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Weld334m - User’s manual

4 – EMERGENCY STOP condition during or outside the welding pulse

NOTE: The Emergency stop signal is active at 0V

During emergency time-period situation the welding control behaviour will be:

- A started spot must be ended. In case of bad quality spot, with retry function programmed, all

required retry-spots must be done

- If a quality spot alarm occurs it can be reset by PC or HHT

- NO dedicated message is generated/stored, to indicate the situation

- This situation is not to be considered an emergency but just a standard cycle operation, during that,

all process have to be suspended

EMERGENCY

SIGNAL

PRE SQUEEZE

WELD

HOLD

SQUEEZE

SPOT DONE

NO FK

ALARM

NO SPOT

CYCLE

CASE 1

CASE 2

Closed

(If it happens)

Open

Closed

Open

CURRENT

Summary of Contents for Weld334m

Page 1: ...USER S MANUAL Weld334m HC HCM HIC HIM Ed 5 December 2004 Doc 39000326...

Page 2: ...ed 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 dist...

Page 3: ...00 programming unit 14 2 4 4 Connection through Laptop 14 3 POWER SUPPLY AND 24V FOR I O 15 3 1 CONTROL DEVICE POWER SUPPLY 15 3 1 1 PS Description of signals 15 3 1 2 Connections for main power suppl...

Page 4: ...Ethernet 100Base T connector 54 12 2 4 Ethernet status LED s 54 12 3 ETHERNET CONNECTION CABLE 54 12 3 1 Features 54 12 3 2 Connection type 54 13 F383 COM RS422 SERIAL COMMUNICATION CARD 57 13 1 P15...

Page 5: ...agnostic pressure control 80 Interbus S general architecture of I O communications 81 Ethernet Tcp Ip Example of network architecture 82 InterBus S Example of network architecture 83 WHITE PAGE 84 APP...

Page 6: ...Weld334m User s manual VI WHITE PAGE...

Page 7: ...arts 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 t...

Page 8: ...entrusted only to qualified personnel Incorrect parameter settings may cause damage or injury because of undesired molten material splashes during welding It is compulsory to wear protective goggles...

Page 9: ...d 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 f...

Page 10: ...dary 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...

Page 11: ...ng 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 co...

Page 12: ...uptions 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 w...

Page 13: ...ng 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...

Page 14: ...Weld334m User s manual 8 WHITE PAGE...

Page 15: ...mits 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...

Page 16: ...tional configuration card pack I O Expansion Memory Card Printer EVS Proportional Network Through these cards the control device can Be configured for advanced or special applications which are used i...

Page 17: ...00 33035900 33038100 33038600 Card name F370 PSM F351 BUS F363 DPY F384 CPU F353 ADC F364 SEV F360 IOB F356 IOE F376 OPC F359 MCP F381 ETH F386 ETH Card description Order code Type Power supply BUS in...

Page 18: ...ELDING centralising system see optional Current sensor input TA type 150mV kA adjustable Analogue voltage input TV 36V max Analogue voltage input TFE 36V max External sync 12 33Vac System program On f...

Page 19: ...s CE marking Operating temperature 0 to 60 C humidity 0 to 80 without condensation Storage temperature 40 to 80 humidity 0 to 90 without condensation Weight 2 5Kg maximum depending on the configuratio...

Page 20: ...mensions L 200mm H 90mm Pr 35mm Operating temperature 0 to 45 C with humidity from 0 to 80 without condensation Storage temperature 40 to 80 with humidity from 0 to 90 without condensation Weight 500g...

Page 21: ...ce 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 sy...

Page 22: ...er 14 4 32 4Vac Dc supply 1 2 3 4 WELD334m PS P21 Firing device SCR 1 2 Insulation transformer Welding transformer 380Vac line Power supply External Sync Pulse control 12 33Vac 24Vdc external power fe...

Page 23: ...d334 24 0V I O 3 2 1 Selecting 24V internal or external 24V supply for I O input is distributed in such a way to have two internal separate lines These lines are alternate between one another One line...

Page 24: ...supply connected to pin 6 and pin 7 of the PS see paragraph 3 2 2 figures c and d Summary Table of 24V I O jumpers of cards 24V Selection J1 J2 Internal 1 2 1 2 Internal indirect 2 3 1 2 External 2 3...

Page 25: ...eeder side Faston 1 2 3 4 P20 1 2 3 4 5 6 7 0V 8 0V PS PWR External power feeder 24VE 24 0 SYNC Power supply External synch Weld334m 24 0V I O If earthing for 24VE supply has been performed on the ext...

Page 26: ...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 necessa...

Page 27: ...mains taken directly from the power line of the SCRs jumpers are to be set to PWR RTN standard configuration 2 If the synchronism signal is to be taken directly from the power group through an attenu...

Page 28: ...Weld334m User s manual 22 WHITE PAGE...

Page 29: ...ogramming unit HHT JP1 connector is used to power the programming keycard via CPU The connectors JP2 3 4 5 6 distribute 24VI and 24VE supply for the I O points Connectors P1 6 form the digital BUS P1...

Page 30: ...Weld334m User s manual F351 BUS Interconnection card 24 WHITE PAGE...

Page 31: ...n intervenes Reset push button The Reset push button is placed in the lower part This control has direct influence on the 68332 and is used in case of system shutdown to re start the program with no n...

Page 32: ...Weld334m User s manual F384 CPU Microprocessor card 26 Card layout Standard setting of jumpers JP4 5 8 9 Off JP3 3 4 6 7 JP6 On...

Page 33: ...It is used for connecting the current sensor The acquisition of this signal when welding current is constant permits the real time check on the current trend during the welding pulse Input is so arran...

Page 34: ...erating 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 100 of the pressure value w...

Page 35: ...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 So...

Page 36: ...Weld334m User s manual F353 ADC Analogue Card 30 WHITE PAGE...

Page 37: ...tions 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...

Page 38: ...th the 0V of the 24SV Maximum load 600 ohm Minimum load 200 ohm Converter resolution 12 bit Converter accuracy 3 lsb Protection against permanent short circuits Protection of ISERV outlet pin against...

Page 39: ...Use of 24V I O 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 J5...

Page 40: ...Weld334m User s manual F364 SEV and F385 SEV Proportional Servovalve Modules 34 WHITE PAGE...

Page 41: ...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...

Page 42: ...Weld334m User s manual F359 MCP Memory Card and Printer 36 WHITE PAGE...

Page 43: ...ource for 24V supply is dependent on the type of connection used on the PS connector of the power feeder see technical section of power supply 24V is protected against short circuit by the self resett...

Page 44: ...time with current 10mA In the case of a Weld334m IMF integrated inverter the function becomes Inverter Ready P21 Functional description of signals Pin Signal Function 1 24TRASF 24V power supply to SCR...

Page 45: ...nd of the pressure cycles the control device ready to execute the welding pulse activates the request for welding and waits for the consent CONSALD CONS TO WELDING It needs a common wire contact 11 co...

Page 46: ...Weld334m User s manual F360 IOB I O Basic card 40 Card layout jumpers setting JP1 Off J1 2 3 24 Vdc External J2 1 2 24Vdc Internal...

Page 47: ...rent Welding diagnostics 11 READY Ready Status 12 STATUS Weld Yes No Status 13 EVSA Channel A welding Solen Valve Solen Valve control 14 EVASA Channel A addit Opening solen Valve Solen Valve control 1...

Page 48: ...set automatically but it can be fitted with a shutdown function in the Setup menu See chapters on Alarms and Setup in the programming section 8 ALARM2 Machine alarm Active at 24V It shuts down the cyc...

Page 49: ...is not recognised and the electrodes go open again When the pressure cycles are completed the Start signal stays in the self holding mode up to the end of the Holding cycles See cycle time diagrams i...

Page 50: ...de 17 CODEP Program code parity code 18 RESAH Alarm 2 reset P24 Functional description of input signals Pin Signal Function 1 STARTA Channel A Start Active at 24V The control device activates the EVSA...

Page 51: ...rm counter reset Active at 24V It clears the counter of spots active on channel A if no dressing or electrodes change is active 8 RESASB Same as RESASA but for channel B 9 RAVOK Validation of Dressing...

Page 52: ...It is used for the logic check of CODE0 5 inputs and is dependent on the setting done in the Setup menu see list of codes on page 47 Warning If not used this input must be disabled see Setup section...

Page 53: ...ary codes of the 64 welding programs Si gnal s Par i t y CO DE0 CO DE1 CO DE2 CO DE3 CO DE4 CO DE5 CO DEP Even O dd PRO G RAM 64 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27...

Page 54: ...Weld334m User s manual F356 IOE I O Expansion Card 48 WHITE PAGE...

Page 55: ...e internal bus the second part comprises an optical interface circuit towards the field powered by an external 24Vdc through the P25 connector Thus the InterBus S serial communication as it is autonom...

Page 56: ...ion Related bit ST START Welding sequence start Control Word 1 Bit 0 FK FINESEQ Sequence end active Status Word 1 Bit 0 MS STATUS Weld YES enabled Control Word 1 Bit 7 BE READY Control device ready St...

Page 57: ...2 Under normal operating conditions of the InterBus S Bus if the control device is switched OFF the F376 OPC card generates a Module error type error and sends a Peripheral error indication signal to...

Page 58: ...Weld334m User s manual F376 OPC Field Bus InterBus S Card 52 Card layout...

Page 59: ...case of breakdown without having to carry out manual net configuration operations on the replacement control device To set the addresses for connection to the network please consult the programming m...

Page 60: ...thernet connection cable 12 3 1 Features Cable type 100Base T Category 5 or 5e UTP up to 100m Cable type 10Base T Category 3 4 5 or 5e UTP up to 100m 12 3 2 Connection type The RJ45 connection layout...

Page 61: ...Weld334m User s manual F386 Ethernet 100Base T and CANbus module 55 Card layout...

Page 62: ...Weld334m User s manual F386 Ethernet 100Base T and CANbus module 56 WHITE PAGE...

Page 63: ...omaly in the serial port or in the cable one or both LEDs remain switched ON or OFF 13 1 P15 Connection port Sub D 9 pin Female Connector Pin Signal Function 5 RXD Inverting differential input 9 nc No...

Page 64: ...Weld334m User s manual F383 COM RS422 Serial communication card 58 Card layout...

Page 65: ...re 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 I...

Page 66: ...change has been completed The signal must be active for at least 100 ms 4 Reset Alarm Bit 1 All alarms no longer active will be reset without further action from the welding control 5 6 Reset alarm S...

Page 67: ...r gun 8 8 Not used 9 Not used 10 Not used 11 Not used 12 Not used 13 Start log 14 Stop log 15 Reset communication fault Control Word 2 Functional description Bit Signal Function 0 7 Reset gun 1 8 step...

Page 68: ...tc are integrated with a Spot Index value and the name of the welding spot WARNING If there is no specific parameter setting where a program code value different from zero Control Word 1 bit 8 13 and...

Page 69: ...without anomalies 1 RICHRAV Bit 1 The welding control requires electrode to be dressed The bit is set to 0 when dressing gives confirmation through the signal electrode dressing end 2 PREALARM Bit 1...

Page 70: ...LARM 2 Bit 1 Signals the presence of an alarm with error code 50 planned alarm 13 15 Not used Status Word 2 Status Word 2 defines the commands relating to the management of supplementary stepper funct...

Page 71: ...bit 4 13 Element Thickness bit 5 14 Element Thickness bit 6 15 Element Thickness bit 7 Status Word 3 Functional description Bit Signal Function 0 7 Weld Force With this byte the control communicates...

Page 72: ...set The information is confirmed by the robot via the inputs Bit 0 7 Reset gun confirmation The detailed description of this function is given in the Programming Manual of the Weld 334m Weld334 in out...

Page 73: ...Weld334m User s manual 67 APPENDIX...

Page 74: ...Weld334m User s manual 68...

Page 75: ...they are done correctly Replacing the modular cards 1 Switch off the machine and disconnect wiring 2 Disassemble the control device from the machine support 3 Remove the front panel by undoing the 3...

Page 76: ...connector is fitted correctly 9 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 10 Re install the control...

Page 77: ...tion of the new control device 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 know...

Page 78: ...achine support 3 Remove the front part by undoing the 3 fastening screws 4 Draw out the card located sideways the CPU card 5 Disconnect the F384 CPU card and draw it out tilting it sideways 6 Disconne...

Page 79: ...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 1 The program code is s...

Page 80: ...2 START recognition with use in manual environment 1 Start and Program Code must stay stable Program parity 0 24 Start EVS 0 24 Program code Call recognition T Min 40mS Max 60mS since Start 1 0 24 0...

Page 81: ...l diagram NOTE The Emergency stop signal is active at 0V PROGRAM CODE EMERGENCY FK SERVOVALVE ALARM CHANGE TO 2 not considered still hold Pgm 1 WELD HOT TIME FINISHING HOLD CHANGE TO 1 0 0 0 0 0 24 24...

Page 82: ...nction programmed all required retry spots must be done If a quality spot alarm occurs it can be reset by PC or HHT NO dedicated message is generated stored to indicate the situation This situation is...

Page 83: ...e NOTE The Emergency stop signal is active at 0V 6 START disabled condition during the welding pulse EMERGENCY START FK if spot done since START ON same as standard condition 24V 0 24V 0 24V 0 Closed...

Page 84: ...art cycle Stored in Setup function EV1 0 100 Nominal value during welding cycle Stored in each program EV2 0 100 Pressure variation value Stored in each program Change is done after n cycles and in mo...

Page 85: ...e 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 Servoval...

Page 86: ...ess in PROC mode The control executes the sequence respecting the set timings The diagnostic function signals any pressure errors Process in WAIT mode The welding pulse is only given when the nominal...

Page 87: ...re Guns Power supply SCR control SCR temperature Paramete I O signals PLC Robot controller I O F359 DRUCKE M E M O R Y C A R D F35 ACQ LOOP ALARM STSER P 2 P 3 F360 24Vd E A P2 1 2 3 4 5 6 7 8 9 1 0 1...

Page 88: ...R D F353 ACQ LOOP ALARM STSERV P 2 P 3 F360 IOB 24Vdc E A P 1 2 3 4 5 6 7 8 9 10 11 12 N C COM N A F384 CPU LOW BAT RUN P 9 RESET F354 PBS P 1 3 0 Sync PS REMOTE OUT F357 IBO UL RD ST MT RC BA FK BE...

Page 89: ...M E M O R Y C A R D F353 ACQ LOOP ALARM STSERV P 2 P 3 F360 IOB 24Vdc E A P 1 2 3 4 5 6 7 8 9 10 11 12 N C COM N A F384 CPU LOW BAT RUN P 9 RESET F354 PBS P 1 3 Sync PS REMOTE OUT F357 IBO UL RD ST M...

Page 90: ...Weld334m User s manual 84 WHITE PAGE...

Page 91: ...Weld334m User s manual 85 APPENDIX C Weld334m Application diagram Dwg 33033311 02 Dwg 33033315 02 Dwg 33033316 02...

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