PHASEMASTER™ 6 DIRECT ENERGY WELDING CONTROL
990-083
vii
CHAPTER 3: OPERATING INSTRUCTIONS
.................................................................
3-1
Section I. Operation..........................................................................................................
3-1
Power Up ..............................................................................................................
3-1
Select Run or Program State ..................................................................................
3-1
Select Schedule......................................................................................................
3-1
Change Schedule Parameters .................................................................................
3-1
Change Parameters for Schedules 1 through 7 ........................................................
3-3
Copying Information in Schedule 0 to Another Schedule .........................................
3-4
Alarms ........................................................................................................................
3-4
SCR Alarm A1 ......................................................................................................
3-4
Machine Alarm A2.................................................................................................
3-4
Machine Alarm A3.................................................................................................
3-5
Machine Alarm A4.................................................................................................
3-5
Machine Alarm A5.................................................................................................
3-5
Section II. Programmable Options .....................................................................................
3-5
Status Display..............................................................................................................
3-5
Schedule Protection Feature.........................................................................................
3-6
Line Voltage Compensation Feature .............................................................................
3-6
Line Voltage Compensation Feature On .................................................................
3-7
Line Voltage Compensation Feature Off .................................................................
3-7
Alarm Display..............................................................................................................
3-7
Change Schedule Protection.........................................................................................
3-8
Schedule Protection Feature On.............................................................................
3-8
Schedule Protection Feature Off.............................................................................
3-8
Section III. Adjusting Weld Heads ....................................................................................
3-9
Adjusting Air Actuated Weld Heads.............................................................................
3-9
Section IV. Developing Weld Schedules............................................................................
3-11
Resistance Welding Parameters ....................................................................................
3-11
Weld Schedule Development........................................................................................
3-11
Weld Head Parameters ..........................................................................................
3-12
Welding Transformer Parameters............................................................................
3-13
PM6 Control Parameters .......................................................................................
3-14
Making a Weld ............................................................................................................
3-14
Evaluating the Weld......................................................................................................
3-15
Weak Weld ...........................................................................................................
3-15
Electrode Sticking..................................................................................................
3-15
Electrode Force and %CURRENT ........................................................................
3-16
Causes of Imperfect Welds ..........................................................................................
3-16
Polarity..................................................................................................................
3-16
Output Voltage vs Weld Quality.............................................................................
3-17
Weld Strength Profiles..................................................................................................
3-19
Destructive Testing.......................................................................................................
3-19
