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Version 1.2 Ver. No.SM059 (or later) Ver. No.SP038 (or later) Ver. No.SD038 (or later) Ver. No.SO033 (or later)

SPECIFICATIONS WELDING CONTROLLER

STN21- Series

For the safety use, read the safety precautions of thisinstruction manual thoroughly to have a proper understanding of it before operating this equipment. Besure to keep this manual in a specified place afterreading. 2004.3.10 No.F-202-

F-202 Ver1.2 OBARA Corp. .Specifications Page - 2

Notes on safety and handling procedure

= Notes on safety and handling procedure =

Read this instruction manual thoroughly before using in order to use the product properly.

Installation, maintenance inspection, and repairing service of this equipment must be provided by qualified technicians or those who sufficiently understand welding machines for safety reasons.

For safety purposes, operation of this equipment must be made by skilled persons who understand what is described in this manual and are able to provide necessary safety control.

For safety training, reference is made to various kinds of seminars and qualification tests for welding technicians and engineers held under the auspices of Welding Academy, Welding Association, and related organizations.

Be sure to keep this instruction manual at a specified place for everyone. For further information, please contact any of our offices whose phone or fax numbers are listed below.

Manufacturer: OBARA Corporation Head Office: 4-2-37 Ogami, Ayase-shi, Kanagawa-ken 252-1104 JAPAN

Phones:

OBARA CORP. JAPAN TEL +81-467-70-7688 FAX +81-467-70-7699

OBARA CORP. U.S.A.

HERCULES WELDING

PRODUCTS DIVISION TEL +1-586-755-1250 FAX +1-586-755-6790

CINCINNATI PLANT TEL +1-859-283-5490 FAX +1-859-283-5498

CANADA OFFICE TEL +1-519-485-6277 FAX +1-519-485-6277

OBARA CORP. DE MEXICO TEL +52-49-71-1525 FAX +52-49-71-1526

OBARA EUROPE LTD. TEL +44-118-9302464 FAX +44-118-9323483

OBARA FRANCE REPRESENTATIVE OFFICE

TEL +33-3-20-61-55-56 FAX +33-3-20-61-55-54

OBARA (MALAYSIA) SDN.BHD. TEL +60-3-5191-9688 FAX +60-3-5191-9699

OBARA (NANJING) MACHINERY & ELECTRIC, LTD.

TEL +86-25-2104304 FAX +86-25-2104305

OBARA (SHANGHAI) CO.,LTD TEL +86-21-58316177 FAX +86-21-58209793

OBARA (THAILAND) CO., LTD. TEL +66-2-7499595 FAX +66-2-7499598

OBARA KOREA CORP. TEL +82-2-868-3366 FAX +82-2-838-3365

OBARA AUSTRALIA PTY.LTD TEL +61-3-9764-1388 FAX +61-3-9764-1398

OBARA CORP. INDIA BRANCH OFFICE TEL +91-44-6202489 FAX +91-44-6217966

All rights reserved. Printed in Japan.


Safety precautions

= Safety precautions = Read this instruction manual thoroughly before use in order to and use the product properly. The cautionary instructions in this users guide are for safer operation to prevent danger and damage that

may occur to you and other persons.

While adequate safety considerations were given to the design and manufacture of this welder, items in the cautionary articles of this users manual must always be followed to ensure the safe usage. Using the

welder without following these instructions may cause bodily accidents such as death and severe injuries.

Varying degrees of damages and dangers may occur when the equipment is mishandled. These degrees are categorized into 2 levels in this instruction manual, and they are accompanied by symbols,

that should catch your attention, and signaling words as warning indicators. These symbols and signal

words to induce your caution are used with exactly the same meanings on the equipments warning

labels.

Attention Calling Symbol

Signal Word Description

! DANGER Improper handling of the equipment may cause a

dangerous situation that can lead to eventual death or

severe injuries.

! CAUTION Improper handling of the equipment may cause a

dangerous situation that can lead to intermediate level

injuries, light injuries, and/or material damage.

The attention catching symbols indicate general situations. The severe injuries mentioned above include, but not limited to, wounds, burns (at high and low temperatures),

electrical shock, bone fracture, intoxication, and other injuries that leave after effects requiring hospitalization or

prolonged outpatient medical care.

On the other hand, intermediate level injuries and light injuries include, but not limited to, injuries such as

electrical shock and burns that do not require hospitalization or prolonged outpatient medical care, while

material damages include damages to property, and expanded damages related to equipment.

!

Mandated Conducts that must be done. Grounding workfor example.

Prohibited Conducts that must not be done.

The symbols indicate general situations.


Limitation on operator

Limitation on operator

In order to maintain the safety of the operations, do not allow the following people to engage in the operations.

! DANGER

Mentally disabled.

Those with disability in hands, legs, eyes, and ears.

Drug (including narcotics) abusers.

Intoxicated.

Anyone who uses a heart pacemaker.

Those who do not wear specified protection devices.

Those who are non-qualified, (Those who have not had sufficient training in the operation of the equipment.)

Those with loose long hairs.

Safety training

Operators of the gun should have enough knowledge and skill of the followings.

! CAUTION ! To understand the contents of this instruction manual. ! To understand the meaning of warning labels. ! To acquire the method of heart massage and artificial respiration(CPR). ! To check protective attire such as that of fire fighters. ! To clarify places and personnel to contact in emergency. ! To acquire/check how to treat burns and injuries, and the location of first aid kit. ! To check the location of emergency stop switch and how to reset it. ! To understand how to inspect the system. ! To have enough knowledge on electricity to understand it. ! To understand the system, wiring diagram, and voltage. ! To have enough knowledge on resistance welding to understand it.


Items to follow as safety precautions


Always follow the instructions below in order to prevent bodily injuries. DANGER !

! 1. Although considerations for safety have been adequately incorporated into the design and

manufacture of this welder, make sure the cautionary instructions in this instruction manual are strictly obeyed upon usage of this equipment. Operating without following these cautionary instructions may cause or lead to eventual death, severe wounds, or other bodily- injury-related accidents.

! 2. Make sure that works on the power source on the input side, selection of installation site, and

storage of products and handling of waste material after welding operations should comply with related laws and ordinances as well as your companys internal rules.

3. Make sure that no one enters the area surrounding the welder as well as welding operation site carelessly.

4. Do not let anyone on a heart pacemakers come near the area surrounding the welder or welding operation site unless he or she is permitted to do so by a physician. The welder generates a magnetic field in the surrounding area while it is charged, and thus, poses negative affects to the pacemakers operation.

! 5. In order to assure safety, make sure that the installation, maintenance and inspection, and

repairs of this welder should be conducted by personnel with appropriate qualifications or someone who is well versed with welders.

! 6. In order to assure safe operation of this welder, make sure it is operated by personnel who has

a good understanding of the contents of this instruction manual, and have the knowledge and skills to operate it safely.

7. Do not use this welder for any purposes other than welding.



Always follow the following instructions in order to avoid electrical shocks. DANGER !

Touching a charged part other than the secondary conductor may cause life

threatening electrical shocks and/or burns. Touching both ends of the secondary conductor simultaneously may cause

electrical shocks.

1. Do not touch any charged part other than the secondary conductor. ! 2. Make sure that the welder is grounded by a certified electrician in accordance with the law

(electrical installation technology regulation). ! 3. Make sure that installation, maintenance, and inspection are conducted at least 5 minutes after

all of the input side power source are turned off by the switches on the switch box. Since capacitors may still be charged even after the input side power sources are turned off, make sure that the operation is conducted after checking that there is no voltage charged.

4. Do not use cables that have capacities below the specified requirement, that are damaged, or

that are exposing their conductive parts. ! 5. Tighten the weld part of the cable securely and insulate it.

6. Do not use the welder with its case or cover removed. ! 7. Do not use torn or wet gloves. Always wear dry and well insulated gloves during operations. ! 8. Make periodical inspection and maintenance and use the equipment only after the damaged

parts are repaired. ! 9. Use high grade cooling water with a resistance of 5000-cm or more, which contains no

precipitate or sediment. ! 10. When preparing cables, pneumatic hoses, water hoses and other tubing and wiring, use the

ones that can adequately withstand the specified load or pressure. ! 11. When the welder is not being used, make sure that the power source for all of its devices is

turned off. ! 12. Do not open any door of the devices in any case except when necessary such as in

maintenance. When using the devices, be sure to lock the doors with keys, which should be securely managed by authorized personnel.


DANGER ! Do not insert fingers or hands between the electrodes.

Placing a body part, such as hands, fingers, arms, etc., between electrodes will

cause the body part to be squeezed by the electrodes which, in turn will lead to bone fracture or other injuries.

1. Do not insert your hands, fingers, arms, or other body parts between the electrodes. ! 2. Check for safety around the welder upon turning on the power or supplying pressurized air.

Use appropriate protective devices to protect yourself and others from splashes, spatter, and noise that are generated during welding operations.

CAUTION !


Airborne splashes and spatter may hurt your eyes and/or cause burns.

Noise may cause hearing disorders.

! 1. Wear protective glasses to shield your eyes from airborne splashes and spatter. ! 2. Wear protective attire such as protective gloves, long-sleeve clothes, and leather aprons. ! 3. Install a protective curtain around the area surrounding the welding work site so that splashes

and spatter are not projected towards other people. ! 4. Utilize sound proofing devices if the noise level is high.

Always follow the following precautionary instructions in order to prevent fire and explosion. ! CAUTION

Splashes and spatter generated during a weld and a hot base

metal right after a weld may cause fire.

Cables with imperfect connections may cause fire due to the heat generated when they are charged.

! 1. Remove inflammable objects so that airborne splashes and spatter are not projected towards

them. If they cannot be removed, cover the inflammable objects with a nonflammable cover.

2. Do not weld near combustible and/or inflammable gases.

3. Do not let base metals that are hot immediately after a weld get near inflammable objects. ! 4. Tighten the weld part of the cable securely and insulate it. ! 5. Prepare for unexpected accidents by having a fire extinguisher placed near the welding site.


Indications of dangerous parts and precautions Type of warning labels and place to be attached

Warning labels

! DANGER The shaded areas in the figures show the

high-voltage hazardous areas of the

equipment.

Type of warning labels


Table of contents

Table of contents

1. Related manual ..............................................................................................10

2. Featurs ...........................................................................................................10

3. Basic specifications .......................................................................................11

3.1 Model ........................................................................................................................................11

3.2 Control......................................................................................................................................11

3.3 Input / Output ...........................................................................................................................12

3.4 Dimensions and Weight..........................................................................................................13

3.5 Facility Specifications.............................................................................................................13

3.6 Accuracy ..................................................................................................................................14

3.7 Coating Color...........................................................................................................................14

3.8 SCR characteristics.................................................................................................................15


Related manual

1. Related manual The instruction manual of this equipment consists of individual manuals shown below.

. Specifications

. Installation manual

. Operating manual

. Maintenance manual

. Reference manual

. Supplemental manual

Instruction manual

This manual contains specifications instructions for this equipment, Read this manual thoroughly to have a proper understanding of the specifications before operating the equipment.

2. Featurs

1. For 240 welding conditions. 2. Improved gun controlling functions

Retract control is available in standard models Up to 4 guns can be controlled.

(Combination of 2 guns and 2 retract guns can be controlled.) Additional Valve-selector function

3. Improved welding sequence 3-step welding with tempering applicable to aluminum welding Flexible setting of delay time Step-up function of up to 16 steps and can be set to any value

4. Down sized main frame 5. Improved controllability

Easy data input with back-lighted 4-line indication 6. For Installing Plurality of Units

Input of welding condition is possible from one TP-Net toward several Timers.


Model Input / Output

3. Basic specifications

3.1 Model STN21-G (For Plurality of unit)

3.2 Control

Control Method Full-digital control (synchronous) Control Series 4 Series/15 Series/16 Groups, 240 series maximum

Up to 8 guns (counter/Step Up control), or Up to 4 guns (solenoid control) (combination of 2 guns and 2 retract guns can be controlled.)

Setting Method Remote setting Time Control Squeeze Delay Time 0 to 99 cycles (all series)

Squeeze Time 1 to 99 cycles (all series) Slope Time 1 to 30 cycles (all series) Weld-1 Time 0 to 99 cycles (all series) Cool-1 Time 0 to 99 cycles (all series) Weld-2 Time 0 to 99 cycles (all series) Down Slope Time 0 to 99 cycles (all series) Cool-2 Time 0 to 99 cycles (all series) Weld-3 Time 0 to 99 cycles (all series) Hold Time 1 to 99 cycles (all series) Off Time 4 to 99 cycles (all series) Pressure Rise Time, 1 0 to 99 cycles (all series) Pressure Rise Time, 2 0 to 99 cycles (all series) Pressure Rise Time, 3 0 to 99 cycles (all series) Hold End Delay Time 0 to 99 cycles (Common to all series)

Cycle Control Number of Pulsation 1 to 9 (all series) Number of Re-weld Sequence 1 (can be specified by a parameter.)

Current Control Constant-current control Primary-current feedback by CT Current voltage control Direct setting from 2000 to 60000A (100A in step) Primary- current range 50 to 1500A

Voltage Control Constant-voltage control Percentage setting from 25 to 100% Note Since control ranges applicable to the settings of the current and voltage

controls depend on the connected load, the maximum and minimum control currents vary with the load.

For example The minimum current will flow during welding if the welding time is specified, though setting a welding current to 2000A.

Step Control Step-up setting: Up to 16 steps


Available number of weld spots: Up to 9999 spots/step

Alarm Messages Thyristor shorted Cable shorted Weld-1,2,3 cycle num. few Thyristor over temperature D/N Fatal error Current flow rate high Transformer over temperature No current Start switch trouble (D/N) Current frequency abnormal Current low Start switch trouble (115) Illegal parameter Compensation voltage low Communication time-out error CPU operation failure Current high Communication data error Illegal data setting Compensation voltage high OP communication error Illegal current setting Peak current high Weld off warning AD error 1 Line voltage low Continuous pressure warning AD error 2 Current unbalance

3.3 Input / Output

Solenoid Valve Specifications DC24V Rated current: 0.5A or less Note1: Be sure to use the total current of each valve output by 0.8A or less. Note2: Be sure to provide a surge absorber to the solenoid valve.

Not use for DeviceNet Parameter : Remote I/O .OFF [ Input ] Starting Input 1 N.O. contact, 4 series

o 4 N.O. contact, 1 series

Group Input 2 N.O. contact, 1 series Retract Starting Input 1 N.O. contact, 2 series

internal : 24VDC Input current : 20mA

Step Selection Clear Input 1 N.O. contact, 1 series Step Reset Input 1 N.O. contact, 1 series Alarm Reset Input 1 N.O. contact, 1 series Weld ON/OFF Switch Input 1 N.O. contact, 1 series Safety Switch Input 1 N.O. contact, 1 series [ Output ] Hold End Output 1 N.O. contact, 1 series

Relay contact output Max. voltage : 24VDCMax. current : 0.5A

Alarm Output 1 N.O/N.C. contact, 1 series Step Last Stage Out. 1 N.O. contact, 1 series ( Current Signal Output )*

Step Up Finish Out. 1 N.O. contact, 1 series *The step last stage signal output works instead of current detection signal output when the parameter is effective.

Note3: N.O. shows the Normally Open. N.C. shows reverse to N.O.


Dimensions and Weight

Use for DeviceNet Parameter : Remote I/O .ON [ Input ] D/N Input 1-6 6 N.O.

internal : 24VDC Input current : 20mA

Step Reset Input 1 N.O. contact, 1 series Alarm Reset Input 1 N.O. contact, 1 series Weld ON/OFF Switch Input 1 N.O. contact, 1 series Safety Switch Input 1 N.O. contact, 1 series [ Output ] D/N Output 1-4 1 N.O. contact, 1 series (DC24V output Max.current 0.5A) D/N Output 5-8 1 N.O. contact, 1 series (Relay contact output Max.current 0.5A)

3.4 Dimensions and Weight

Dimensions 320 (W)470 (H)195 (D)

Weight 18 kg

3.5 Facility Specifications Rated Voltage Single-phase 200/220/380/400/420/440Vac 50/60 Hz

(Selected by switching the range on the base voltage.) Rated voltage regulation within 20% of rated voltage

Power Consumption 50 VA (not in weld) Frequency 50/60 Hz (automatically selected on power-on) Temperature 0 to 50

Humidity 90% or less (non-condensing) Cooling Water Inlet port: 30 or less

Flow rate: 6 liters/min. Maximum water pressure: 0.3 Mpa or less Electric resistance: 5000cm or higher

Thyristor AE11-5S07U772 (Size: E, 1100A type) Preservation Period of Set data 10 years

CAUTION Handling the welding set data The data stored in the timer memory is preserved for 10years after it is input given the timer is in the normal operating condition. The data may be damaged when there is a failure to the main PC board. It is strongly recommended that the user write the important welding conditions down separately just in case the data stored in the timer is lost.

!


Accuracy

3.6 Accuracy Power-source Voltage Regulation Within 10% Resistance Load Regulation Within 10% Setting Accuracy 3% (of full scale) Repeatability 3% (of full scale)

3.7 Coating Color

Frame Paint Color: Orange (color chip No.: E5-259) Source: Book of standard color samples for painting

(Issued in 1981 by Japan Painting Industry Association)


SCR characteristics

3.8 SCR characteristics SCR Type AE11-5S07U772 (AE11)

AW13-5S07U772 (AW13) Ratings and characteristics

Model Item condition Symbol

AD90 AE12Unit

Repetitive peak off-state voltage VDRM 1600 V

Non-repetitive peak off-state reverse voltage VDSM 1700 V

R.M.S.water temperature 30flow rate 6 L/min IT(RSM) 900 1200 A

R.M.S. current at 10% duty cycle20 cycles water temperature 30flow rate 6 L/min 2150 2400 A

1 cycle-surge on-state current (50Hz non-repetitive) ITSM 10000 A

15 cycle-surge on-state current (50Hz non-repetitive) 5000 A

Peak gate power dissipation PGM 10 W

Average gate power dissipation PG(AV) 2 W

Peak gate current IGM 3 A

Peak gate voltage VGM 20 V

Peak reverse gate voltage VRGM 5 V

Motion junction temperature Tjw 40 125

Water temperature Tw 0 30

Storage temperature range Tstg 40 80

Maximum Rating

Mass 2.5 Kg Maximum peak off-state current (Tj=125,VDM=VDRM) IDM 30 mA

Maximum peak reverse current (Tj=125,VDM=VDRM)

IRM 30 mA

Maximum on-state voltage (Tj=25,TM =1700A)

VTM 1.69 V

Maximum gate trigger current (Tj=25,VD =6,IT =1A)

IGT 150 mA

Maximum gate trigger voltage (Tj=25,VD =6,IT =1A)

VGT 3 V

Minimum gate non-trigger current (Tj=125,VD =2/3VDRM)

IGD 10 mA

Minimum gate non-trigger voltage (Tj=125,VD =2/3VDRM)

VG 0.25 V

Minimum critical rate of rise of off-state voltage (Tj=125,VD =2/3VDRM)

dv/dt 500 V/s

Characte-ristics

Thermal resistance (between junction and cooling water, flow rate 6/min Rth(j-w) 0.120 /w

F-202 Ver1.2

SCR characteristics

Duty cycle R.M.S. current rating AD90-ST230C160 ( 900A-Type )

Condition Frequency 50 Hz Flow rate 6L/min Cooling water temperature 30

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F-202 Ver1.2

SCR characteristics

Duty cycle R.M.S. current rating AE12-ST330C160 ( 1200A-Type )

Condition Frequency 50 Hz Flow rate 6L/min

ater temperature 30n=5

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Version 1.5 Ver. No.SM059 (or later)Ver. No.SP038 (or later)Ver. No.SD038 (or later)Ver. No.SO033 (or later)

INSTALLATION MANUAL WELDING CONTROLLER

STN21- Series

For the safety use, read the safety precautions ofthis instruction manual thoroughly to have a properunderstanding of it before operating this equipment.

Be sure to keep this manual in a specified placeafter reading. 2004.03.10 No.F-201-

Table of contents

F-201 Ver1.5 OBARA Corp. .Installation manual Page - 9

Table of contents

1. Related manual ...........................................................................................10

2. Installation ...................................................................................................11

2.1 Installation ................................................................................................................. 11

2.2 Connecting Power Cable and Welding Transformer.............................................. 12

2.3 Grounding.................................................................................................................. 12

2.4 Installing Cooling-water Hose.................................................................................. 13

2.5 Connecting TP-Net Cable ......................................................................................... 13

2.6 Connecting Controlling Lines .................................................................................. 14

2.7 TB1 Input / Output for Parameter setting Remote I/O : ON............................... 17

2.8 Inputting Start Signal and Instructions ................................................................... 18

2.9 Step Clear .................................................................................................................. 19

2.10 Step Select Clear....................................................................................................... 19

3. Precautions in Supplying Initial Power ........................................................19

3.1 Checking Items before Powering On....................................................................... 20

3.2 Checking Items in Powering On .............................................................................. 20

3.3 Emergency Stop ........................................................................................................ 20

4. Storage Instructions ....................................................................................21

Related manual



. Specifications


. Operating manual


. Reference manual


Instruction manual

This manual contains installation details of this equipment, Read this manual thoroughly to have a proper understanding of the installation before operating the equipment.

Installation


2. Installation 2.1 Installation

(1) Weight STN21 Standard model 18kg (2) Space Requirements 506 (W) x 507 (D) x 500 (H)

506 (W) x 532 (D) x 500 (H) Hose-nipple specifications (3) Installation Install the equipment using 4 mounting holes at the bottom of

the mainframe. Mounting hole diameter (11)

Precautions in Installation

! Install the controller in a place where ambient temperature is between 0 to 40 and out of direct sunlight.

! Provide lightening protection to the controllers incoming power source according to appropriate rules and regulations.

! Avoid locations subject to water or oil ingress, or dust containing metal. Space RequirementsMainframe Bottom-side View

Bottom View Mainframe Mounting hole Diagram

* The controller is the hose-nipple type.

Connecting Power Cable and Welding Transformer


2.2 Connecting Power Cable and Welding Transformer Power Cable: Connect it to "01-02" of the power connection terminal at the bottom

of the controller. Welding Transformer: Connect it to "01-03" of the power connection terminal at the bottom

of the controller. (Refer to the following diagram for connections.)

Wiring Instructions ! Connecting wire: 100mm2 or larger in size (Refer to the following diagram.) ! Withstand voltage: AC600V or higher ! Voltage-drop in welding: Less than 20% of the rated voltage ! Power source: Install the fuse on the base of power source.! No Fuse Breaker (NFB): Install the NFB or ELB between the controller and the

welding power source before using the controller.Welding Transformer Capacity

Welding Transformer Capacity NFB Rated Current (AC380 to 440V) Wire Size

35kVA - 55kVA 100A 38mm2 or larger

- 125kVA 225A 60mm2 or larger

- 180kVA 350A (400A frame) 100mm2 or larger

Note: Any NFB other than described above does not protect the circuit from overload. (If you have any questions, please contact us.)

2.3 Grounding

! Grounding wire: Connect it to the "grounding connection terminal" in the lower part of the controller. (Refer to the following diagram.)

Grounding Instructions Connecting wire: 50mm2 or larger in size (Larger than half the size of the power cable.) !

Connect welding transformer cable here. 01-03 (M10 bolt)

Connect power cable here. 01-02 (M10 bolt)

Connect grounding wire here.(M8 bolt)

Power Cable Grounding wire

Example of Connection

Installing Cooling-water Hose


2.4 Installing Cooling-water Hose Cooling-water Hose: To provide cooling water use 9.5mm (3/8 inch) bore hose . (Refer to the

following diagram.) Cooling-water Requirements

! Temperature at the inlet port: 10 to 30 Maximum pressure: 0.3 MPa or less Flowrate: 6 L/min or higher Resistance: 5000cm or higher !

Cooling-water Instructions Use clean water or industrial water for cooling . Do not use water characterized with

electrolyte such as saline. ! For circulating cooling water, renew the water entirely once in every six months or renew 5 to

10% of the entire water at all times (Since water will evaporate). If using the controller in a place where freezeing occurs, be sure to drain the water from the

controller when not in use. !

If using the low resistance cooling water, the hose length 2M or higher, ! 2.5 Connecting TP-Net Cable

Connect the TP-Net cable to the connector (CN4) on the right side of the main board located on the upper side of the timer mainframe. (Refer to the following diagram for the connecting locations of the cables.)

Connect pendant cable here.

Water OUTLET

Water INLET

Nipple-type Model

Water OUTLET

Water INLET

Standard Model

Connecting Diagram of Cooling-water Hose and Pendant Cable

Connecting Controlling Lines

F-201 Ver1.5

2.6 Connecting Controlling Lines Connect the wires to the TB1 terminal block on the upper side of the controller. (Refer to the instructions affixed tDescription of Conne

Item

SOL1,2

SOL7,8

ALARM

STEP UP FINIOUTPUT STEP LAST STOUTPUT ( CURRENT DETECSIGNAL OUTPUT )

Out

put

HOLD END

GROUP 0 to 3

START SW1 t

RETRACT STSW7, 8 ALARM RESE

WELD ON/OF

STEP CLEAR

STEP SELECTCLEAR

TRANS. THER

Inpu

t

SAFETY SW

o the block.) OBARA Corp. .Installation manual Page - 14

cting Item: Description

Outputs a signal to each of the solenoid valves of GUN1 and GUN2. Outputs a signal to the retract valve. It can be also used as an output signal to each of the solenoid valves of GUN3 and GUN4. Outputs an alarm signal on occurrence of fatal or warning (caution) alarm. Related Parameters:

Caution, Test W ALM, ALM Mode, and ALM Out SH Outputs a signal on completion of the specified steps in the Step-up

function. AGE

TION

When the final step stage, this output signal is on. When the parameter Pr is on, the current detection signal output is made effective. Outputs a signal every weld spot. When an error has been detected, the output depends on the error condition. Related Parameters:

Hold Out , Hold A Dly

Binary input of GROUP 0,1,2,3 will select the welding condition group from 0 to 15.

o 4

1. An input to start operation. Up to 240 conditions can be selected by the combination input of the Start switch, Group 0,1,2,3.

2. Inputting one of these signals and the STEP SELECT CLEAR signal simultaneously will reset the value of Step preset to a specified gun.

Related Parameters: AB Mode, Sw mode, and One Shoot

ART An input to start the Retract function

T Short-circuiting this will reset a currently issued alarm.

F A switch to externally operate/stop the welding. The terminals, A12 and B13, need to be short-circuited when not in use since these terminals are N.C. (Welding is available when closed.) Clears the Step-up data of up to GUN8.

Inputting this signal and the Start switch simultaneously will specify a gun number and clears its Step data. Refer to Section 2.9 for details of the connection.

MO Connection of the thermostat wire of the welding transformer N.C. (Closed in normal state). A switch to stop the timer in case of emergency. N.C. (Activates when closed.)

Parameter: The mode to select timer functions or carry out basic setups. Refer to"V. Reference manual" for details.



Connection Example of Robot Control Board Condition: B Mode (binary switch input) Step control is enable.

2 Refer to Section, 2.7 "Inputting Start Switch and Instructions". The step last stage signal output works instead of current detection signal

output when the parameter is effective.



Connection Example of Portable Transformer Condition: Selectable between A-Mode and 1 retracted gun


2.7 TB1 Input / Output for Parameter setting Remote I/O : ON Each Input and Output item became DeviceNet I/O at the time of the Remote I/O : ON choice. Refer to the bottom table for the details.

Parameter Remote I/O : OFF

Parameter Remote I/O : ON

Table of TB1 item TB1 standard

D/N output 1 to 4 - common DC24V output

D/N output 5 to 8 relay contact output

D/N input 1 to 6 relay contact input

Alarm reset Short-circuiting this will reset a currently issued alarm.

Weld ON/OFF A switch to externally operate/stop the welding. N.C. (Closed in possible for welding)

Step clear Clears the Step-up data of up to GUN8.

Transf. thermo Connection of the thermostat wire of the welding transformer. N.C. (Closed in normal state).

Safety SW A switch to stop the timer in case of emergency. N.C. (Activates when closed.)

Inputting Start Signal and Instructions


2.8 Inputting Start Signal and Instructions Inputting Start Switch Signal :

Operation mode is selectable between A-Mode and B-Mode by setting the corresponding parameter of the timer.

A-Mode: Employs welding conditions of the Series corresponding to an activated Start switch. Mainly used for systems to which portable guns are connected.

B-Mode: Selects one of the Series from 1 to 15 by combination input of the Start switch signal, assuming the switch number to be a binary code.

Group : Group Selection:

Series from 1 to 15 is called "Group". The binary input of the Group SW allows one of the Groups from 1 to 3 to be selected. As shown in the following table, no input selects Group 0.

A Mode (4 series)

Series 1 Series 2 Series 3 Series 4

Start Switch 1

Start Switch 2

Start Switch 3

Start Switch 4

Group

B Mode (1 to F :15 series)

Series 1 2 3 4 5 6 7 8 9 A B C D E F

Start SW1

Start SW2

Start SW3

Start SW4

Group

Group Selection

Group 0 1 2 3 4 5 6 7 8 9 A B C D E F

Group 0

Group 1

Group 2

Group 3

Maximum welding conditions = 15series x 16groups = 240conditions


Inputting Start Signal and Instructions

Inputting Instructions of Start Signal In B-Mode, a long interval between activation of each Start switches may select a wrong Series. Keep the intervals between activation of each Start switch within 5ms. Alternatively, the following method is available.

Example of Start Switch Input

At first, close the relays, CR18, and then close the contact, CR0, after CR0 short interval. This method of closing the contact, CR0, after closing the six relays poses no problem if the differences in closing timing of the relays are moderate.

CR0 : Input common CR1 : Relay contact for SW 1 CR2 : Relay contact for SW 2 CR3 : Relay contact for SW 3 CR4 : Relay contact for SW 4 CR5 : Relay contact for Group 0CR6 : Relay contact for Group 1CR7 : Relay contact for Group 2CR8 : Relay contact for Group 3

Common

Terminal Block

Wiring Example

Diagram of Starting Switch Input 2.9 Step Clear

If the step up function is being used, then inputting a step clear signal to the TB1 terminal block will clear the gun step conditions.

(Note) When the parameter Ps and P8 are both enable, step series1 only can be cleared by this input signal (TB1-A14).

2.10 Step Select Clear Inputting a signal to Step select clear and Start switch on the TB1 terminal block at the same time allows a gun number to be specified and its step data to be reset. And Step select clear follows the data established in Step return (Welding condition). Specifying a Step select clear:

TB1 : B14 Step select clear

TB1 : A12 Input common + +

TB1 : Combination of the start SW Combination of the S.SW for Step clear

The inside treatment of step select clear:

GUN num. which shows a specified to combination of the Start SW is looked up from the welding condition table.

Selected to step select clear

Ra

eference to GUN num. t selected to

combination of Start SW

Precautions in Supplying Initial Power


(Note) When the parameter Ps and P8 are both enable, the action of step select clear changes to the following.

1. The Step return" disappears from welding condition items. 2. The step state of step series2 is set to1, and the step count is reset by this input signal

(TB1-A14). 3. Step series2 only can be cleared by this input signal (TB1-A14).

3. Precautions in Supplying Initial Power 3.1 Checking Items before Powering On

Before powering on the controller, make sure that the wires are connected correctly and check the following items:

1. Connection of the power cable 2. Connection to the welding transformer 3. Grounding 4. Connection of the control wires 5. Installation and flowrate, 6L/min, of the cooling water

3.2 Checking Items in Powering On

Before powering on the controller, carry out the following checks: 1. Make sure that you are protected with safety equipment such as safety goggles and

insulating gloves. 2. Immediately after turning on the power, check the controller for noise, smoke, and smell. 3. Make sure that TP-Net/DP-Net displays no alarm message. If any, correct the problem by

referring to IV. Maintenance manual. 4. 5 minutes after turning on the power, make sure that the controller does not generate noise,

smoke, and smell. 5. Set welding data and parameters according to the procedures instructed in V. Reference

manual. 6. Start welding by the Star switch, and verify that the gun corresponding to the selected

Series operates. 3.3 Emergency Stop

Opening the signal circuit of SAFETY SWITCH on the TB1 terminal block will immediately stop the valves and the supply of welding current. System engineers must utilize this as occasion demands.


4. Storage Instructions

To store the timer, observe the following instructions: 1. Drain the water off from SCR by air blowing. 2. Make sure that the inside of the mainframe is dust free. 3. Place the timer in its original plastic bag so as to prevent penetration of dust into the timer. 4. Store the timer in a place where temperature is between 0 and 60 with 70% or less

humidity and condensation of humidity will not occur. Avoid locations receive vibrations or direct sunlight.


OPERATING MANUAL WELDING CONTROLLER

STN21- Series



F-201 Ver1.5 OBARA Corp. .Operating manual Page - 9

Table of contents

Table of contents

1. Related manual ...........................................................................................10

2. Precautions in Operation.............................................................................11

3. Products System Configuration...................................................................11

3.1 Connecting to Robot Gun.......................................................................................................11

4. Alarm Messages and Precautions ..............................................................12

4.1 Precautions at Occurrence of Alarm .....................................................................................12

4.2 Alarm Messages on TP-Net/DP-Net .......................................................................................12


Related manual


. Specifications


. Operating manual


. Reference manual


Instruction manual

This manual contains operating instructions for this equipment. Read this manual thoroughly to have a proper understanding of equipment operation before use.


Products System Configuration

2. Precautions in Operation

!

!

!

! CAUTION

1. Before using the equipment, make sure that the cooling-water flowrate is at the stated level (6 L/min).

2. Only qualified engineers can change welding data. If any of the data requires

change, contact a manager and make sure that a qualified engineer changesthe data.

3. If you find any abnormality or alarm messages during operation, immediately

stop the operation and contact a manager. 4. This manual exclusively describes instructions for the controller. For other

products such as welding guns and so on, read the corresponding manual.

3. Products System Configuration 3.1 Connecting to Robot Gun


Alarm Messages and Precautions

4. Alarm Messages and Precautions 4.1 Precautions at Occurrence of Alarm

4.2 Alarm Messages on TP-Net/DP-Net Display of Alarm Message and List of Alarm Message

1. If you discover any abnormality during operation, check TP-Net and DP-Net. 2. Operators must stop the operation immediately and contact a manager when

discovering any abnormality during operation. 3. Do not operate TP-Net when any of the alarm messages appear.

! CAUTION

!

!

DP-Net Alarm messages appear here.

Alarm indication lamp flickers.

TP-Net


Alarm Messages and Precautions

Fatal Alarms: Alarm Name Alarm Message

Thyristor shorted SCR Break

Thyristor over temperature SCR Over Heat

Transformer over temperature Trans Over Heat

Current frequency abnormal Illegal Freq.

Illegal parameter Illegal Param

Illegal data setting Illegal Data

Illegal current setting Illegal Curr.

AD error 1 AD1 Error

AD error 2 AD2 Error

Cable shorted (Electrode sticking) Cable Short

Warning Alarms: No current No Current

Current low Current Low

Compensation voltage low % Voltage Low

Current high Current High

Compensation voltage high %Voltage High

Peak Current high PeakCurr High

Line voltage low Line Volt. Low

Cautionary Alarms: Current unbalance Cur. Unbalance

Weld-1 cycle few W1 Cycle Few



Current flow rate high FlowRate Over

Indicative Alarms: Start switch trouble ( 015) Illegal Start ( 015)

Communication time-out error Comi. Time Out

Communication data error Comi. Data Err

OP communication error OP TP Com. Err.

Weld off warning No Weld Warn.

Continuous pressure warning No Weld2 Warn.

Specific Alarm: CPU operation failure CPU Error

DeviceNet fatal error DN-PCB Error


MAINTENANCE MANUAL WELDING CONTROLLER

STN21- Series



F-201 Ver1.5 OBARA Corp. .Maintenance manual Page - 9

Table of contents

Table of contents

1. Related manual ...........................................................................................10

2. Products Block Diagram..............................................................................10

3. Pre-operation Checks .................................................................................11

4. Maintenance and Inspection .......................................................................11

5. Maintenance................................................................................................12

5.1 Precautions in Maintenance ...................................................................................................12

6. Trouble Shooting.........................................................................................13

6.1 Faults Undetectable by Alarm Messages..............................................................................13

6.2 Alarm Descriptions and Remedies ........................................................................................15

7. Check I/O Information ...................................................................................22

7.1 I/O information list at the time of DeviceNet intact................................................................22

7.2 I/O information list at the time of DeviceNet use. ..................................................................24


Related manual


. Specifications


. Operating manual


. Reference manual


Instruction manual

This manual contains maintenance information for this equipment. Read this manual thoroughly to have a proper understanding of the maintenance requirements before operating the equipment.

2. Products Block Diagram


Pre-operation Checks

3. Pre-operation Checks Before starting welding, carry out the following checks in order to use the controller safely.

Checking Item Requirements

SCR There must be no water leakage.

Cooling Water Flowrate must reach the stated level.

Power Lamp The lamp will turn on/off by powering on/off.

4. Maintenance and Inspection

To use the controller safely, carry out the following servicing tasks at the stated running-time intervals.

Interval

Checking Item Requirements

Dai

ly

Wee

kly

Mon

thly

Annu

ally

Occ

asio

nally

Check TP-Net to verify that the required welding data have been properly set.

Preset Data 1 Check TP-Net to verify that the required parameters have been properly set.

Welding-current Measurement Verify that the flowrate of the welding current reaches the required level.

Connection of the input/output signal wires No loose connection

Appearance of the input/output signal wires

No visible damage nor disconnection

Connection of the grounding wire No loose connection

Appearance of the grounding wire


Connection of the cables to the power source and the welding transformer

No loose connection

Appearance of the cables to the power source and the welding transformer


Internal state of the controller Inside of the controller must be kept clean.

Cooling-water circuit (SCR) Check by blowing air to verify that sufficient water can circulate.


Maintenance

5. Maintenance

! Before carrying out maintenance tasks, you must thoroughly read and understand V. Reference manual.

5.1 Precautions in Maintenance

1. Before carrying out maintenance tasks, be sure to turn off the power source and check with a voltmeter (AC 500V) to verify that the welding current has been shut off.

2. The power indication lamp may not be lit because the bulb has burnt out, for example, although power may still be present. When you check the presence of the power using the power indication lamp always verify that the power indication lamp goes out by turning off the main power source. (Verify the status of the lamp in bothsituations.)

3. If a maintenance task needs to be carried out with the power source on do not touch the following parts or cables as high voltage is present. To carry out the task maintenance engineers must work on insulating rubber sheet and wear insulating gloves. Touching the following parts may result in a serious accident or even death from electric shock. (1) TBO power terminal block: 01, 02, and 03 (2) SCR and its surrounding area (3) The PC-1091 trigger circuit and its surrounding area (painted white) (4) The RP1 and RP2 resistors (5) The CP1 large capacitor (6) The F1 input fuse

4. If you need to put your hands into the mainframe during maintenance always wearinsulating gloves. Do not carry out maintenance tasks with bare hands or you may suffer an injury, for example, cutting your hands on a corner of a part.

5. Do not carry out maintenance tasks in poor lighting. Carrying out the maintenance tasks in poor lighting may result in mistakes or contact with hazardous sections, leading to a serious accident or even death.

6. When you perform a welding test during maintenance, always ensure that the cooling-water flowrate reaches 6L/min. Carrying out a welding test with insufficient cooling water may generate excessive heat in the cables or the hoses, and result in hoses bursting.

7. Do not replace any parts on the PCB. Replace the PCB if necessary. The Obara Corporation does not guarantee any malfunction or failure resulting from the replacement of parts on the PCB.

!

!

!

!

!

! DANGER


Trouble Shooting

6. Trouble Shooting 6.1 Faults Undetectable by Alarm Messages

The power indication lamp does not light.

Symptom Cause Remedy Welding power circuit breaker trips.

Wrong wiring of 01-02 and 01-03

See II. Installation manual, and correct the wring.

Excessive heat from the timers large resistor

Welding power is connected to 01-03.

See II. Installation manual, and correct the wring.

Imperfect contact of the CN2 connector in the timer

Check the connector for contact.

Power cable is installed properly.

Faulty lamp Replace the lamp.

The gun does not operate though the Start switch has been pressed.

Symptom Cause Remedy Disconnection of a D/N communication cable or the connector has separated.

A wiring check of after an error check and a cable, or exchange.

The parameter Pq Remote I/O is OFF setup.

A parameter Pq Remote I/O is turned ON.

Check the timer mode to see that it is not set to Weld disable or Continuous pressurization mode.

Check TP-Net.

D/N timer input information Weld mode is not turned on.

A check of the contents of communication.

The power indication lamp is on but no alarm message appears.

Disconnection or wrong wiring of the wire connected to A16-B16, SAFETY SW, on the TB1 terminal board.

Check the wiring

The alarm message, No Current, appears.

See Section 6.2, and correct the problem.

The alarm message, Start switch trouble.

D/N timer input information Starting series 1 to 8 is not turned on.

A check of the contents of communication.


Trouble Shooting

No indication appears on TP-Net/DP-Net display

Symptom Cause Remedy

Faulty cable. Replace the cable. The power indication lamp of the timer is on but the display is faulty. TP-Net/DP-Net is faulty. Replace TP-Net/DP-Net.

The target timer number is not displayed on TP-Net/DP-Net screen.

Symptom Cause Remedy The target timer number is not displayed on TP-Net screen. Disconnection or failure of a Timer-Timer connection cable.

Change or check of a Timer-Timer connection cable.

The power supply of Timer which it is going to choose is not turned on.

An injection of a power supply.

There is a timer of the same number setup. Parameter : Po TM Number

Change of parameter" timer number." TP-Net is alone connected to timer which wants to change a number. Then, a power supply is switched on, pushing Home key in TP-Net. The cable of TP-Net may be taken out and inserted instead of a power supply injection. If it rises normally, it will be made the edit mode of a parameter and a number will be changed.


Trouble Shooting

6.2 Alarm Descriptions and Remedies

Fatal Alarms Alarm Name Alarm Message Category

Thyristor shorted SCR Break Fatal

Detecting Method

Welding current is measured at the final cycle of the Hold-end time. If the measured current is greater than the stated level, the controller issues the Thyristor shorted alarm.

Cause/ Remedy

1. Faulty thyristor Replace the thyristor. 2. Faulty main board Replace the main board.

Alarm Name Alarm Message Category

Thyristor over temperature SCR Over Heat Fatal Detecting Method

The controller issues the alarm when the thyristor thermostat switch has been activated, regardless of the state of the controller.

Cause/ Remedy

1. Check duty cycle. 3. Replace the thyristor with a larger one.

2. Insufficient cooling water 4. Replace the thyristor.


Transformer over temperature Trans Over Heat Fatal Detecting Method

The controller issues this alarm when the transformer thermostat switch has been activated, regardless of the state of the controller.

Cause/ Remedy

1. Check duty cycle. 3. Replace the transformer with one having

larger rated capacity.

2. Insufficient cooling water 4. Replace the transformer.


Current frequency abnormal Illegal Freq. Fatal

Detecting Method

The controller checks frequency to select between 50 Hz and 60 Hz when it is turned on and issues this alarm if the frequency ranges outside the stated bandwidth.

Cause/ Remedy Check the controller power supply.


Illegal parameter Illegal Param. Fatal Detecting Method The controller issues this alarm when the parameter data has been lost.

Cause/ Remedy 1. Check and re-enter the parameters. 2. Replace the PCB.


Trouble Shooting


Illegal data setting Illegal Data Fatal Detecting Method

The controller issues this alarm if the welding condition data of an activated Series is outside the range, or the welding times, W1 to W3, are all set to 0.

Cause/ Remedy Check and correct the welding condition data.


Illegal current setting Illegal Curr. Fatal Detecting Method

The controller issues this alarm when the preset current of the activated Series is 0 but welding time is set to any value other than 0.

Cause/ Remedy Check and correct the welding condition data.


AD error 1 AD1 Error Fatal Detecting Method The controller issues this alarm when the measured current is abnormal.

Cause/ Remedy 1. Replace the timer. 2. Replace the CT.


AD error 2 AD Error Fatal Detecting Method The controller issues this alarm when the measured current is abnormal.

Cause/ Remedy 1. Replace the timer.


Cable shorted Cable Short Fatal Detecting Method The controller issues this alarm when the test current exceeds a specific level.

Cause/ Remedy Replace the secondary cable.


Trouble Shooting


DeviceNet unusual detection DN PCB Error Fatal Detecting Method

Timer is [ reception or ] a time of detecting about abnormalities. Automatic reset is performed after an unusual return.

Cause/ Remedy

1. Failure of a substrate. change to UCS board 2. The abnormalities in the exterior of Timer.

Warning Alarms Alarm Name Alarm Message Category

No Current No Current Warning Detecting Method

The controller issues this alarm when the measured current is 0 or the welding cycle is set to 0.

Cause/ Remedy

1. Secondary cable disconnection Re-fit / replace the cable. 2. The ignition circuit of the timer is at fault. Replace the timer. 3. Disconnection of the thyristor gate wire (G1, K1, G2, and K2) Re-fit 4. Thyristor Replace.


Current low Current Low Warning Detecting Method

The controller issues this alarm when the measured current falls short of the preset current.

Cause/ Remedy

1. Voltage variation is too large. Replace the cable with a larger one. Check the power supply. 2. Deterioration of the secondary-cable Replace the cable. 3. Incorrect welding parameters (welding current and lower current limit)

Check welding conditions. 4. Significant error in transformer turn ratio parameter. Check welding

conditions.


Trouble Shooting


Compensation voltage low % Voltage Low Warning Detecting Method

In constant current control, the controller issues this alarm when the measured voltage falls short of the preset voltage in %.

Cause/ Remedy

1. Voltage variation is too large. Replace the cable with a larger one. Check the incoming system. 2. Check the constant voltage and the preset voltage in %. 3. Deterioration of the secondary-cable Replace the cable. 4. Check the preset value of lower current limit.


Current high Current High Warning Detecting Method

The controller issues this alarm when the measured current exceeds the preset current.

Cause/ Remedy

1. In correct welding conditions (welding current and upper current limit) Check welding conditions.

2. Significant error in transformer turn ratio parameter. Check welding conditions.

3. Power voltage is unstable. Check the power supply.


Compensation voltage high % Voltage High Warning Detecting Method

In constant current control, the controller issues this alarm when the measured voltage exceeds the preset voltage in %.

Cause/ Remedy

1. Check the constant voltage and the preset voltage in %. 2. Power voltage is unstable. Check the incoming system.


Peak current high PeakCurr High Warning Detecting Method

This controller issues this alarm when the current has a peak value, Its bigger than the setting value.

Cause/ Remedy

1. During GUN action : Check welding conditions squeeze time 2. In correct welding conditions Peak current Limit : Check welding conditions.3. Voltage variation is too large. : Check the incoming system. : Check the balance of power supply.


Trouble Shooting


Line voltage low Line Volt. Low Cautionary Detecting Method

The controller issues this alarm when the measured voltage falls short of V limit of welding condition.

Cause/ Remedy

1. Voltage variation is too large. Replace the cable with a larger one. Check the incoming system. Check the duty cycle.

2. Check the setting of the power-voltage lower limit (V limit).

Cautionary Alarm Messages


Current unbalance Cur. Unbalance Cautionary Detecting Method

The controller issues this alarm when the lower and upper limits of welding current disagree.

Cause/ Remedy

1. Disconnection or imperfect contact of the thyristor gate wire. Check wiring, or replace the thyristor. 2. The ignition circuit of the main board is at fault. Replace the board. 3. Check the squeeze time. This alarm may also appear when welding current is

applied while the gun moves.


Weld 1-3 cycle few W1(2 or 3) Cycle Few Cautionary Detecting Method

The controller issues this alarm when the welding current has not been supplied for the number of welding cycles specified (Weld 1 to 3).

Cause/ Remedy

1. Welding sequence has started before the gun has reached the required pressure. Check the welding sequence.


Current flow rate high FlowRate Over Cautionary Detecting Method

The controller issues this alarm when the measured flow rate is greater than the preset value of C. Flow+ or FC Count.

Cause/ Remedy

1. Deterioration of the secondary cable. Replace the secondary cable. 2. The welding current is set to too high. Check the setting of welding current.3. Illegal C. Flow+ value. Correct the setting. 4. Voltage variation is too large. Replace the cable with a larger one. Check the incoming power supply. Check the duty cycle. 5. Illegal transformer turn ratio value. Correct the setting.


Trouble Shooting

Indicative Alarm Alarm Name Alarm Message Category

Start-switch (SW 0 to 15) trouble Illegal Start (0~F) Alarm Message

Detecting Method

The controller checks the Start switch status when the power is turned on and issues this alarm if any of the switches is ON.

Cause/ Remedy 1. Wrong wiring of the Start switch. Check wiring.


Communication time-out error Comi. Time Out Alarm Message Detecting Method

The controller issues this alarm when an error occurs during communication between TP-Net/DP-Net and the timer.

Cause/ Remedy

1. Pendant cable faulty. Replace the cable. 2. TP-Net/DP-Net is faulty. Replace TP-Net/DP-Net.


Communication data error Comi. Data Err Alarm Message Detecting Method

The controller issues this alarm when the CRC errors (time-out) have been detected 10 times successively.

Cause/ Remedy

1. TP-Net / DP-Net cable faulty Replace the cable.


Weld off warning No Weld Warn. Cautionary /IndicativeAlarm Message Detecting Method

The controller issues this alarm when receiving a input signal from the Start switch if the timer is set to Weld disable.

Cause/ Remedy 1. Cancel Weld disable.


Continuous pressure warning No Weld2 Warn. Cautionary /IndicativeAlarm Message Detecting Method

The controller issues this alarm when receiving a input signal from the Start switch if the timer is set to Weld disable & sol. Valve control.

Cause/ Remedy 1. Cancel Weld disable & sol. Valve control.


Trouble Shooting

Specific Alarm Message


CPU operation failure CPU Error Alarm Message (Message may not appear.)

Detecting Method

The controller issues this alarm when detecting that the watch dog timer has been activated. This alarm message may not appear but a pulse signal is output.

Cause/ Remedy 1. The main board is faulty. Replace the board.

Check I/O Information

7. Check I/O Information Checked by TP-Net on the present information. Please confirm in V. Reference manual.

7.1 I/O information list at the time of DeviceNet intact. I/O information display

Input / output table ( Note: Other ports uses to this date. )

Display # Terminal block TB1 output information

N 1 0 0 0 0 0 0 0 0 0 0

N10

N11

N12 Retract SOL

N13 Retract SOL8

N14 Alarm

N15 Hold end

N16 Final step N17

Last step ( Current d signal )

N1 0000 0000 00 N2 0011 0001 31 N3 0000 0000 00 N4 0000 0000 00 N5 0000 0000 00 N6 0000 0000 00 N7 0000 0000 00 N8 0000 0000 00

N2 0011 0001 31

Bit 7 Bit 0

1 shows ON, 0 shows OFF

Binary code off on

Hexadecimal code FF

Terminal block TB1

Input information

Display #

N3

Terminal block TB1

Input information

Start SW N30

Start SW2 N31

Start SW3 N32 Display #

N2

N20

N21

N22 F-201 Ver1.5 OBARA Corp. .Maintenance manual Page - 22

N23 Start SW4 N33

N24 Group N34

N25 Group N35

N26 Retract start SW N36 Weld On / OFF SW

N27 Retract start SW N37 Alarm reset

The step last stage signal output works instead of current detection signal output when the parameter is effective.



( Note: Other ports uses to this date.)

Display #

N4

Terminal block TB1

Input information

Display #

N5

Terminal block TB1

Input information

N40 N50

N41 N51

N42 Step clear N52

N43 Step select clear N53

N44 TRANSF. Thermostat N54 Group3

N45 SCR thermostat N55

N46 N56

N47 N57

Display #

N6

Terminal block TB1

Input information

N60 SW start (LED)

N61

N62

N63

N64 Group2

N65

N66

N67



7.2 I/O information list at the time of DeviceNet use. Since the I/O specification of TB1 changes at the time of DeviceNet use, the contents of a display of I/O information also change.

Input / output table (Note: Other ports uses to this date.)

Display #

N1

Terminal block TB1

Input information

Display #

N2

Terminal block TB1

Input information

N10 N20

N11 N21

N12 N22 D/N Input 1

N13 N23 D/N Input 2

N14 Alarm N24 D/N Input 3

N15 Hold end N25 D/N Input 4

N16 Final step N26 D/N Input 5

N17 Last step N27 D/N Input 6

Display #

N3

Terminal block TB1

Input information

Display #

N4

Terminal block TB1

Input information

N30 N40

N31 N41

N32 N42 Step clear

N33 N43

N34 N44 TRANSF. Thermostat

N35 N45

N36 Weld On / OFF SW N46

N37 Alarm reset N47


REFERENCE MANUAL WELDING CONTROLLER

STN21- Series



F-201 Ver1.5 OBARA Corp. .Reference manual Page - 9

Table of contents

Table of contents 1. Related manual ...........................................................................................11

2. General Description ....................................................................................11

2.1 Products Overview..................................................................................................................11

2.2 Flow Chart: From inputting welding condition to welding ..................................................12

2.3 Welding Data............................................................................................................................13

3. Operating DP-Net........................................................................................14

3.1 Display Pendant Operation Panel Keys and their Functions ..............................................14

3.2 Operation Flow Chart ..............................................................................................................14

4. Operating TP-Net ........................................................................................15

4.1 Teaching Pendant Operation Panel Layout ..........................................................................15

4.2 Functional Descriptions of Operation Panel Keys ...............................................................16

4.3 Descriptions of Function Keys...............................................................................................17

4.4 Copy Functions .......................................................................................................................18

4.5 Viewing Data by Scrolling.......................................................................................................19

5. Descriptions of Modes.................................................................................20

5.1 Changing Timer Mode.............................................................................................................20

5.2 Precautions of Set Mode.........................................................................................................21

6. Monitoring welding Sequence .....................................................................22

6.1 Weld Monitor Screen...............................................................................................................22

6.2 Resetting Gun Counter ...........................................................................................................23

6.3 Resetting Steps........................................................................................................................23

7. Setting Parameters .....................................................................................24

7.1 Descriptions of Parameter Functions....................................................................................24

7.2 Note on Changing Parameters ...............................................................................................29

8. Setting Welding Conditions .........................................................................30

8.1 Basic Sequence .......................................................................................................................30

8.2 Description of Welding Conditions........................................................................................31


9. Specific Welding Sequence ........................................................................34

10. Alarm Output ..............................................................................................38

10.1 Classifications of Alarms.......................................................................................................38

10.2 Settings Associated with Alarms..........................................................................................38

10.3 Timing Charts of Sequences at Occurrence of Alarm ........................................................39

11. Step Up .......................................................................................................44

11.1 Step-up Control.......................................................................................................................44

11.2 Setting Procedure to Use Step-up Function ........................................................................45

12. Pressure Adjustment (Option).....................................................................46

12.1 Setting for proportional valve control ..................................................................................46

12.2 Pressure Adjustment Sequence............................................................................................46

12.2 Pressure Adjustment Sequence............................................................................................47

13. Pressure Selector Function .........................................................................47

13.1 Procedure to Use Pressure Selector Function ....................................................................47

13.2 Pressure Selector Function Basic Sequence ......................................................................47

14. Weld Interlock Function...............................................................................48

14.1 Procedure to Use Weld Interlock Function ..........................................................................48

14.2 Weld Interlock Timing Chart ..................................................................................................48


Related manual


. Specifications


. Operating manual


. Reference manual

Instruction manual


This manual contains the reference section for this equipment, Read this manual thoroughly to have a proper understanding before operating the equipment.

2. General Description 2.1 Products Overview

The system configuration of this equipment is as follows: STN21Timer-Welding controller TP-NetEdit welding condition data, parameter data, monitor welding result

and display alarm message. DP-NetMonitor welding result and display alarm message, and welding

condition data. PN/C(Pendant Cable)For the network cable, connect between STN21 and TP-Net

or DP-Net. PJCFor the network cable, connect between STN21 and STN21.

(For multiple units connection with Optional function)


2.2 Flow Chart: From inputting welding condition to welding To start welding, proceed as follows:

Set functions and basic conditions according to your company standards.

ng Parameters, for details.

Flow Chart: From inputting welding condition to welding

Refer to Section 7, Setti

F1 F5 Shift #TM

Home

Set welding conditions. Group

Select

Refer to Section 8, Setting Welding Conditions, for details.

Verify that the controller has been properly installed.

Before powering on the controller for the first time, carry out the following pre-operation checks. Check:

1. Installation of the power cable 2. Wiring of the welding transformer 3. Wiring of the control wires on the TB1 terminal board 4. Verification of the rated power voltage on the timer nameplate 5. Wiring of the DeviceNet

Refer to II. Installation manual for details of installation.

After checking the items listed right, turn on the power source.

Input welding conditions.0

Set w lding conditions. e

Set parameters.

Enter Set Mode. To set welding conditions, enter Set Mode since the controller is in MonitorMode when turning on the power source.

The above key ou to Set Mode. Verify that the indication lamp is on.

operation takes y

Setting is complete.

Verify that welding is correctly performed.

F4 F8

F4 F8

Input welding conditions with TP-Net. Refer to Section 4, Operating TP-Net.

Carry out a test welding to verify that the settings are correct. You can monitor the welding sequence in Monitor Welding Sequence. Refer to

Section 6, Monitoring welding, for details. If the test weld failed: Check and correct the cause of the problem. Locate and correct the

parameters and the welding conditions. If the alarm lamp flickers correct the

problem by referring to IV. Maintenance manual.

OK

NG

F1 F5F2 F6#TM

Home

F4 F8

F-201 Ver1.5 OB

TM Data: The data stored in the timTP Data: The data stored in the TPParameters: Enables timer functions to

= 240 conditions

Welding Data

2.3 Welding Data The welding data available for STN21 Series fall into two main categories: Parameters (to select functions) and Welding conditions. 15 Series (conditions) of welding condition data make up one Group. 16 Groups and parameters make up one Unit. (Refer to the following figure.) The timer can maintain and control the data of 240 kinds of welding conditions. TP-Net can independently maintain 5 times as many as data that the timer can.

N

15 conditions x 16 groups

T

TM stored Data

TP-Net

Data Edit Data Copy ARA Corp. .Reference manual Page - 13

er. (Welding data) -Net as an external data. be selected or set. Refer to Section 6.1 for details.

P-Net stored Data

5 unit

Data Copy


Display Pendant Operation Panel Keys and their Functions

3. Operating DP-Net 3.1 Display Pendant Operation Panel Keys and their Functions

Operation Panel Keys: Name Description

Step Reset Clears the step counts when the Step function is enabled.

Reset

1. Resets alarms. 2. Clears the weld counter. 3. Clears the alarm history. 4. Suspends operations.

Home Displays the initial screen that appears upon turning on the power.

Each key scrolls the display in the direction indicated on it.

Shift Selects functions such as I/O data and so on when another key is pressed while this key is held down (e.g. Shift + Scroll key).

Indication Lamps (Indicate the state of the controller.):

Name Description Same as those

on TP-Net Refer to the sections describing the

indication lamps on TP-Net. 3.2 Operation Flow Chart

To select items, press the Return key.

Reset Shift +

Reset alarms

Power on

Monitor welding

I/O status Alarm history Parameter monitor

Reset step number

Change number

Clear history

Display weld count.

Display step count.

Reset

Shift +

Reset gun counter

Reset

StepReset

Shift + Step

Reset

Verify welding conditions

Select Group

Monitor conditions

To display the initial screen, press the Home key. Home

TM-No. Select ( For multiple units connectionwith Optional function )


Teaching Pendant Operation Panel Layout

4. Operating TP-Net 4.1 Teaching Pendant Operation Panel Layout

Displayhe forth line from the top

corresponding to function s.

T

key

F1~F8

Ready

Set

Conti. Press

No Weld

0~F / on off

ReturnScroll key

Help

Reset

Step Reset

Shift

SW Start

Step last stage

Step up finish

Alarm

F-Disp,Select

TM#/Home


4.2 Functional Descriptions of Operation Panel Keys Operation Panel Keys

Name Description

F1~F4 / F5~F8

Function keys are used to select a menu. To select F5 to F8, press Shift + a corresponding function key. The F8 key is exclusively used to return to the previous menu.

F-Disp Select

This key also allows you to select whether the function description is displayed at the bottom of the display.

0~9 & . / A~F / ON & OFF

Keys for inputting data. To input A to F, press Shift + a key corresponding to a numerical value to be input. ON and OFF keys operate regardless of the Shift key.

TM# / Home

1. The button for returning to an initial screen. 2. A key to display and edit a currently connected TM#. A key to select a timer number to be monitored. 3. The selection mode of Timer number is expressed as Shift+TM#/Homekey.

Step Reset A key to reset the step counter when the Step function is enabled.

Reset

A key used to: 1. Reset currently issued alarms 2. Reset the spots count currently displayed on the weld counter 3. Clear the alarm history when it is displayed 4. Suspend operations

Keys to scroll the screen to the direction indicated on them.

Help A key to display the screens help facility. The screen contains a detailed description of the function keys. Shift An auxiliary key to select A to F and F5 to F8.

Indication Lamps (Indicate the state of the controller)

Name Description

Ready Lights when the controller is ready to receive welding data after TP has completed initial processing and then received initial data through communication.

No Weld Lights when the controller is in the Weld off mode.

Conti.Press Lights when the controller is in the Weld off mode and the gun-pressure control is in continuous pressurization mode. Set Lights when the controller is in data setting mode.

SW Start Lights when the Start switch of the controller is turned on. Step last stage Lights when the controller has entered the final step.

Step up finish Lights when the controller has entered the Step end phase.

Alarm Lights when the controller has detected trouble.

Functional Descriptions of Operation Panel Keys

F-

Descriptions of Function Keys

4.3 Descriptions of Function Keys Pressing a function key (F1 to F8) will display a corresponding screen as shown below. Pressing the Home key allows you to return to the Monitor screen.

F1 Step Change

F2 I/O Monitor

F3 Alarm History

F1 Monitor

0 to 15 Group Select

F2 TM Data Set

F1 Edit

F2 Function Copy

F3 Series Copy

F4 Group Copy

F5 Group Verify

F1 Operation

F2 No Weld

F4 Mode Select

F1 Unit Edit

F3 TP Data Edit

0 to 15 Group Select

F1 Edit, F5 Group Verify

F2 Unit Copy

F1

F2

F3

F4

F3 Parameter

F4 Para. Copy

F1 TM TP, F4 TM TP

Displays the monitored data of the current welding and alarm history and so on.

Enables the currently set step number to be changed when the Step-up function is used.(Step Change)

Displays the I/O status. (Usually not used.)

Displays alarm history. (last 100 alarms)

Displays the data stored in the timer.

Selects one of the Groups from 0 to 15.

Enables the welding data to be set.

Copies data between groups specifying the unit-number.

Compares data between groups specifying the unit-number.

Selects one of the Groups from 0 to 15.

Copies the data of a selected Unit from the timer to the pendan

Documents

STN 21 ENGLISH.pdf