Weld334m 2,0系统编程手册

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Weld334mProgramming Manual

Release 2.0

Edition 4 June 2004 Code 39000425

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Programming Manual

GF WELDINGII

GF WELDING S.p.A.

Strada del Portone, 18/24 10137 TORINO (Italia)

Tel.:

Tel.:

Fax:e-mail:

web:

011-3033.278 (Italy Salesdept.)011-3033.270-279 (Foreign Salesdept.)

011-3033.277 (Italy Service)011-3033.274 (Foreign Service)

[email protected]

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Warranty

All conditions of warranty as described in this section are general andcomplete the specific purchasing conditions. In any case they refer to thelocal jurisdiction and to eventual particular conditions, agreed with the

purchaser, included in the contract of purchase.

In particular the period of warranty is one year after delivery, if not agreedin the purchasing contract differently.

FurthermoreCompanyGF WELDING S.p.A.guarantees the Weld 334m tobe free of any defects caused by manufacturing. In case an error shouldoccur during warranty period, which is caused by manufacturing, the makerwill carry out all necessary repairs or exchange defect parts. The maker

insists on the right to decide, whether to exchange or repair the defectparts. The user has to pay for shipment costs.

CompanyGF WELDING S.p.A. will not take any responsibility for damagesor resultant damages of the customer caused by shipment delays,manufacturing defects or breakdown of the control.

Company GF WELDING S.p.A. does not guarantee the software orhardware of the welding control to be free of errors or to be competitivewith each standard or in particular to comply with the specialmanufacturing demands of the user.

In particular CompanyGF WELDING S.p.A. does not take responsibility forthe correctness of the weld- and current-increment programs, which werecreated for the production demands of the user.

The warranty terminates with breakdowns caused by wrong connectings,improper use or faulty operation. This refers to damages caused byelectrostatic discharge, which occurs during connection or disconnection ofenergized devices, tampering and/or executed reparations from staff non-authorised from GF WELDING.

Keyboards, cables, trackballs, connectors or other consumable parts are notcovered by this warranty.

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INDEX

1 GENERAL NOTES CONCERNING PROGRAMMING ............................. 1-1

1.1 Programming...................................................................................1-1

1.2 Manual Keyboard HCM 4300 HHT.....................................................1-1

1.2.1 Keys ............................................................................................... 1-21.2.2 Display............................................................................................ 1-3

1.3 Menu structure ................................................................................1-5

2 CONFIGURATION ........................................ 2-1

2.1 Parameter of the Configuration menu..............................................2-1

2.1.1 Configuration parameters................................................................... 2-12.1.1.1 Release Software........................................................................... 2-12.1.1.2 Software Release keyboard (HHT) .................................................... 2-22.1.1.3 Language ..................................................................................... 2-22.1.1.4 Date and time............................................................................... 2-2

2.1.2 Addresses for connection to the Ethernet TCP/IP network ....................... 2-32.1.2.1 IP Address.................................................................................... 2-3

2.1.2.2 SubNet Mask................................................................................. 2-32.1.2.3 TCP Port....................................................................................... 2-3

3 BASE SETTINGS ............................................ 3-1

3.1 SETUP Menu -CONFIGURATION WELD 334m ...................................3-1

3.1.1 Parameter of SETUP - WELD334M CONFIGURATION............................... 3-23.1.1.1 WMS-NET network address: ............................................................ 3-23.1.1.2 Device name:................................................................................ 3-23.1.1.3 Working mode:.............................................................................. 3-23.1.1.4 Preset Analog output:..................................................................... 3-23.1.1.5 Weld alarm threshold A: ................................................................. 3-33.1.1.6 Weld alarm threshold B: ................................................................. 3-33.1.1.7 Current transducer: ....................................................................... 3-33.1.1.8 N. current transducers: .................................................................. 3-3

3.1.1.9 Start code parity............................................................................ 3-43.1.1.10 Module address parity: .................................................................. 3-43.1.1.11 Execution in repeat: ...................................................................... 3-43.1.1.12 Execution with current:.................................................................. 3-43.1.1.13 Station type:................................................................................ 3-53.1.1.14 PRESSURE-OK Input mode:............................................................ 3-53.1.1.15 SVV Ang-Out 4-20mA check........................................................... 3-53.1.1.16 End of sequence output minimum time (FINESEQ)............................. 3-5

3.2 Menu SETUP - GUN PARAMETERS 0 ................................................3-6

3.2.1 Parameter on page SETUPGUN PARAMETERS 0.................................... 3-63.2.1.1 Max. Electrode force [kN]: .............................................................. 3-63.2.1.2 Coil sensitivity [mV/kA]: ................................................................. 3-73.2.1.3 Sensitivity TF [V/kN]...................................................................... 3-73.2.1.4 Measured Parameter I min [kA]:...................................................... 3-73.2.1.5 Measured Parameter I max[kA]: ...................................................... 3-7

3.2.1.6 Measured Parameter CosPhi: ........................................................... 3-7

3.3 SETUP Menu - ALARMS CONFIGURATION ........................................3-8

3.3.1 Alarms Configurationin REPORT menu. ...............................................3-103.3.2 Machine Shutdown Enable of Diagnostic Alarms .................................3-10

3.4 Menu SETUP - CABLE WEAR........................................................... 3-11

3.4.1 SETUP CABLE WEAR ......................................................................3-123.4.1.1 Enable ........................................................................................3-123.4.1.2 Prewarning ..................................................................................3-123.4.1.3 Stop ...........................................................................................3-123.4.1.4 Counter.......................................................................................3-12

3.5 Menu SETUP TIP DRESSER WEAR ...............................................3-13

3.5.1 Comment to the SETUP TIP DRESSER WEAR.....................................3-133.5.1.1 Enable ........................................................................................3-143.5.1.2 Prewarning: [%]......................................................................3-143.5.1.3 Stop: ..........................................................................................3-143.5.1.4 Counter.......................................................................................3-14

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4 MENU PROG (WELD PROGRAMS) ................................ 4-1

4.1 Copy welding programs F2 COPY.................................................4-2

4.2 Clear welding program F3 CLEAR....................................................4-3

4.3 Selection Single spot - Repeated spot F5 SS/RPT............................4-4

4.4 Menu EDIT F1 EDIT..........................................................................4-5

4.4.1 Welding control circuit ....................................................................... 4-54.4.2 Welding mode .................................................................................. 4-54.4.3 I/O Signals of the control during weld sequence .................................... 4-74.4.4 Example: Edit Weld program .............................................................. 4-74.4.5 Function keys of menu EDIT WELD PROGRAM ....................................... 4-94.4.6 Table of parameters for different welding modes...................................4-104.4.7 Parameters of menu EDIT WELD PROGRAMS .......................................4-11

4.4.7.1 Program number ..........................................................................4-114.4.7.2 Program name [ : ]......................................................................4-114.4.7.3 Mode of welding [ : ]....................................................................4-114.4.7.4 Enable program [ : ] .....................................................................4-114.4.7.5 Pulse type [ PLS: ]........................................................................4-124.4.7.6 Number of pulses [ : ] ...................................................................4-13

4.4.7.7 Stepper/Electrode parameter [ Stp_: ].............................................4-134.4.7.8 Presqueeze [ 1.Sqz: ]...................................................................4-144.4.7.9 Squeeze [ 2.Sqz: ].......................................................................4-144.4.7.10 Hold time [ Hold: ].......................................................................4-144.4.7.11 Open [ Open: ]............................................................................4-144.4.7.12 Equivalent energy value [ VEE_ ]: ..................................................4-174.4.7.13 Squeeze variation cycles [ CPV_: ] .................................................4-174.4.7.14 Squeeze variation mode [ MPV_: ] .................................................4-184.4.7.15 Electrode force 1. [ P1: ]...............................................................4-224.4.7.16 Electrode force 2. [ P2: ]...............................................................4-224.4.7.17 CosPhi nominal [ CosPhi: ] ............................................................4-224.4.7.18 Maximum Current tolerance [ %I.max:]..........................................4-234.4.7.19 Minimum current tolerance [ %I. min: ]..........................................4-234.4.7.20 Tolerance range (min-max-lim) of welding current:...........................4-24

4.4.7.21 Limit current tolerance [ %I. lim: ].................................................4-254.4.7.22 Electrode force tolerance [%T. Prs:] ...............................................4-254.4.7.23 Electrode Force Diagnostic Mode [%T. Prs:].....................................4-264.4.7.24 Spot repetition [Rtr:]....................................................................4-264.4.7.25 Firing angle limitation [Ang:].........................................................4-274.4.7.26 Sheet thickness [Th.1, Th.2, Th.3] .................................................4-284.4.7.27 Up-slope [ Up_S:]........................................................................4-284.4.7.28 Down-slope cycles [ Dw_S: ] .........................................................4-294.4.7.29 Cool time [ Wait: ] .......................................................................4-314.4.7.30 Weld time [Weld] :......................................................................4-314.4.7.31 Delayed firing of first half-cycle [ 1^Ang: ] ......................................4-324.4.7.32 Welding current [ Pwr %: ] ...........................................................4-324.4.7.33 Diagnostics current [ I.Dgs.:] ........................................................4-324.4.7.34 Blanking cycles [Blank: ]..............................................................4-324.4.7.35 Welding current programmed in kA [ I.Prg.: ] ..................................4-33

4.4.7.36 Measured welding current [ I: kA ].................................................4-33

5 STEPPER MENU ...................................................... 5-1

5.1 Copy steppers F2 COPY....................................................................5-3

5.2 Clear Stepper F3 CLEAR...................................................................5-3

5.3 Reset spot counter F1 RESET..........................................................5-4

5.4 Modify stepper counter content F2 PRESET..................................5-6

5.5 Relevant I/O Signals for steppers: ..................................................5-7

5.6 EDIT (Creation and modification of stepper) F1 EDIT...................5-9

5.6.1 Dressing 1 ....................................................................................... 5-95.6.2 Dressing 2 ......................................................................................5-105.6.3 Parameter for Dressing 1 ..................................................................5-11

5.6.3.1 Stepper number [ S: ] ...................................................................5-11

5.6.3.2 Stepper name [ : ]........................................................................5-115.6.3.3 Dressing mode [ : ].......................................................................5-115.6.3.4 Stepper data format [ : ] ...............................................................5-12

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5.6.3.5 Prewarning__:..............................................................................5-125.6.3.6 Stop_______:..............................................................................5-125.6.3.7 Dressing_:...................................................................................5-125.6.3.8 Offset_______: ............................................................................5-12

5.6.3.9 Pt. x Pieces _______:....................................................................5-135.6.3.10 P.x Emergency : ..........................................................................5-135.6.4 Parameter for Dressing 2 ..................................................................5-13

5.6.4.1 Pt.x Dressing_ : ...........................................................................5-145.6.4.2 Pt.x Emergency:...........................................................................5-14

5.6.5 Stepper: Current - and pressure increment curve .................................5-155.6.6 Increment with Graphic method.........................................................5-165.6.7 Increment with Tabular method .........................................................5-18

5.6.7.1 Tabular stepper Menu....................................................................5-195.6.7.2 Programming the Tabular increment................................................5-19

6 TRACE MENU ............................................................. 6-1

6.1 Parameter of page SPOT TRACE F1 PROG....................................6-1

6.1.1 Parameter SPOT TRACE ..................................................................... 6-26.1.1.1 Program number [ P: ] ................................................................... 6-2

6.1.1.2 Program name [ : ]........................................................................ 6-26.1.1.3 Welding mode [ : ]......................................................................... 6-26.1.1.4 Welding time [ Cycles: ] ................................................................ 6-26.1.1.5 Nominal welding current [ I Prg.: ].................................................. 6-26.1.1.6 Setpoint current [ I Nom: ] ............................................................. 6-36.1.1.7 Measured welding current [ I. Mis: kA ]...................................... 6-36.1.1.8 Stepper number [ Stp : ] ................................................................ 6-36.1.1.9 Stepper counter [ Cnt : ] ................................................................ 6-36.1.1.10 Current increment in (%) [ INC% : ] .............................................. 6-36.1.1.11 Setpoint Electrode force 1 [ Prs1: ]................................................. 6-36.1.1.12 Setpoint Electrode force 2 [ Prs2: ].................................................. 6-46.1.1.13 CosPhi [ CosPhi: ] ....................................................................... 6-4

6.2 I/O TRACE F2 I/O ..........................................................................6-5

6.2.1 Index of I/O abbreviations ................................................................. 6-6

6.3 Special functions F3 TEST ..............................................................6-8

7 ALARMS MENU ........................................................ 7-1

7.1 Error categories...............................................................................7-3

7.1.1 Index: abbreviations of reset procedures:............................................. 7-37.1.2 Process diagnostics (Error code from 01 to 50)...................................... 7-47.1.3 Normal or hardware errors (error code 51 to 100) ................................. 7-57.1.4 Fatal error (Error code 101 and higher) ............................................... 7-6

7.2 I/O Signals, which are caused by errors..........................................7-7

8 MENU REPORT ............................................. 8-1

8.1 Define Reports.................................................................................8-2

8.2 Modify reports F5 MODIF................................................................8-2

8.3 View reports F1 VIEW...............................................................8-3

9 CARD MENU (BACKUP OF DATA) ....................9.1

9.1 Load firmware to the control ........................................................... 9.1

9.2 Store/load of Programs................................................................... 9.3

APPENDIX ...............................................................................................1

Appendix A Operating diagrams.................................................................. 1

Operating diagram 1 - Single cycle sequence ........................................................... 2Operation diagram 3 Type of weld ....................................................................... 4Operating diagram 4 - Dressing 1 stepper mode (part 1 of 2)..................................... 5Operating diagram 5 - Dressing 1 stepper mode (part 2 of 2)..................................... 6Operating diagram 6 - Dressing 2 stepper mode....................................................... 7Operating diagram 7 Seam mode ........................................................................ 8Operating diagram 8 Cycle mode ..................................................................... 9

Appendix B DIAGNOSTICS ALARMS............................................................ 1Description of alarms............................................................................................ 1

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Programming Manual

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PREFACE

This manual contains theoretical and technical details about the usage andoperation of the welding control Weld334m.

Mainly this is a programming instruction, which is useful for persons, whoare setting up the parameters of the control. Knowledge of electrotechnicalbasics as well as experience about resistance welding are mandatory to useand program the welding control.

Concerning safety, danger of resistance welding devices, safety rules, start-up of the control and technical features please refer to the HardwareManual. The spot weld is the result of complex electrical, thermic,metallurgic and mechanic processes, which are performed within a shortamount of time.

To use the welding control knowledge about technical correlations betweenall effective parameters of resistance welding is necessary.

These parameters have to be specified by the operator or other factors

need to be considered, which refer to environmental issues or precedingprocess steps. The operator, however specifies effective parameters of thecontrol - 5 out of more than 100. However, the 2 most importantparameters define the necessary thermal energy for successful welding. Insome cases inadequate conditions of preceding process steps like bad fittingparts or insufficient design of devices can be compensated by efficientcombination of the control parameters.

The operator has to find the working point within the process window inorder to provide quality and safety of welding. The control carries out theprogrammed parameters only. The errors issued by the control indicatedeviations from fixed settings. In any case the spot may not be of badquality.

Please notice, that state of the art controls like Weld334m, which offerconstant current control, stepper, error diagnostics, statistical functions andmore, will not guarantee perfect weldings in any case. The control repeatsthe process with highest amount of precision, as it was programmed by theoperator. In case errors are issued by diagnostics of the control,countermeasures must be done instantly. In most cases of abnormality thecurrent could not reach full amount because the secondary circuit does notpermit more or parts are far apart.

The actual welding quality results from the programming of the operatorand not from the control only.

This manual shall enable the user, to learn about how to program thecontrol and to look as a reference in order to perform the task quickly andsecurely. This programming instructions will not be a substitute for training

on resistance welding.

All details mentioned in this manual are not guaranteed and can be changedwithout notice. Company GF WELDING does not have any obligations onthis item.

The soft- and hardware as described in this manual is part of a Licensingagreement and all information must be kept confidential.

It is prohibited to pass the documentation of soft- and hardware to a thirdparty. The purchaser is allowed to make one copy of the software as abackup.

Parts of this manual including copies or other notes may not be duplicatedor distributed by electronic or mechanic means without written permission

of Company GF WELDING S.p.A.Copyright by GF WELDING S.p.A.

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Programming ManualGeneral Notes

GF WELDING 1-1

1 General notes concerning Programming

1.1 Programming

There are three different ways how to program the welding control WELD334m:

1 Usage of the hand held keyboard HCM 4300 HHT (Hand Held Terminal), which isconnected to the control unit.

2 Usage of the Personal Computer or Laptop with WMS Software (WeldingManagement System), which is connected to the control unit with a cable suppliedby GF WELDING S.p.A.

3 Via Main computer with WMS Software, which offers control function and centralprogramming of each welding control, which are connected to the main computer

via bus system.

For Usage of WMS (delivered separately by GF WELDING) a computer with followingfeatures is necessary:

Processor Pentium

Microsoft Windows 3.1, 3.11, 95, 98, NT4, 2000

10 MB HDD

1.2 Manual Keyboard HCM 4300 HHT

The manual keyboard HCM 4300 HHT is an external device for programminglocally.

The HHT is connected to the Weld334m by a 9-pin Sub D connector. Thematching plug is located at the upper left corner on the frontside (markedwith the HHT Symbol).

The HHT may be plugged or disconnected during operation of the control.

Attention:

The WELD320 Welding control is using the same connector type as theprevious Weld 334m for the manual keyboard. These two manual keyboardshowever are not compatible and may only be used together with the same

welding control version. HHT as well as the control unit can be damagedhardly.

The HHT has a liquid crystal display with 240x64 pixels. A text consisting of8 lines with 40 signs each can be displayed.

Around the display there is an input area with 13 keys allocated.

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1.2.1 Keys

All kind of standard functions and related keys are described in thefollowing.

Arrow keys:

Are there any data displayed on the screen, the 4 arrow keys will move thecursor into the 4 directions.

Soft keys: F1 F2 F3 F4 F5

These keys activate the functions above, which are displayed in the lowerbar.

Keys: + (plus) - (minus)

These keys change the content or values of the fields, where the cursor islocated. In case of a numeric field, the number will be increased (+) ordecreased (-). In case of a character field, the predefined words will alter.

Remark:

The definition of field will be explained in the following.

To 'edit' means to setup or change data, which are displayed ina field.

ESC key:

With the Escape or Abort-key running operations will be stopped and the

program will return to the previous menu.

Pressing ESC several times is useful to return to the main menu.

ENT key:

This key confirms the entry of data or values.

When the function 'SAVE' is displayed in the lower bar, the ENT key willperform the same function as the key. In order to confirm changes thesave function must be activated by pushing the related key. The displayedstar (*) in the upper bar will disappear, when changes are saved.

SETUP - Cable wearEnable ON OFFPrewarning 000001 000001Stop 0000100 0000100

Counter 100 100RESET-A RESET-B SET-A SET-B ETC

F1

+

_

ENT

ESC

F5F4F3F2F1

HCM 4300 HHT

BA

Lower barData areaU er bar

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1.2.2 Display

The display is divided into three different areas:

Upper bar: contains the title of the active page(menu)

Data area: contains all fields, which can be edited

Lower bar: contains the related functions of the keys F1F5

Upper display bar:

Contains the title of the active page (Mask).

The star (*) at the right end of the upper bar shows, that some change ofone field is not save yet.

REMARK:

In case the star (*) does not disappear after saving some entry,

any faulty data entry is indicated. For example: the first sign ofan numeric field must be a number, the entry must be corrected.

The cursor jumps to the faulty or missing data field and indicateswhere to correct the entry.

Data area

In the data area all operating parameters of the control, which can beedited, are displayed. Furthermore statistical or dynamic information in thefixed or changing fields can be read. However they can not be edited.

On some pages the data area may have more than 6 lines. Use the arrowkeys to take a look at the remaining lines.

In the data area there are three different kinds of fields displayed: Fixed fields, which can not be edited (contain descriptions)

Changing fields, which can not be edited (contain measured or calculatedvalues)

Fields, which can be edited (contain all programmable parameters)

In order to distinguish fields, which can be edited, from fields, which cannot be edited, just move the cursor using the arrow keys. The cursor willappear on fields only, which can be edited.

There are three different kind of fields, which can be edited:

with predefined character values

Fields with numeric values Fields with character values, which can be edited (signs or numbers)

Fields with predefined character values

After selecting a field by using the arrow keys, press + or - key to togglebetween the predefined values.

Example: in the SETUP menu the module code parity can have one of threesettings:

OFF

EVEN

ODD

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Fields with numeric values

After selecting a field (use the arrow keys ), change the valueby using + or - key and the number will increase or decrease.

In case a printer is installed in parallel to the control, the active menu can

be printout. In the printouts of the menus additionally the upper and lowerlimits are shown at the left side of the related fields.

Example: In the SETUP menu the number of current sensors can beentered, which can be in the range between 1 and 6. On theprintout you can see on the left side of the field [1-6].

Fields with character values

After selecting the field (use the arrow keys ), which shall beedited, the + and - key can be used in order to find following signs:

A B C D E F G H I J K L M N O P Q R S T U V W X Y Z 0 * + - / 0 1 2 3 4 5 6 8 9

The first digit of a character field must be a sign.

The maximum length of a character field is indicated by the final position ofthe cursor, where it can be moved.

Example: In the setup menu the field, which shows the Module name, thename is preset with 'Weld 334m'. This is the default setting ofthe maker.

Lower bar

The lower bar shows all the functions which are related to the soft keysF1F5.

EXAMPLE:

In case the F1 key is defined with Page+ (next page), the data area doesnot show the whole content of the activated page. Use F1 key and theremaining data in the next page will be shown.

In case the F2 key is defined with the COPY function, the copy procedureof a program will be initiated by pushing F2.

In case the F5 key is defined with ETC , besides the 4 shown functions,further functions exist. The further functions will be displayed by pushingthe F5 key.

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1.3 Menu structure

On the HHT 8 Submenus can be accessed from the main menu.

ALARMS: errorlog of the last 500 error messages

PROG: Setup and editing of welding programs

STEPPER: Current/Pressure curve, setup and editing of stepper programs

TRACE: Display of relevant information about each spot welds and statusof inputs and outputs in real time

CARD: Ensures storage of data. Displays functions for use of RAM card

REPORT: Summary of operation data and errorlog of the last 24 hours

CONFIG: Display and modification of date, time and language

SETUP: Base settings

During installation of the control, following 6 steps must be performed:

1. Configuration of the control (go into the menus CONFIG and SETUP)

2. Programming of the control (go into the menus PROG and STEPPER)

3. Checking of performed spot welds (go into the menu TRACE)

4. To check the errorlog go into the menu ALARMS

5. To check the number of error messages go into the menu REPORT

6. To make a backup of all control parameters go into the menu CARD

The description of the different menus follows the above mentioned

sequence

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Programming instructionsLanguage/Date/Time

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2 Configuration

2.1 Parameter of the Configuration menu

In the Configuration menu the following is shown:

Software version of control

Software version of HHT

Further configuration setup can be done:

language

date and time

In case the control is connected to a centralized network management,through the program "WMS", the time and date will automatically be

updated to those of the central PC.

Since the CONFIG menu is dynamic, if the welding control is configured withthe F381-ETH card, the NETWORK function is assigned to function key F1.

Following table shows the complete CONFIG menu:

Configuration

SoftwareRelease Language

EnglishDate & Time

Mon 09/02/199809:54:17

All function keys, which are available in the Configuration menu:

F1 NETWORK: This enables you to access the menu of the addressesfor connection to the Ethernet TCP/IP network.

The F5 key performs 2 different functions:

F5 MODIFY: modification of elements by selection of predefined valuesand names

F5 SAVE: saves all entered changes (in case of correct data entry,the star* in the upper bar of the submenu will disappear)

2.1.1 Configuration parameters

2.1.1.1 Release Software

Parameter: Pixed text, which cannot be edited

Prog. Version: Preset by the manufacturer

Description: Model of welding control and firmware version installed

Example: WELD334m v1.1

The firmware can be changed by memory card (see

section 9)

WELD334m v.1.1

HCM 4300 HHT v2.00

NETWORK MODIFY

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2.1.1.2 Software Release keyboard (HHT)

Parameter: fixed text, which cannot be edited

Prog. Version: Preset by the manufacturer

Description: HHT Model and firmware version installed

Example: HCM 4300 HHT v2.00

2.1.1.3 Language

Parameter: a preset language can be selected

Prog. Version: Changeable, according to the family of chosen languages(see Note).

Description: This allows the language used by the welding control in thevarious menus to be selected; the languages available are:Italian, English, German, French, Spanish, Portuguese,Dutch, Polish.

Remark: From release 1.10, the number of languages available is limited to

3-4; the languages are chosen during production of the weldingcontrol. In order to up-date the software to one of the languageslisted (and not present in the configuration) contact GF WELDINGAfter-Sales Dept.

2.1.1.4 Date and time

Parameter: some number can be entered

Prog. Options: Date (From 01/01/1980 till 31/12/2030)

Time (From 00:00:00 till 23:59:59)

Description: Allows to change date and time of the control unit

Format of date is: DD/MM/YYYY

Format of time is: hh:mm:ss

When pushing SAVE the clock starts at second zero

Example: In order to shift the clock by one hour please follow thisprocedure:

1. Press the F5 key in the CONFIG menu (MODIFY). The functionof the F5 key will change to SAVE.

2. Press the arrow key 4 times and the cursor will be positionedon time.

3. Press the + key once. The hour will be increased by onehour.

4. Press the F5 key once. All changes will be saved. The star inthe upper bar will disappear. The function of the F5 key willchange to MODIFY.

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2.1.2 Addresses for connection to the Ethernet TCP/IP network

On accessing the NETWORK CONFIGURATION menu (F5)(F3) you can define the IPaddress, the Subnetwork and the Port for connecting the welding control to the WMS

centralized network management with TCP/IP network.

NETWORK CONFIGURATION

IP Address : 192.168.000.008

SubNet Mask : 255.255.255.000

TCP Port : 01200

2.1.2.1 IP Address

An IP address consists of 4 numbers between 0 and 255 separated by full-stops. The address is free: however, if the centralized network is connectedto the company network, you must check that the IP addresses have notalready been used by other devices or PCs.

2.1.2.2 SubNet Mask

This number, together with the address, identifies the subnetwork in whichthe welding control is situated. The protocol subnetwork is predefined(Class C): normally all welding controls plus the WMS, that comprise asystem, must belong to the same subnetwork.

2.1.2.3 TCP Port

The HOSTPORT channel is predefined at 01200 (5 editable figures);however, if you modify the number conflicts may occur. The HOSTPORTvalue of the welding control must be the same as that set in the WMSapplication software.

SAVE

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WHITE PAGE

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Programming instructionsSetup

GF WELDING 3-1

3 Base settings

The base settings of the welding control are done in the SETUP menu.

The SETUP menu consists of 4 pages (masks). Following choices arepossible:

1. SETUP - WELD 334m CONFIGURATION: Main parameters of theconfiguration

2. SETUP GUN PARAMETERS 0 (0-16): Specific configurations of usedguns = stepper

3. SETUP - ALARMS CONFIGURATION: Selection of error messages, whichwill block restarts and will be reported in the errorlog (REPORT)

4. SETUP - CABLE WEAR: Setup of spot counters to specify maintenanceintervals (for example: exchange of gun cables)

5. SETUP TIP DRESSER WEAR: parameters concerning the toolmaintenance for dressing electrodes

3.1 SETUP Menu -CONFIGURATION WELD 334m

Following table shows the page SETUP - WELD334M CONFIGURATION. Eachvalue can be selected using the arrow keys on the HHT:

REMARK: All values in brackets show the range of each setup parameter

SETUP WELD334m CONFIGURATION

WMS-NET network address (0 32) : 00

Device name (8 digits) : FASE 334mWorking mode (WELD320 WELD334m) : WELD334m

Preset analog output: (0 100) : 050

Weld alarm threshold A: (1 20) : 01

Weld alarm threshold B: (1 20) : 01

Current transducer : ENABLED

N.current transducers (1 6) : 1

Start code parity ( OFF - EVEN - ODD) : OFF

Module address parity ( OFF - EVEN - ODD) : OFF

Execution in repeat : OFFExecution with current (OFF - ON) : OFF

Station type (Automatic - manual) : Manual

Pressure-OK Input mode (24V=OK - 0V=OK) : 24V=OK

EOS Output minimum time ( 0 - 99) : 00

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Function keys of SETUP - WELD334M CONFIGURATION

F1 PAGE+: Move to the next page in the SETUP menu

F4 PRINT: Print the complete SETUP menu

F5 SAVE: Saves all changes. In case all entries were ok, the star inthe upper bar will disappear.

Key : Scrolls the menu of the Configuration page in the Setupmenu

Key + -: Changes the parameters

3.1.1 Parameter of SETUP - WELD334M CONFIGURATION

3.1.1.1 WMS-NET network address:

Parameter : can not be edited

Range: (00 32)

Description: Displayed in network mode. Shows the address of thecontrol in the WMS-NET. This variable text is a read textonly (it may be modified via Hardware only).

3.1.1.2 Device name:

Parameter: some alphanumeric value can be entered

limits: 8 digits - the first must be a sign

Description: Name of the welding control (mnemonic). It isrecommended to use the name of the station.

3.1.1.3 Working mode:

Parameter: a preset value must be selected

Range: (WELD320 WELD334m)

Description: Adapts the welding control to Normal operation(Weld334m) or to the functions of the previous version(WELD320).

3.1.1.4 Preset Analog output:

Parameter: a numeric value need to be entered

Range: (0 100)

Description: Applicable only on controls with servo valve command.This is the analog voltage in %, which is applied afterreset. The electrode force will be same as the specifiedpercentage of the maximum force, which is set after Resetor at the first start after a no voltage status

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GF WELDING 3-3

3.1.1.5 Weld alarm threshold A:

Parameter: a numeric value must be entered

Range: (1 20)

Description: specifies the number of allowable faulty weld spots in indicatedby alarm Code E005 in sequence (occur after the lowercurrent limit has not been reached.)See also section 4.4.7.20

Channel A only.

REMARK: The control manages 2 welding guns (channel A= gun1 and channel B = gun2). Each gun iscontrolled by valve EVSA and EVSB and startbutton STARTA and STARTB.

3.1.1.6 Weld alarm threshold B:


Range: (1 20)Description: specifies the number of allowable faulty weld spots

indicated by alarm Code E005 in sequence (Meas. cur. *

*

N01

N02

N03

N04

N05

N06

N07

N08

N09

N10

N11

N12

N13

N14

N15

N16

E005 Meas.cur.< min threshold

E006 Meas.cur.> max threshold

E031 Meas.cur.< lim threshold

E032 Null welding current

E001- Stepper warning channel A

E002- Stepper warning channel B

E000-OK

E000-OK

E000-OK

E000-OK

E000-OK

E000-OK

E000-OK

E000-OK

E000-OK

E000-OKA B C

Column A: Abort function of error active (with *)

Column B: Order number

Column C: Error code and error description

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GF WELDING 3-9

Notes on previous table:

The error messages E005, E006, E031, E032, E001 and E002 are used inthe menu REPORT (See section 8)

The error messages E031, E032, E001 and E002 are configured withabort function.

The error message is selected by the cursor > on position N05, whichrefers to code E001.

Code E000-OK means: no error message is programmed.

The error message, which is configured with abort function,prevents any restart. The user has to reset the alarm.

All error messages, which are configured without abort function, arelogged in the alarm history or in menu REPORT.

On the page SETUP - ALARMS CONFIGURATION, following

function keys are available:

F1 PAGE+: Moves to the next page of the SETUP menu

F2 SELECT: Enables or disables the ABORT functions with respect tothe alarm indicated by the pointer >

F3 ALL: Enables or disables the abort function of all 16 errormessages

F4 PRINT: Prints actual page

F5 SAVE: Saves all changes

Usage of keys: (ESC + - ENT SETUP ALARMS

CONFIGURATION)

ON the page SETUP - ALARMS CONFIGURATION the cursor > is moved inthe left column and the functions of certain keys differ as described insection 1.2.1

Functions of each keys are given in Table below:

Key : moves the cursor up in the left column

Key : Error code Exxx will be increased or decreased

Keys + -: moves the cursor up or down by 5 lines in the left column

ESC key: The escape key stops running actions and returns to theprevious menu. Any changes are not saved.

ENT key: The Ent or Return key can enable or disable the actualselected alarm (position of cursor >).

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GF WELDING3-10

3.3.1 Alarms Configurationin REPORT menu.

In the REPORT menu bargraphs show, how often certain errors occurred.(see section 8.3).

On this page in the SETUP menu, it can be defined, which process diagnosismessages (E001 - E050) are logged in the REPORT menu.

There are some error messages (E001 - E002 - E003 - E004 - E046 - E049- E050), which will not increase the error log counter, even they areexisting in the SETUP - ALARMS CONFIGURATION menu.

These alarms do not have effect on the statistical analysis of the faults ofthe faulty welds as they concern the electrodes or cables wear.

They are existing in the SETUP - ALARMS CONFIGURATION menu in orderto configure them with abort function.

SETUP - ALARMS CONFIGURATION

>

N01

N02N03

N04

N05

E001-Stepper warning channel A

E002-Stepper warning channel BE006Meas. Curr.> max. threshold

E031Meas. Curr.< lim. threshold

E032Nul welding current

Example: to define the message E015-Tip force out of tolerance, inthe REPORT menu, following steps must be performed:

1. Select the first empty position with the cursor (E000-OK)

2. Push thekey several times until the desired Error code andError description is displayed.

3. Press F5 SAVE

3.3.2 Machine Shutdown Enable of Diagnostic Alarms

There are some welding processes, where messages with abort function arerecommended in order find root cause before operation is continued. Thecontrol is stopped until the reset signal is present on the RESAH input or bypressing F1 key from ALARMS HISTORY menu.

SETUP ALARMS CONFIGURATION

*

>*

N01

N02

N03

N04

N05

E001-Stepper warning channel A

E002-Stepper warning channel c. B

E006Meas. Curr.> max. threshold

E031Meas. Curr.< lim. Threshold

E032Nul welding current

Example: To configure as an abort alarm the error message E032-Nul welding current, perform following steps

1. Move the cursor to the position, where the Error E015 is displayed.

2. Press F2 SELECT and the star (*) in the first column will appear.

3. Press F5 SAVE.

PAGE+ SAVEPRINTALLSELECT

PAGE+ SAVEPRINTALLSELECT

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GF WELDING 3-11

3.4 Menu SETUP - CABLE WEAR

Following table shows the page SETUP - CABLE WEAR on the HHT.

REMARK: the text in brackets is not shown on the HHT. It informs about the

upper and lower limits of the given fields.

PAGE CABLE WEAR menu

SETUP CABLE WEAR

Enable (ON OFF) ON OFF

Prewarning(1-999999) 000001 000001

Stop (100 999999) 0000100 0000100

Counter (0 999999) 100 100

Other commands appearing on Cable Wear menu

Function key of the menu SETUP CABLE WEAR:

F1 RESET-A: Reset of spot counter for welding channel A.

REMARK: no confirmation will follow or be requested.

F2 RESET-B: Reset of spot counter for welding channel B.

REMARK: no confirmation will follow or be requested.

F3 SET-A: Presetting of the spot counter for welding channel A. Afterpressing F3 a window with the counter setting will appear.Select the desired counter number using +,- and arrowkeys. Confirm change by pushing ENT and SAVE with F4.

Remark: the maximum value is given by the programmedStop value.

F4 SET-B: Presetting of the spot counter for welding channel B. Afterpressing F4 a window with the preset counter will appear.Select the desired counter number using +,- and arrowkeys. Confirm change by pushing ENT and SAVE with F4.

Remark: the maximum value is given by the programmedStop value.

F5 ETC: Shows further functions of the menu

F1 PAGE+: go to next page of the SETUP menu

F3 PRINT: Prints out the content of the actual page

F4 SAVE: Saves all inputs and changes

A B

PAGE+ ETCSAVEPRINT

RESET-A ETCSET-BSET-ARESET-B

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GF WELDING3-12

3.4.1 SETUP CABLE WEAR

This function consists of 2 independent spot counters for channel A and B.The spot counter of channel A counts all spots, which are initiated fromStart A. The spot counter of channel B counts all spots which are initiated

form Start B. There is no relation to steppers. However same as withstepper functions it is possible to issue messages as soon as somepredefined counter is reached.This function enables maintenance intervals defined by number of spots. Itonly makes sense to use this function in case of repeatability of cable wearand maintenance intervals. The estimation of counts per maintenance isempirical.This function is mainly used for devices with gun cables to indicate, whenthe cable needs to be replaced. Further options are possible. Theapplication allows to define the maximum number of welds, which can beperformed by one cable. As soon as this count is reached a error messageE046 (channel A, gun1) or E047 (channel B, gun2) will be issued. Inaddition a prewarning can be programmed, where the messages E003 (gunA) or E004 (gun B) are issued. This messages indicate maintenance work

must be done soon.Please note the biggest benefit you may get with host computer managedby WMS.All values must be found by experience. A welding machine equipped withtwo guns (A and B) is capable to run 500.000 welds on gun A and 850.00welds on gun B. The operator will set the prewarning thresholds with thesevalues whereas the alarm thresholds are increased by about 10%. Thisgives some safety margin before the machine will be stopped. The numberof welds on gun A would be 550.000 and for gun B 935.000.In opposite to the stepper no outputs will be generated.

3.4.1.1 Enable

Parameter: Preset values must be selected

Options: (ON - OFF)

Description: Enables the count of welds for cable wear management ofchannel A/B. When to Off position, the counter of executedwelds is not incremented

3.4.1.2 Prewarning


Range: (1 - 9.999.999)

Description: Number of welds necessary to generate a Cable WearPrealarm of channel A/B.

3.4.1.3 Stop


Range: (100 - 10.000.000)

Description: Number of spots before the maintenance must be carriedout

3.4.1.4 Counter

Parameter: enter the actual number of spots

Range: (0 10.000.000)

Description: Shows the actual number of spots. The counters can be

modified manually using SET-A or SET-B.

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GF WELDING 3-13

3.5 Menu SETUP TIP DRESSER WEAR

The table below shows the SETUP TIP DRESSER WEAR page (displayed onthe hand-held keyboard)

NOTE: Text between brackets is not displayed on the hand-held keyboard.It provides useful information on the limits of the value appearing inthe adjacent field.

SETUP TIP DRESSER WEAR

Enable(ON OFF) ON

%Prewarning 000001

Stop (10099999999) 00001000

Counter (0 9999999) 0

Function keys of the SETUP TIP DRESSER WEAR

F1 PAGE+: Allows moving to the next SETUP page

F2 RESET: Reset command of dressing counter

NOTE: No additional confirmation of operation is requested

F3 PRESET: Manual setting of counter for executed dressings. Bypressing the F3 key, a window will appear in which theCounter Preset may be set. This value shall have to bevalidated by pressing the ENT key and then F5 SAVE key.

NOTE: Maximum settable value is equal to theprogrammed STOP value

F4 PRINT: Executes the print of the current page

F5 SAVE: Permits moving into other Setup menu pages

3.5.1 Comment to the SETUP TIP DRESSER WEAR

This page allows the user to manage the DRESSER wear function (wearresults from the operation of the machine over time). This meansdetermining a maximum number of operations the dresser is capable ofdoing; a prealarm and an alarm threshold are programmed. This function,

similar to the one used to control the Cable Wear function, allowsprogramming, in a rational manner, the maintenance interventions on thedresser. In the same way as Cable Wear, when set thresholds are reached,the welding control warns the user on the necessity of performingmaintenance operations (this is done by displaying the E007 message andthen E045 message). If the alarm has been configured as an Abort function(refer to Setup 3.3), the welding cycle is shutdown.

It should be noted that maximum flexibility in use of this function isobtained by linking the welding control to the remote central unit forWeld334m (WMS) welding controls. In fact this unit has been equipped withenhanced functions for highlighting, in a quick and simple manner, thestatus of cable wear and electrode wear counters. And this represents aprecious help for operators.

PAGE+ SAVEPRINTPRESETRESET

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GF WELDING3-14

Unlike the electrode wear management, the TIP DRESSER WEAR function isnot dependent on programs, special clamps and it has no dedicatedoutputs.

* Only if configured as an Abort alarm on the Setup- Alarm Configuration

3.5.1.1 Enable

Parameter: Preset values must be selected

Range: (ON - OFF)

Description: Enables the count of dressing operations. When to the OFFposition, the counter is not increased.

3.5.1.2 Prewarning: [%]


Range: (1 - 100)

Description: Number of welds required before the request for DresserMaintenance is displayed.Once this threshold is reached, the welding control willgenerate E007 message to indicate that the Stop value isabout to be attained.This warning is only loaded to the Alarm History.

3.5.1.3 Stop:


Range: (100 - 10.000.000)

Description: Number of dressing operations required before the requestfor Dresser To Be Reset is displayed. Once this threshold isreached, the welding control will generate E045 message

to indicate that the Stop value has been attained.This warning is only loaded to the Alarm History andwhether the alarm code has been configured as an AbortFunction in the Setup- Alarm Configuration menu, thewelding cycle will be shutdown.It is necessary to reset the counter (to do this press F2-RESET key) to reset the operating conditions.

3.5.1.4 Counter


Range: (0 10.000.000)

Description: Counter of dressing operations executed. Counter may beforced out through the F3-Preset key and then validatedby pressing ENT key.

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Programming instructionsWeld programs

GF WELDING 4-1

4 Menu PROG (Weld programs)

All kind of parameters of the 255 possible weld programs can be accessedin the menu PROG (WELD PROGRAMS).

The menu PROG shows a list of all existing programs with the mainparameters including date/time of the last modification.

The following table shows the directory.

(Only 10 out of 255 programs are shown).

Page menu WELD PROGRAMS

WELD PROGRAMS

> P01

P02

P03

P04P05

TEST111

BODEN3

PAVIM3

SEITENTAAA

Const. Cur

Normal

Const. Cur

Const. CurConst. Cur

.

ON

OFF

ON

ONON

S00

S00

S00

S00S01

S.SP

S.SP

S.SP

S.SPRPT

WELD PROGRAMS

>

P01

P02

P03

P04

P05

P06

P07

P08

P09

P10

TEST111

TEST222

BODEN3

SEITENT

AAA

BBB

CCC

Const. Cur

Const. Cur

Normal

Monitor

Const. Cur

Monitor

Corr.Cos

ON

OFF

ON

ON

ON

ON

ON

S00

S00

S00

S00

S01

S01

S02

RPT

RPT

RPT

RPT

SS

SS

SS

Mon 09/02/1998 09:11:23

Tue 10/02/1998 10:11:32

Mon 09/02/1998 11:11:04

Mon 09/02/1998 18:11:55

Tue 10/02/1998 09:11:44

Mon 09/02/1998 09:11:19

Fri 06/02/1998 09:11:56

A B C D E F G H

COLUMN A: The cursor> can be moved by using the arrow keys

COLUMN B: Program number (P01 P255)

COLUMN C: Program name (mnemonic)

COLUMN D: Welding mode(see section 4.4.1)

COLUMN E: Program activation (see section 4.4.7.4)

COLUMN F: STEPPER which belongs to welding program (Autom.Current/pressure increment see section 4.4.7.7). S00means, no STEPPER program is assigned to the weldprogram.

COLUMN G: Key F5 selects the option repeat / single spot (RPT/SS) inseries with the other consents required (see section3.1.1.11)

COLUMN H: Date and time of create or modify the program

EDIT SS/RPTPRINTCLEARCOPY

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REMARK:Column H is displayed in alternative to columns D E F G whenusing arrow keys

The content of the columns can be changed by selecting the programs usingthe arrow keys and pushing F1 EDIT. Column G can be changed by using F5SS/RPT only.

Key + proceeds to the 5 succeeding, whereas key - proceeds to the 5previous programs.

Function keys in the menu WELD PROGRAMS:

F1 EDIT: Selects the program next to the cursor > for editing (seesection 4.4)

F2 COPY: a menu will be opened (see section 4.1) in order to copy aprogram

F3 CLEAR: a menu will be opened (see section 4.2) in order to delete

a programF4 PRINT: all parameters will be printed, which belong to the

program where the cursor is positioned

F5 SS/RPT: Selection of operating mode (see section 4.3)

SS= Single spotRPT= Repeated spot

4.1 Copy welding programs F2 COPY

In this menu programs will be copied. This means to transfer data of oneprogram to another program.

Page menu COPY WELD PROGRAMS

COPY WELD PROGRAMS

> P01

P02

P03

P04

P05

TEST111

TEST222

PAVIM3

FIANCATA

AAA

Const. Cur

Normal

Const. Cur

Const. Cur

Const. Cur

ON

OFF

ON

ON

ON

S00

S00

S00

S00

S01

SS

SS

SS

SS

RPT

Example: Copy of parameters of program Nr.4 (P04) to program 8(program 4 must contain data, program 8 may contain data butmust not be edited)

1. From menu WELD PROGRAMS, push F2 key COPY and the upper displaybar will show COPY WELD PROGRAMS. The F1 key selects and the F5 keycopies the program.

2. Move the cursor to the program (source),which shall be copied, by usingthe arrows

3. In order to select the program, which shall be copied, push F1 SELECTand the ENT key. The star * will appear next to line P04 in column A.

4. Move the cursor to the program (target) using the arrows Allparameters of the source program will be transferred to the targetprogram.

SELECT COPY

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GF WELDING 4-3

5. Push F5 key COPY. All parameters of program 4 will be transferred toprogram 8.

6. To go back to menu WELD PROGRAMS push ESC key.

4.2 Clear welding program F3 CLEAR

To clear means to cancel all parameters of a program. It is not possible toaccess a program, which was cleared.

Page menu CLEARweld programs

CLEAR WELD PROGRAMS

> P01

P02

P03

P04

P05

TEST111

TEST222

BODEN3

SEITENT

AAA

Cont.Cur

Normal

Cont.Cur

Cont.Cur

Cont.Cur

ON

OFF

ON

ON

ON

S00

S00

S00

S00

S01

SS

SS

SS

SS

RPT

Example: Clear program Nr. 2.

1. Push F3 key CLEAR from menu WELD PROGRAMS.In the upper display bar CLEAR WELD PRGRAMS will appear. F1 willselect a single program, F2 will select all programs and F5 takes care ofthe function CLEAR.

2. Use the arrow keys and move the cursor to the program P01, which

shall be cleared.3. In order to select the program, which shall be cleared, push the F1 key

SELECT or push the ENT key. The star * will appear in column A next toP01. In case all programs of the control shall be deleted, push key F2ALL. To undo this command key F2 ALL must be pushed again.

4. Press F5 CLEAR and the message CONFIRM? [ENT=YES / ESC = NO] willappear.

5. Confirm with ENT key.

6. In order to go back to menu WELD PROGRAMS, push ESC key.

SELECT CLEARALL

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GF WELDING4-4

4.3 Selection Single spot - Repeated spot F5 SS/RPT

SS (Single spot): After start one weld operation will be executed. Fornext weld, Start must be activated again. This

operation mode is used for automatic devices.

RPT (Repeated spot): Weld operations will be executed as long as Startis closed. This operation is used for manualdevices.

Page menu weld programs SINGLE SPOT - RIPEAT

WELD PROGRAMS

> P01

P02

P03

P04

P05

TEST111

TEST222

BODEN3

SEITENT

AAA

Const.Cur

Normal

Const.Cur

Const.Cur

Const.Cur

ON

OFF

ON

ON

ON

S00

S00

S00

S00

S01

SS

SS

SS

SS

RPT

Example: Serial spot ( repeat mode )with program P01

1. Program P01 is preset with option SS (see column G)

2. Move cursor to program P01 using the arrow keys .

3. Push key F5 in menu WELD PROGRAMS. Option RPT (columnG) will be changed to S.SP.

Also refer to the diagrams with enabled and disabled functions in

section 4.4.7.11.

EDIT SS/RPTPRINTCLEARCOPY

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4.4 Menu EDIT F1 EDIT

To set welding parameters is the most important task of the control.

All parameters of the welding programs (Current, cycles, electrode forceetc) can be edited.

The quality of weld is determined by the parameters, which were given bythe operator.

Please take notice the control offers additional functions. For this reason,the parameters must adapt to the hardware, which is in use. All parameterswith free functions should be adapted to the welding, whereas all defaultparameters, which are set by maker, should not be touched.

4.4.1 Welding control circuit

The welding control circuit has following structure:

Thyristor (SCR) on primary circuit of the welding transformer

Welding transformer

Current transducer (sensor) on secondary circuit of the weldingtransformer

Electrodes, which are connected to the secondary circuit of thetransformer

The current of the primary circuit is controlled by the thyristor.

The current control is done by changing the firing angle of the thyristor(phase angle control)

Control

WELD334m

SCR

HHT

Transformer

Input signal Output signal

Current

transducer

ElectrodesLine

4.4.2 Welding mode

Six different welding modes can be selected within one program:

1.NORMALNormal welding. In the NORMAL mode, the user sets the percentage ofmaximum current with which he wants to perform welding. There is noverification of the actual welding current as no current transducer isexpected to be installed.

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2.MONITOR

Same as Normal operation mode, however in addition it is possible tomonitor actual current. This makes process diagnosis easy (see section4.4.7.20). A current transducer is mandatory.

3. CONSTANT CURRENTActual current in kA will be same as setpoint current. This is achieved bythe welding control, which sets the ignition angle of the thyristor.Parasitic effects like change of impedance of the secondary circuit orchanges of voltage supply will be compensated and the welding currentwill be kept constant. A current transducer is mandatory (see section4.4.7.20).

4. SEAM NORMALOperation mode is for seam welding only. In this mode the activeparameters (see section 4.4.6) will be repeated until the start signal isswitched off. The welding program can be changed withoutinterrupting the Signal START. The Seam normal operation mode issimilar to Normal apart from the parameter downslope.

5. SEAM MONITORThis operation mode is similar to Monitor apart from the parameterslopedown.

6. SEAM CONSTANT CURRENTThis operation mode is similar to CONSTANT CURRENT apart from theparameter slopedown.

7. HALF CYCLE:This welding mode must be selected if the welding control is installed inplant where the welding technology known as AL-Sis applied.For this type of application, the duration of welding is fixed and consistsof a single network half-wave.The sequence of welding spots is produced by alternating the input of

the primary welding circuit with a positive half-wave and a negative half-wave, so as to avoid saturating the transformer. (See diagram in theappendix for an example)

8. HALF CYCLE MONITOR: As for the HALF CYCLE mode, with thepossibility of monitoring the current and making any process diagnosticsrequired (see point 4.4.7.19). A current sensor is mandatory.

All operation modes mentioned above effect the menu EDIT WELDPROGRAMS dynamically, where all displayed parameters will change independency on the selected Welding Mode. See also Operating Diagram3 of Appendix A page 4.

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4.4.3 I/O Signals of the control during weld sequence

Following I/O signals effect the execution of the welding process:

4.4.4 Example: Edit Weld program

A new program shall be edited - in this example program 8 is used:

1. Press ESC in order to return to the main menu.

2. Press key F2 PROG

3. Press arrow key until cursor is placed in the line of program P08.

4. Press key F1 EDIT.

5. The default menu for program editing consists of two pages, which canbe shown using key F1 PAGE+. It looks as follows:

WELD

334m

SALDA SI

With weld current

CODE0 - CODE 5

Programcode

CODE P

Parity code Program.

STARTB

Cycle start ch. B

STARTA

Cycle start ch. A

CONSSALD

Weld enable

REPEAT

Repeat mode

FINESEQ

End of sequence

FINESALD

End of weld

RICHSALD

Weld request

I/VSERV

control servo valve

EVPB

Pressure variation ch.B

EVPA

Pressure variation ch.A

EVSA

Weld valve channel A

EVSB

Weld valve channel B

SOLOPR

Force only

STSERV

Status servo.valve

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GF WELDING4-8

Program menu Normalmode: Page 1

P:08 : : Normal :ON PLS: N : 00

Stp_: 00 VEE_: 00

1Sqz_: 00 CPV_: 00

2Sqz_: 00 MPV_: 0

Hold: 00 P1: 00.00

Open_: 00 P2: 00.00

Program menu Normalmode: Page 2

P:08 : : Normal :ON PLS: N : 00

CosPhi : 0.80

First the mode of welding must be defined:

In this example the mode CONSTANT CURRENT shall be used. This is themost common mode, which takes advantage of the whole capability of thecontrol.

To change the mode of welding proceed by following steps:

1. Push the arrow key twice and the cursor will be placed on the field,where the preset value 'Const.Cur' can be selected.

2. Push key + twice and the operation mode will be switched from NORMALto Const.Cur

Following tables show how it looks, when a 'Const.Cur' program is edited(use key F1 PAGE+)

Program menu Costant Current mode: Page 1

P:08 : : Const.Curr. : ON PLS:N: 00

Stp_: 00 VEE_: 00

1Sqz: 00 CPV_: 00

2Sqz: 00 MPV_: 0

Hold : 00 P1: 00.00

Open: 00 P2: 00.00

Up_S : 00 1^Ang: 000

Weld : 00 a Pwr %: 000

Dw_S : 00

Wait: 00 I: KA

Up_S: 00 1Ang : 000Weld: 00 Blank: 000

Dw_S : 00 I.Prg : 000.0

Wait_ : 00 I: KA

Up_S : 00 1^Ang: 000Weld : 00 Pwr %:000

Dw_S : 00

Wait : 00 I: KA

PAGE + PROG +PROG -SAVE



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GF WELDING 4-9


P:08 : : Const.Cur : ON PLS:N: 00

%I.min: 00

%I.max: 00 Rtr: 00

%I.lim: 00 Ang: 000


P:08 : : Const.Cur : ON PLS:N: 00

Th.1 : 00.00Th.2 : 00.00

Th.3 : 00.00

The parameters can be edited by usage of the function keys.

All values must be within a certain range, otherwise the data can not be

saved.

4.4.5 Function keys of menu EDIT WELD PROGRAM

F1 PAGE+: go to next page

F2 SAVE: saves all allowable changes (the star * in the upper rightcorner will disappear).

F3 PROG -: go to previous program

F4 PROG +: go to next program

REMARK: in case the special pulse mode is selected, thefunction keys will modify:

F3 PULSE -: parameters of previous pulse

F4 PULSE +: parameters of next pulse are shown

F5 ETC: go to next page with the functions F1 PAGE+ ; F2 SAVE ;F3 PROG - ; F4 PROG + ; F5 ETC

Furthermore the right upper corner of the display shows the pulse number(see section 4.4.6) which is actually selected.

Up_S : 00 1^Ang: 000

Weld : 00 Blank: 00

Dw_S : 00 I.Prg: 000.0

Wait : 00 I: KA


Up_S : 00 1^Ang: 000Weld : 00 Blank: 00

Dw_S : 00 I.Prg: 000.0

Wait : 00 I: KA


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GF WELDING4-10

4.4.6 Table of parameters for different welding modes

All kind of parameters of the weld program depend on the actual operationmode (welding mode),which was selected in the opened program.

Following table shows the actual existing parameters of each operationmode: (Y) exist (N) not exist.

Welding modes

Description

Abbreviation

Normal

Monitor

Const.Cur.

SeamN.

SeamM.

SeamC.C.

C

ycleN.

C

ycleM.

Program Nr. P: yes yes yes yes yes yes yes yes

Program name : yes yes yes yes yes yes yes yesWelding mode : yes yes yes yes yes yes yes yes

Enable programs : yes yes yes yes yes yes yes yes

Pulse type PLS: yes yes yes no no no no no

Number of pulses : yes yes yes yes yes yes 1 1

Stepper/electrode parameter Stp_: yes yes yes yes yes yes yes yes

Presqueeze time 1. Sqz_: yes yes yes yes yes yes yes yes

squeeze time 2,. Sqz_: yes yes yes yes yes yes yes yes

Hold time Hold _: yes yes yes yes yes yes yes yes

Open time Open_: yes yes yes yes yes yes yes yes

Equivalent energy value VEE_: yes yes yes yes yes yes yes yes

Delay squeeze control CPV_: yes yes yes yes yes yes yes yes

Squeeze variation mode MPV_: yes yes yes yes yes yes yes yes

Electrode force 1. P1: yes yes yes yes yes yes yes yesElectrode force 2. P2: yes yes yes yes yes yes yes yes

CosPhi nominal CosPhi: yes yes no yes yes no yes yes

maximum current tolerance %I.max: no yes yes no yes yes no yes

Minimum current tolerance %I. min: no yes yes no yes yes no yes

Limit current tolerance %I. lim: no yes yes no yes yes no yes

Electrode force tolerance %T. Prs: yes yes yes yes yes yes yes yes

Electrode force diagnostic mode %T. Prs: yes yes yes yes yes yes yes yes

Repeating spots RTR: no yes yes no no no no no

Firing angle limitation Ang: no no yes no no yes no no

Sheet thickness Th. yes yes yes yes yes yes yes yes

Upslope cycles UpS: yes yes yes yes yes yes no no

Downslope cycles DwS: yes yes yes no no no no no

Cool time Wait_: yes yes yes yes yes yes yes yesWeld time Weld: yes yes yes yes yes yes no no

Delayed firing of first half-cycle 1Ang: yes yes yes yes yes yes no no

Welding current Pwr %: yes yes no yes yes no yes yes

Diagnostics current I.Dgs.: no yes no no yes no no yes

Blanking cycles (Blank) Blank: no no yes no no yes no no

Welding current in kA I.Prg.: no no yes no no yes no no

Measured welding current I: kA no yes yes no yes yes yes yes

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GF WELDING 4-11

4.4.7 Parameters of menu EDIT WELD PROGRAMS

In respect of different welding modes there are 2 categories of parameters:

Hot parameters:These parameters will have an effect on the result. They

are located within the box on the right side of the menuEDIT WELD PROGRAMS and they are shown on both pagesof the menu.

Cold parameters:All parameters for electrodes, diagnostics etc.All process times are given in cycles. One cycle is 20mswith a supply frequency of 50Hz and about 16.7ms with asupply frequency of 60Hz.The abbreviation or the symbol of each parameter isshown in brackets.The list below gives the description of all of theparameters concerning the different welding modes.

4.4.7.1 Program number


Range: (01 255)

Description: Order number

In case the cursor is placed in some other field, nextprogram can be shown by pressing F3 PROG- or F4PROG+. All parameters of the new selected program aredisplayed.

4.4.7.2 Program name [ : ]

Parameter: a character value must be given

Limits: 8 characters, first must be a sign

Description: Name of the welding program, mnemonic only. Thisparameter is also shown in column C of table WELDPROGRAMS (see section 4).

4.4.7.3 Mode of welding [ : ]


Presettings: (Normal Monitor - Const.Cur Seam N. Seam M. Seam C.C. Cycle N. Cycle M.)

Description: See Section 4.4.1. This parameter is also shown in columnD of table WELD PROGRAMS (see section 4).

4.4.7.4 Enable program [ : ]


Presettings: (ON OFF)

Description: This function enables (ON)or disables (OFF)the weldingprogram. In case a disabled program will be selected,error message E091will be issued. This parameter is alsoshown in column E of table WELD PROGRAMS.(see section 4).

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GF WELDING4-12

4.4.7.5 Pulse type [ PLS: ]


Presettings: (N S) Normals and Specials

Description: One pulse means duration of current (welding time),where the current is not interrupted [Weld:].

A welding program may consist of several pulses, whichare separated by intervals [Cool time WAIT], where nocurrent is flowing

In case of a single pulse, there is no difference betweenpulse type normal and pulse type special. All pulses arethe same. The slope up time applies to the first pulse,the slope down time applies to the last pulse only.

Pulse type special: each pulse can be setup individually.

In the most simple welding program all welds [Weld] areunified within one single pulse.

For all three types of Seam welds the pulses are of specialtype.

REMARK: The dotted lines in following diagram show exactly one period ofnet frequency (this is 20ms in case of 50Hz).

Pulse type Normal

Following graph shows a welding program, which consists of 5 currentpulses type normal [PLS:N:05].

The current is identical for all pulses.

No slope-up or slope-down cycles are defined. Weld cycles per pulse = 4 cycles [Weld:04]

The cool time between each pulse takes 2 cycles [WAIT:02].

T [cycles)]

I

[KA]

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GF WELDING 4-13

Pulse type special

Following graph shows a welding program, which consists of 3 pulses typespecial [PLS:S:03].

The first pulse (warm-up pulse) takes 4 cycles [Weld:04] and the cooltime, which separates it from the succeeding pulse, takes 2 cycles[WAIT:02].

The second pulse (actual weld) takes 7 cycles [Weld:07] and the cooltime, which separates it from the succeeding pulse, takes 3 cycles[WAIT:03].

The third pulse (postwarming) takes 3 cycles [Weld:03] and the cooltime, which separates it from the succeeding pulse, takes 0 cycles[Wait:00].

The current is identical for all pulses.

No slope-up or slope-down cycles are programmed.

T [cycles)]

I

[KA]

4.4.7.6 Number of pulses [ : ]

Parameter: a numeric value must be specified

Range: (1 20) for pulse type normal(1 4) for pulse type special

Description: Number of pulses, which are effective during weldingoperation.

For pulse type special the number of pulses appears on theright of the upper window with the hot parameters (seesection 4.4.6).

4.4.7.7 Stepper/Electrode parameter [ Stp_: ]


Range: (0 16)Description: this parameter assigns one out of 16 stepper programs to

the welding program (see section 5). A number between 1and 16 can be entered. Normally all welding programs,which command the same gun, have to refer to the samestepper program.

To disable the stepper function, the parameter has to beset to 0.

This parameter is also shown in column F of table WELDPROGRAMS (see section 4).

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GF WELDING4-14

4.4.7.8 Presqueeze [ 1.Sqz: ]


Range: (0 99) (Unit = Periods)

Description: This is the time for closing the gun. In case operationmode RPT is active, the prolonged hold is valid for the firstspot weld only.

4.4.7.9 Squeeze [ 2.Sqz: ]


Range: (0 99) (Unit = periods)

Description: This is the time given for the gun, to build up the electrodeforce after the welding program has started. This timevalue must be found out by experience.

4.4.7.10 Hold time [ Hold: ]Parameter: a numeric value must be specified


Description: This is the time, where the electrode force remains afterwelding. The spot weld shall cool down and reforge underthe influence of the electrodes. This time value must befound out by experience.

4.4.7.11 Open [ Open: ]



Description: This is the time for the gun to open, move to the newposition and close again. It applies for serial welds only.This time value must be found out by experience.

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GF WELDING 4-15

Welding graph for single spot SS

Following graph shows the sequence for single spot:

See also operating diagram 1 of Appendix A page2

The welding program has following parameters:

1Sqz, time for welding guns to close is 3 cycles

2Sqz, time for welding gun to reach nominal squeeze is 2 cycles

one pulse takes 4 cycles and type is Normal [Weld:04]

Up-slope or down-slope cycles are not defined

Hold time is 4 cycles [Hold: 04]

Open time is 3 cycles [Open: 03]

The REPEAT option is not enabled (see section 3.1.1.11)

The input signal START remains until output signal FINESEQ (end of weldcycle) on

T [cycles

STATUS = 1

START

2SQZ

1SQZ

WELD

HOLD

OPEN

Solenoid valve

End of sequence

STATUS = 0

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GF WELDING4-16

Welding graph for repeated spot RPT

Following graph shows the sequence in repeat mode

The welding program has following parameters

1Sqz, time for closing welding guns is 3 cycles [1Sqz:03] 2Sqz, time for closed guns to reach nominal force is 2 cycles[2Sqz:2]

one pulse of welding type Normal takes 4 cycles [Weld:04]

No uplope or downslope cycles are defined

Hold time is 1 cycle [Hold: 01]

Open time is 3 cycles[Open: 03]

Operation mode RPT (see section 3.1.1.11)

The input signal START remains on till begin of second welding sequence

Output signal FINESEQ end of weld cycle will generated as longs as

specified in the menu SETUP- CONFIGURATION WELD334m (see section3.1.1.14)

T [cycles]

STATUS = 1

STARTSTART

2SQZ

1SQZ

WELD

HOLD

OPEN

Prortional valve

End of weldsequence

STATUS = 0

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GF WELDING 4-17

4.4.7.12 Equivalent energy value [ VEE_ ]:


Range: (0 10)

0= no spot counting10= each spot will be countedDescription: If one gun is driven by several welding programs, all

programs will have the same stepper parameters. Thehighest amount of electrode wear (electrode alarm)however is caused by the program, which commands thehighest amount of energy (current as a function of time).

Usually it will be the program, which is used for welding ofthe biggest sheet thickness combination. The equivalentenergy value parameter [VEE_:] makes it possible, toassign electrode wear (electrode lifetime, stepper alarm)due to energy for each welding program.

For the program with the highest amount of electric

energy consumption, means highest amount of electrodewear, VEE_: is set to 10.

After execution of each weld the internal spot counter isincreased by 1. For programs which apply less energy forwelding, where VEE_: has a smaller value, the counter willincrease in proportion to this.

For instance another program which uses half of theenergy, the value for [VEE_:] will be set to 5. In order toincrease the counter by one, 2 spots have to be welded bythis program.

Parameter 0 means, stepper is disabled for this program.Value 10 means, all spots will be counted 100%, 8 = 80%,

7 = 70% etc.

4.4.7.13 Squeeze variation cycles [ CPV_: ]


Range: (0 99) (Unit = cycles)

Description: The control manages 2 welding channels A and B. Onlyservo control valve of channel A will be analysed infollowing examples.

Force can be applied to the electrodes using three differentconfigurations of control valves:

A)Monostable solenoid valve for weld (EVSA) (valve foropening and closing the welding gun)

B)Monostable solenoid valve (EVSA) and a monostablepressure valve (EVPA). When EVPA together with EVSAis actived, a higher amount of force is achieved as withEVSA only.

C)Monostable solenoid valve (EVSA) and a proportionalsolenoid valve for pressure control.

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GF WELDING4-18

The proportional valve applies 3 different values to theelectrodes:

OFFSET (PRESET) OF ANALOG OUTPUT (see section

3.1.1.4)

ELEKTRODE FORCE 1 (see section 4.4.7.15)

ELEKTRODE FORCE 2 (see section 4.4.7.16)

Parameters [ CPV_: ] [ MPV_: ] [ P1: ] [ P2: ] must be set,when configurations type B) or C) are used.

The force control [CPV_:] is clocked by the ON-delay of the2.control valve or the ON-delay of the second setpoint ofthe proportional valve. In case a proportional valve is usedthe analog output PRESET in menu SETUP-CONFIGURATION WELD334m (see section 3.1.1.4) andMAX ELECTRODE FORCE in menu SETUP-GUNPARAMETERS (see section 3.2.1.1) must be set correctly.

4.4.7.14 Squeeze variation mode [ MPV_: ]

Parameter: a preset value must be specified

Presettings: (0 5)

Description: This selects the mode of electrode squeeze variationduring Squeeze-, Weld-and Hold time. The modes ofsqueeze variation depend on the configuration of thesolenoid valves: Type B or Type C (see section 4.4.7.13)can be selected.

For type B solenoid valve EVSA and EVPA can result in twodifferent force values, which are called EVSA and EVSA +EVPA.

Summary of squeeze variation modes with solenoid valve EVSA andpressure control valve EVPA.

MVP=0 No squeeze variation: squeeze remains at constant value EVSA

MVP=1 Squeeze, initially equal to EVSA + EVPA goes to level EVSA aftervariation cycles and returns to level EVSA + EVPA during hold time.

MVP=2 Squeeze, initially equal to EVSA + EVPA goes to level EVSA aftervariation cycles and remains during hold time.

MVP=3 Squeeze, initially equal to EVSA goes to level EVSA + EVPA aftervariation cycles and remains during hold time.

MVP=4 Squeeze, initially equal to EVSA goes to level EVSA + EVPA andafter variation of cycles and returns to level EVSA during hold time.

MVP=5 Squeeze remains at level EVSA throughout the sequence and goesto level EVSA + EVPA during hold time.

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GF WELDING 4-19

Electrode force - graph with 2 monostable solenoid valves.

Following graph shows the different modes of operation (0-5), how theelectrode force changes as a function of time for solenoid valve type 2 (see

section 4.4.7.13).

Force EVSA + EVPA is applied after activation of EVSA and EVPA

Force EVSA is applied after activation of EVSA

Force control [CVP_:] is clocked after squeeze time

OPEN

Mode 4

Mode 3

Mode 5

Mode 0

1SQZ 2SQZ HOLDWELD

EVSA

Mode 1EVSA

EVSA+EVPA

Mode 2

EVSA

EVSA

CPV

EVSA

EVSA

EVSA

EVSA+EVPA

EVSA+EVPA

EVSA+EVPA

EVSA+EVPA

EVSA+EVPA

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GF WELDING 4-21

Electrode force - graph with 1 monostable solenoid valve and 1proportional valve

Following graph shows the different operation modes (0-5), the change ofelectrode force as a function of time for valve configuration type C (seesection 4.4.7.13).

Force P1 is applied by activation of EVSA and the proportional valve withthe parameter P1 (in this example P1 is equal to a minor force)

Force P2 is applied by activation of EVSA and the proportional valve withthe parameter P2 (in this example P2 is equal to a high force)

P1 and P2 are the parameters as described in section 4.4.7.15 andsection 4.4.7.16.

The force control [CPV_:] is started after squeeze time.

Mode 0

1SQZ 2SQZ HOLDWELD OPEN

P1

Mode 1

P2

P1

Mode 2

P2

Mode 4

Documents

Weld334m 2,0系统编程手册