A seepage check Many at a high voltage part danger is in...

Page 11: ...tion of transformer Connect the transformer at the 01 terminal and 03 terminals according to inside the body connection diagram 2 3 the connection of power source Connect the power source at the 01 te...

Page 12: ...welding condition Connect the pilot signal of welding sequence When not used keep this signal open PILOT INPUT The PILOT INPUT 4 BIT 0 signal is binary initiate the sequence when it is turned from OFF...

Page 13: ...is signal open STEEPER RESET When this signal is turned ON the step no and the step counter are reset and the STEPPER COMPLETE OUTPUT is turned OFF Connect this signal to the signal that resets the st...

Page 14: ...used keep this signal open FOOT PALM Chapter 5 3 external input pilot reference The case to use FOOT switch operate ON with a FOOT switch common terminal The case to use PALM switch operate OFF with a...

Page 15: ...OFF c The WELD NO WELD INPUT signal is ON d The EMERGENCY STOP INPUT signal is ON Use this signal for preventing the work from flowing when the operation is in the TEST MODE When not used keep this si...

Page 16: ...m the operators on the maintenance time When not used keep this signal open SELECTABLE OUTPUT This is a no voltage A contact output signal which selects the output function by setting the program acco...

Page 17: ...rt PILOT INPUT signal Schedule No PILOT16 PILOT8 PILOT4 PILOT2 PILOT1 OFF OFF OFF OFF OFF NONE OFF OFF OFF OFF ON 1 OFF OFF OFF ON ON 3 OFF OFF ON OFF ON 5 OFF OFF ON ON ON 7 OFF OFF ON OFF OFF ON 9 O...

Page 18: ...NO and VALVE STEP NO with X1 through X31 Both the program data and the monitor data are arranged with X and Y addresses defined as shown in the following chart COMM sch1 sch31 C 00 C 34 D 00 D 06 D 2...

Page 19: ...determine the secondary cable short circuit A 07 TOTAL WELD COUNT Set the count up output target value of total weld counter common to all the schedule no 1 2 Program of fault detect method Set fault...

Page 20: ...0 the WELD COMPLETE output signal after the abnormal end of the weld sequence will not be turned on Set this at 1 to obtain the WELD COMPLETE output signal even in the case of abnormal end of the weld...

Page 21: ...used treat this in the same way as the SQUEEZE TIME When the PRESSURE CONTROL is used set the pressure stable time after the pressure change For the PRESSURE CONTROL the pressure control unit which is...

Page 22: ...it become feedback control from second CT which copes with the setting no C 23 SCHEDULE WELD COUNT Set the count up reference value of the each schedule weld counter C 24 TESTING CURRENT LEVEL Set the...

Page 23: ...er control of the weld current is not made For the stepper control mode set this at 1 When the GUN VALVE STEPPER select is set at 0 the stepper control is not performed C 33 SCHEDULE WELD COUNTER When...

Page 24: ...in operation N 07 STEP 3 WELD COUNTS 1 9999 TIMES Set the weld count of the step 3 when the stepper is in operation N 08 STEP 4 CURRENT RATE 50 100 Set the weld current rate of step 4 when the stepper...

Page 25: ...CORPORATION 24 N 18 STEP 9 CURRENT RATE 50 100 Set the weld current rate of step 9 when the stepper is in operation N 19 STEP 9 WELD COUNTS 1 9999 TIMES Set the weld count of the step 9 when the stepp...

Page 26: ...e PILOT input 2 is ON this indicator is ON PILOT When the PILOT input 4 is ON this indicator is ON PILOT When the PILOT input 8 is ON this indicator is ON PILOT When the PILOT input 16 is ON this indi...

Page 27: ...tor is ON WELD COMPLETE When the WELD COMPLETE OUTPUT is ON this indicator is ON READY When the READY OUTPUT is ON this indicator is ON COUNTER UP When the COUNT UP OUTPUT is ON this indicator is ON S...

Page 28: ...is active this is ON at the 2 WELD TIME DOWN SLOPE TIME When the PILOT signal is active this is ON at the 2 DOWN SLOPE TIME HOLD TIME When the PILOT signal is active this is ON at the HOLD TIME OFF TI...

Page 29: ...t control mode B 06 FIRING ANGLE This item indicates average value of the actual firing angle of the thyristor in the 1 WELD TIME B 07 EXTINCTION ANGLE This item indicates average value of the actual...

Page 30: ...ndicates the input gain select value of the crrent detect circuit If the current detection does not work in the voltage compensation control mode this item should be changed D 01 POWER FACTOR This ite...

Page 31: ...normal operation of the new controller turn ON the power again E04 NO PRESSURE CONTROLLER This fault is checked for when the initiation is made and alarmed immediately if any This fault indicates that...

Page 32: ...re and cylinder dimension to be set are proper E24 BATTERY DOWN This fault is checked for when the power is turned ON and alarmed immdeiately The battery LED of front panel is twinkles if battery volt...

Page 33: ...dary CT or external wiring Replace external wiring or secondary CT E50 SCR OVER TEMPERATURE This fault is checked for at the initiation and alarmed immediately if any This fault indicates that the thy...

Page 34: ...edule that caused fault in the reverse order of occurrence B 29 FAULT SCHEDULE 9 This item indicates the oldest schedule of all fault schedules in the fault schedule history 2 2 Fault history for each...

Page 35: ...per control of the schedule no to on Set the stepper reset procedure according to the usage Check the present stepper and if necessary reset the stepper Operation procedure There is no special operati...

Page 36: ...h step Thefinal step is always the 9th step To use the output while the final step is in operation set the STEP WELD COUNTS for the 9th step at any other value than 0 The reset operation can be reset...

Page 37: ...ONDARY CABLE BREAK at ALARM Operation procedure There is no special operation required during the normal welding because of the disconnection predict function After processing The case is predicted to...

Page 38: ...ns OFF Squeeze time 1 cycle Weld time 1 cycle Hold time 1 cycle Weld complete time 6 cycle until the pilot signal turns OFF After processing If the short circuit is not detected the weld complete sign...

Page 39: ...s to mark the PILOT INPUT MEHTOD of a control device Figure 5 2 3 1 The case to connect RETRACT ON EXT PILOT ON FOOT PALM ON FOOT This use the FOOT SWITCH operates like Figure 5 3 ON implies here the...

Page 40: ...se the PILOT 1 2 4 8 and operate The PILOT schedule Here is the P1 SWITCH operated ON OFF of the RETRACT VALVE 1 the PA1 SWITCH is operate ON OFF of the RETRACT VALVE 2 3 4 The case to connect RETRACT...

Page 41: ...OFF EXT PILOT ON FOOT PALM OFF PALM The PILOT to the input at PILOT 1 2 4 8 does the welding by the PALM SWITCH A1 A 3 7 The case to connect RETRACT OFF EXT PILOT OFF FOOT PALM ON FOOT or OFF PALM The...

Page 42: ...time irregularity of each pilot signal in the binary pilot mode 1 Basic operation sequence 1 1 Two time weld control sequence Pilot input Valve output Weld Current Weld Complete Output ISQ SQ PU US1 W...

Page 43: ...DS2 CT CT HT CD OT OFF OFF OFF OFF Number of Pulsation 4 In REPEAT mode US2 WT2 DS2 US2 WT2 DS2 ISQ Initial Squeeze Time US Up Slope Time 2 SQ Squeeze Time WT 2 Weld Time PU Pressure Stable Time DS Do...

Page 44: ...S2 WT2 DS2 HT OFF OFF OFF OFF SQ PU US1 WT1 DS1 CT US2 WT2 DS2 HT CD OT CD Approx 6cycle ISQ Initial Squeeze Time US Up Slope Time 2 SQ Squeeze Time WT 2 Weld Time PU Pressure Stable Time DS Down Slop...

Page 45: ...equence in the pulse start mode set the initiation pulse width at rather large value to have a secure initiation Pilot input Pulse signal Valve output Weld current Weld Complete Output ISQ SQ PU US1 W...

Page 46: ...WELCOM 600P CHOWEL CORPORATION 45 1 5 Sequence at a pressure pilot When sequence is not operated valve output is operated according to ON OFF of pilot input Pilot input Valve output OFF OFF...

Page 47: ...lock waiting CT Cool Time Notes The above chart shows a case where PULSATION is set for one time Notes a The interlock input is checked after sequence starts before the initial weld current control st...

Page 48: ...00P CHOWEL CORPORATION 47 2 Fault warning output sequence 2 1 Sequence when detection is made at the initiation Pilot input OFF Valve output OFF Weld complete output OFF Fault output OFF Fault reset i...

Page 49: ...CD OFF OFF OFF OFF US2 WT2 DS2 OFF OFF Fault output Fault reset input If weld complete is ON in case of fault ISQ Initial Squeeze Time US Up Slope Time 2 SQ Squeeze Time WT 2 Weld Time PU Pressure St...

Page 50: ...urrent Weld Complete output ISQ SQ PU US1 WT1 DS1 CT HT CD OFF OFF OFF OFF US2 WT2 DS2 OFF Fault output OT In repeat mode Number of pulsations repeat ISQ Initial Squeeze Time US Up Slope Time 2 SQ Squ...

Page 51: ...PU US1 WT1 DS1 CT US2 WT2 DS2 HT OFF OFF OFF OFF US1 WT1 DS1 CT US2 WT2 DS2 HT CD REWELD sequence ISQ Initial Squeeze Time US Up Slope Time 2 SQ Squeeze Time WT 2 Weld Time PU Pressure Stable Time DS...

Page 52: ...ator of I O signal SEQUENCE INDICATOR LED When the sequence control this indicate the condition of signal normally Reference Chapter 3 1 3 Panel indicator of sequence signal VFD INDICATOR WINDOW It is...

Page 53: ...dress of each area It is able to move to key Init Squeeze Time Among a two s address to be indicating is indicated to the range of the address of direction with the cursor or the description data to s...

Page 54: ...rent to the key can see 3 The function select mode 3 1 Function select The indicator of VFD appears with the Figure 3 1 if it pushs the key Function Data Initialize Schedule Duplicate Reset Function F...

Page 55: ...control device eliminate it is substituted to initialized data in memory The initialization of welding condition accomplish as follows 1 2 the VFD window is indicated to Figure 3 2 if it is pushed to...

Page 56: ...to input when it is identical 4 It press key the cursor move to 5 Input a schedule NO of the place to COPY 6 It press key the cursor move to 7 It inputs the number with if there is an one place to CO...

Page 57: ...dule Duplicate Reset Function Schedule Duplicate Execute by ENT key Sch 03 Sch 02 Sch Schedule Duplicate Execute by ENT key Sch 01 Sch 02 Sch Schedule Duplicate Execute by ENT key Sch 03 Sch 02 Sch Sc...

Page 58: ...unction Data Initialize Schedule Duplicate Reset Function Schedule Duplicate Execute by ENT key Sch 01 Sch 02 Sch Schedule Duplicate Execute by ENT key Sch 01 Sch 02 Sch Schedule Duplicate Execute by...

Page 59: ...e reset function is 1 STEPPER RESET 2 COUNTER RESET 2 kinds 3 If it is accomplished to stepper reset the indicator of VFD is indicated to Figure 3 7 when it pushed the key number Stepper Reset Execute...

Page 60: ...the timer no presently selected press the wanted timer no 0 15 press the key twice the timer no change and the normal display will be resumed Notes The function is valid in the control unit to have a...

Page 61: ...ng history which is saved at the TIMER is initialized Notes This function is used to the case which manage welding DATA to the communication of the PC 3 8 THE POWER SOURCE VOLTAGE MEASUREMENT It does...

Page 62: ...the welding controller and the external I O signal Use this table for troubleshooting Operation mode Test mode Weld mode Operation status Inactive Active Inactive Active POWER LED ON ON ON ON PILOT IN...

Page 63: ...P input signal is not ON Check the wiring to the terminal block or the signal source f The EXTERNAL THERMO input LED is not ON The EXTERNAL THERMO input signal is not ON Check the wiring to the termin...

Page 64: ...eals in the terminal of the device to take It confirm and deals whether an output signal does not have the danger by outbreak action in SOL VALVE or PLC signal termainl after power source is supplied...

Page 65: ...AT FAULT to ON and the trouble will be solved in most cases e Check the length of SHANK and the STROKE of GUN If it makes short by tip dress it may cause no current f When the gun is pressed by the P...

Page 66: ...nt of the welder is impossible b Check the setting up of a low current detection level and the welding time To prevent the overshunt of weld current or inrush current not to flow the current at the sa...

Page 67: ...LE CONDUCTING ANGLE 180 deg EXTINCTION ANGLE 1 2 Control situation in weld and rangle of monitor a After pressure cycle a 1 cycle of current start is normally substituted to TEST CURRENT of fixed firi...

Page 68: ...f TR b When Weld current is increased Actual TR Margin is small because power source is fallen c A computation error of TR Margin is proportional to the size of power source degradation and increases...

Page 69: ...LTAGE IN WELD E12 SELECTABLE MEMORY DATA ERROR E20 FAULT CURRENT PROGRAM ERROR E21 FAULT PRESSURE PROGRAM ERROR E22 FAULT BATTERY DOWN E24 ALARM NO CURRENT FAULT E30 FAULT SCR SHORT E31 FAULT SECONDAR...

Page 70: ...WELCOM 600P CHOWEL CORPORATION 69 PROGRAM DATASHEET OF WELCOM 600P...

Page 71: ...WELCOM 600P CHOWEL CORPORATION 70 ELECTRICAL CONNECTION DIAGRAM OF WELCOM 600P...

Page 72: ...WELCOM 600P CHOWEL CORPORATION 71 OUTSIDE VIEW OF WELCOM 600P...

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