CHOWEL PATC--150A-EU User manual

OM-PATC150A-EU_061205E
INSTRUCTION MANUAL
FOR
RESISTANCE WELDING CONTROLLER
& TRANSFORMER
( MODEL : PATC  150A-EU )
CHOWEL CORPORATION

English Versi n
D c N : OM-PATC150A-EU_061205E
INSTRUCTION MANUAL
FOR
RESISTANCE WELDING CONTROLLER
& TRANSFORMER
Important Safeguards
Read and understand the entire c ntents f this manual, with special
emphasis n the safety material thr ugh ut the manual, bef re installing,
perating, r maintaining this equipment. This equipment and this manual
are f r use nly by pers ns trained and experienced in the safe
perati n f welding equipment. D n t all w untrained pers ns t install,
perate r maintain this equipment. C ntact y ur distribut r if y u d n t
fully understand this manual.
WARNING
T guard against injury, the f ll wing basic safety precauti ns sh uld be
bserved in the instructi n manual f the arc welding equipment

CHOWELCORPORATION M del : PATC  150A-EU
598, SUNGGOK-DONG, ANSAN-CITY, DANWON-GU, Serial Number :
KYUNGGI-DO, REPUBLIC OF KOREA
C pyright CHOWEL c rp rati n ⓒ 2000
First Printing, Oct ber 2006 Printed in K rea
CHOWEL has devel ped this d cument f r its licensees and cust mers. The inf rmati n
c ntained herein is the pr perty f CHOWEL and may n t be c pied, used, r discl sed t
thers with ut pri r written appr val fr m CHOWEL and may n t be c pied, used, r
discl sed t thers with ut pri r written appr val fr m CHOWEL. Users are cauti ned that
the material c ntained herein is subject t change by CHOWEL at any time and with ut
pri r n tice.
The inf rmati n c ntained herein is the pr perty f CHOWEL and shall n t be repr duced
in wh le f in part with ut pri r written appr val f CHOWEL. The inf rmati n c ntained
herein is subject t change with ut n tice and sh uld n t be c nstructed as a c mmitment
by CHOWEL.
CHOWEL assumes n resp nsibility f r any err rs r missi ns in this d cument.

Warranty
═══════
This resistance welding c ntr ller & transf rmer with ur f rmal inspecti n sheets attached
shall be guaranteed against faults due t the negligence f CHOWEL f r either earlier
peri d f 1 year fr m the day f installati n
This warranty shall be applicable t the parts replacement and/ r lab r f r repair in ur
fact ry and transp rtati n c st shall n t be applied.
We will charge the repair f faults caused by the f ll wing reas ns:
◉ Wr ng usage which are pr hibited in the manual
◉ After the expirati n f guarantee peri d
◉ Earthquake, fire, ri t, vi lence, war and any ther natural disaster.
◉ M dificati n, repair r adjustment is perf rmed by unauth rized pers n.
☞ C ntact y ur sales agent f r individual warranty c verage.
WHO DO I CONTACT ？
CHOWEL CORPORATION
598, SUNGGOK-DONG, DANWON-GU, ANSAN-CITY, KYUNGGI-DO, KOREA
ZIP CODE : 425-110
TEL : [phone]
FAX : [phone]
SHENYANG CHOWEL WELDING EQUIPMENT CO., LTD.
NO. 309-4 NORTHEAST AVENUE, DADONG DISTRICT, SHENYANG, CHINA 110044
TEL : [phone] / 0718 / 0720
FAX : [phone]
CHOWEL INDIA BRANCH
PLOT NO. 2112, 13TH MAIN ROAD SHANTHI COLONY, ANNA-NAGAR, CHENNAI
ZIP CODE : 600 040
TEL : [phone]
FAX : [phone]

CHOWEL POLAND SP. ZO. O
UL OKRJET 18, 03-710 WARSZAWA, POLAND
TEL : [phone]
FAX : [phone]
This resistance welding c ntr ller & transf rmer c mplies with the appr priate basic safety
and health requirements f the EC Directives based n its design and type, as br ught
int circulati n by us. The f ll wings are the requirements applied ;
C mply with the f ll wing pr visi ns applying t it
L w V ltage Directive 73/23/ EEC
EMC Directive 89/336/EEC
Applied nati nal technical standards and specificati ns in particular
EN Standards : EN60204-1 / 10.92, EN55011 / 1991 Gr up1 Class A
EN50082 - 2 (EN61000 -4 -2, -4, -5, -11 )
ENV50140, ENV50141, EN50063/ 02.89

READ FIRST
To use this welding controller in safety, the operator should follow
industry standards and safety senses whenever working on, or near
the weld machine.
In some case, failure to follow the warning instruction can lead to
control or machine damage. In other cases failure to follow these
instruction can lead to injury, or death of personnel.
Some example of safe practices are listed below. These examples
are not to be considered a comprehensive listing of safety practices.
Always use safety senses when working with any type of machinery.
 DANGER
During electrical power is ON, this welding controller is charged with
high voltage electricity. Turn electrical power OFF before open the
door.
In the case the door is opened as it is not turn OFF can lead to
injury by an electric shock, or death of personnel.
 WARNING
In some case failure to follow these instructions as follows can lead
to control damage or injury of personnel.
1. Ensure that control / machine is connected to the correct voltage
before turning electrical power ON.
2. Whenever power is ON, stand clear of moving parts. This practice
should be used even if the machine is not actually in use.
3. Before turning electrical power OFF, ensure that personnel are
standing clear of moving parts that are pneumatic or hydraulic
powered.
4. Whenever electrical power is turned OFF, install a "lock-out" device
at the main disconnect to prevent power from being accidentally
turned ON.

 CAUTION
1. Turn electrical power OFF before changing the tap switch at the
weld transformer.
In the case failure to follow the instruction like a welding at
changing the tap switch can lead to injury to personnel.
2. Turn stop cock OFF before some piping work.
In the case failure to follow the instruction like the electrical
circuit is splashed with cooling water can lead to control damage.
 CAUTION
Magnetic fields
It should be borne in mind that welding machine generate intense
magnetic fields. Consequently, "Do not approach the secondary circuit"
of the machine carrying on your person any article that are likely to
suffer damage.
These include the following:
- Any kind of magnetic card or badge, for example credit card, bank
card, magnetic strip telephone card, personal recognition cards,
magnetic clocking-on cards, company permits, passes, etc.
- Any kind of magnetic tape or media, for example cassette, video
cassette, floppy disk, etc.
- Any kind of delicate mechanism, for example electronic calculators,
cameras, motion picture cameras, television cameras, watches
(especially mechanically driven ones).

CONTENTS
1. Introduction
1-1 Outline of PATC-150A-EU ··················································· 1
1-2 Summary of Features ··························································· 2
1-3 About this manual ································································· 2
2. Safety Informations
2-1 When Installing ····································································· 4
2-2 When Programming ····························································· 4
2-3 In Use ····················································································· 5
3. Functions and Specifications
3-1 Transformer Function ·························································· 6
3-2 T/C Function ········································································· 6
3-3 Transformer Specification ··················································· 7
3-4 T/C Specification ·································································· 9
4. Commissioning
4-1 Initialize the program sheet ·············································· 14
4-2 Setting the turns ratio ·························································· 15
4-3 Test welds in TEST mode ················································ 15
5. Installation
5-1 Caution on installing ····························································· 16
5-2 Mechanical install ··································································· 16
5-3 Electrical power connection ················································ 17
5-4 Control Signals ······································································· 18
5-5 Check point prior to use ······················································· 20
5-6 Caution on Operation ··························································· 20
6. Description
6-1 General description ····························································· 21
6-2 Mechanical description ······················································· 21
6-3 Welding control description ················································· 21
6-4 Function description ······························································ 22

6-5 Controller configuration ························································· 22
6-6 Programming ··········································································· 25
6-7 Indicators and Monitor data ················································ 30
6-8 Fault detection ········································································ 32
6-9 Special function and usage ················································ 36
6-10 Other Function ······································································· 39
6-11 Current control method ························································ 40
6-10 Operation sequence ···························································· 42
7. Troubleshooting
7-1 External I/O checking ··························································· 50
7-2 Program checking ·································································· 51
7-3 Other troubleshooting ···························································· 52
8. Regular inspection & Maintenance
8-1 Daily ·························································································· 53
8-2 Weekly ······················································································ 53
8-3 Monthly ····················································································· 53
8-4 Quarterly ··················································································· 54
8-5 annually ···················································································· 54
APPENDIX
1. Weld program sheet ············································································ 55
2. Electrical connection diagram for PATC-150A-EU ······················ 56
3. I/O connector diagram ········································································ 57
4. RC-05 wiring diagram ········································································· 58
5. Outside view of PATC-150A-EU ······················································ 59
6. Outside view of TB-30 ········································································· 60
7. Outside view of RB-10 ········································································· 61
8. Electrical connection for step down T/R and SCR ······················ 62
9. Connection diagram for Timer Box connector ······························· 63
10. Connection diagram for SCR Box connector ······························· 63

CHOWEL / PATC-150A-EU
  
1. Introduction
1-1 Outline of PATC-150A-EU
The PATC-150A-EU is an equipment which is used to spot-weld by moving
gun, with the fixed base material to jig:
* Adequate for large type parts, structural object and spot welding
accompanied by the other jig work of which is difficult with general
stationary air spot welding machine.
* Excellent in immediate response to mobility of welding, changing model for
items.
* Widely used in the field of automobile car body, boiler making.
* Having manufactured with an effective cooling water circulation durable air
pressure material matching with any type of gun, kickless cable according
to user's convenience that enables higher quality and reliable welding.
Thyristor are fitted which capacity 900A, 1200V at continuous load in primary
circuit of welding transformer.
Using 8bit high performance micro processor, PATC-150A-EU is a high specification
system that is easy to maintain and use. Extensive software features give the
PATC-150A-EU a high degree of programming flexibility.
Programming is performed in two stage as "Common program" and "Schedule
program"
Common program and schedule program may be accomplished using a TB-30
(Teaching Box-30). This may be connected when required. The display delivers
status and fault message, if happen, by LCD.
And RB-10 (Reset Box-10) can monitor various kind of weld data and it may be
installed permanently by RC-05 (Reset Cable - 05). These including RS485 multi
drop port for central communication.

CHOWEL / PATC-150A-EU
  
1-2 Summary of Features
- Operation in Constant current control mode or Voltage compensation mode
- Teach facility for setting the welding current
- Heat programmable as amps of welding current or from 20 to 130% of maximum
of heat
- Closed loop primary feedback by C.T in Constant current mode
- Open loop supply voltage compensation
- Automatic sensing of supply frequency 50 / 60Hz
- 15 welding programs
- Single / dual gun operation
- Programmable weld pulsations (Max. 10 pulse)
- Programmable up slope
- Automatic reweld in the event of weld failure
- Fault output
- 2 schedule counter (Each valve output)
- Programmable 2 schedule for heat step up
- Remote programming
- Built in diagnostic routines
- Extensive monitoring
- Maintenance free photo mos contact output
1-3 About this manual
The propose of this manual is to show you how to install, configure, program and
commission the PATC-150A-EU (Chapter 4, 5 and 6). You can find that Chapter 4
and 6 are closely linked to each other. This is because in order to complete the
programming, some of the commissioning will need to be fulfilled.
Conversely, to commissioning is completed, programs may be created and altered at
will.

CHOWEL / PATC-150A-EU
  
The PATC-150A-EU has an extensive range of features so it is important to follow
the configuration and programming instructions in Chapter 6 rather then risk
confusion by trying to work them out as you go alone. To help avoid difficulties, in
appendix is a set of tables. When you are ready to enter the settings into the
PATC-150A-EU, you need simply refer to your entries in the tables.
The tables may also be used as a permanent record of the settings.
On reading Chapter 6, Description, the manual will also help you understand what
the PATC-150A-EU consists of and how it works. In chapter 2, Functions and
Specification is a list of specifications for quick reference. Chapter 2, Safety
information, should be read and understood before any work is done on the
PATC-150A-EU.

CHOWEL / PATC-150A-EU
  
2. Safety Information
Warning
The PATC-150A-EU operates at high voltages which could be dangerous if it is
not correctly installed and used. Competent personnel only should install,
commission, program, maintenance and use the PATC-150A-EU. Read and make
sure you understand the following information.
Caution
Beware of the welding machine. You may inadvertently cause it to weld.
2-1 When Installing...
. Make sure the isolator in the main supply is switched OFF and the fuse is
removed before making electrical connections to the PATC-150A-EU.
Take necessary safety precautions to ensure no-one else can switch on the
supply during installation.
. Make earth connections in accordance with EN regulations Wiring Regulations or
to the standard that applies in your country.
. Clear plastic panel cover the components operating at high voltage. This panel
are removed for installation. Removal instructions are given in Chapter 5,
installation. The panel must be re-fitted before the mains supply isolator is
switched on. The PATC-150A-EU should never be operated by unauthorised
personnel with the panel removed.
. Do not position the PATC-150A-EU where it is possible for water to be sprayed
over it.
2-2 When Programming...
. If you remove the cover of the SCR box when the mains supply is connected, do
not attempt to push any article or a finger around the edges of the clear panel.
. There are no components that remained charged at high voltages after the supply
has been removed.

CHOWEL / PATC-150A-EU
  
2-3 In Use...
. Do not leave the SCR box cover remove unnecessarily. This may allow dirt and
moisture to enter the unit. Make sure the door is fully closed and the fastener is
tightened.
. Do not pour or spray water over the case.
. Observe health and safety regulations.


CHOWEL / PATC-150A-EU
  
3. Function and Specification
3-1. Transformer Function
3-1-1 Class F insulation
3-1-2 C cores and windings epoxy resin full moulded.
3-1-3 Secondary coil water cooling system
3-1-4 Dual gun secondary lugs
3-1-5 Thermostat are fitted to the secondary lug to protect against overload or
reduced water flow.
3-1-6 High conductivity copper is used for both primary and secondary castings.
On installation it is essential that safety wire linking the runway trolley
the transformer are fitted.
3-2 T/C Function
3-2-1 Welding Condition and Current Control
. Weld Schedule : 15 (Binary 4 bit)
. Gun Valve Select : 2
. Current Control : Voltage compensation mode
or Constant current mode through feedback
control primary current.
. Weld operation : Up slope, #1,#2 weld
. Stepper : 2 Stepper schedule.
3-2-2 Inputs and Outputs
. Gun valve : DC 24V
. In/Outputs circuit : Solid State.
3-2-3 Counter
. counter schedule : 2 ( 0 - 99,999,999 ) Each valve output count
3-2-4 Fault Detection
. Function
: Timer has ability to record weld schedule number and fault code
. Weld current fault detection level
: Programmable high and low limits.

CHOWEL / PATC-150A-EU
  
3-2-5 Alarm and Measurement function
. Monitors
: Welding current, Line voltage, T/R margin... various monitor items.
. Open of welding cable
: Notice by analysis measure of testing weld current.
3-2-6 Communication System
. Communication is available to monitor weld condition and results without
affecting machine operation.
3-2-7 Memory and Data
. Maintenance
: 5 years and more by Lithium battery.
3-3. TRANSFORMER Specifications
3-3-1. General Specification
Model
PATC-150A-EU
Rated Capacity(at the 50% D.C.)(KVA)
150
Rated input voltage(V)
380
Phase(Ø)
Single
Rated frequency( ㎐ )
50 / 60
Max. input capacity(KVA)
380
Max. short circuit current((KA)
16
Max. secondary output voltage(V)
23.75
Duty cycle(%)
7.8
Cooling water consumption( ℓ /min)
6 (quantity for only TR.)
Connection
hose size (inch×mm)
Air inlet
1/2" × Ø13
Water inlet
1/2" × Ø13
Water outlet
3/4" × Ø19
Output terminal distance for
kickless cable(mm)
27
Solenoid valve
4sets. DC 24V (2 Retract valve include)
Insulation classification
F

CHOWEL / PATC-150A-EU
  
3-3-2. Air supply and Cooling water Requirements
Air supply source Max. supply pressure : 6.5 ㎏ f/ ㎠ ( ≒ 6.37 bar)
Min. supply pressure : 3.0 ㎏ f/ ㎠ ( ≒ 2.94 bar)
Cooling water source Max. supply pressure : 3.0 ㎏ f/ ㎠ ( ≒ 2.94 bar)
Min. supply pressure : 1.0 ㎏ f/ ㎠ ( ≒ 0.98 bar)
Cooling water temperature : lower than 30 ℃ (80 ℉ )
( at the water inlet )
Cooling water quantity : 6 ℓ /min (for only TR.)
Electric resistivity : More than 5000 Ω cm
3-3-3 ． Air supply circuit diagram
※ Function of each part
① Ball Valve( Check valve) : main air line ON/OFF (1/2")
② Air Filter : Filtering particle and moisture from the air
③ Lubricator : Lubrication of air supply circuit.
④ Regulator : Regulate air pressure out of main air.
⑤ Silencer : Reduces noise of air exhaust
⑥ Solenoid V/V : Controls air supply direction
⑦ Space Regulator : Regulate air pressure out of B port

CHOWEL / PATC-150A-EU
  
3-3-4 ． Water cooling circuit diagram
※ Function of each part
① Ball V/V (Check V/V : 1/2") : Main cooling water line ON/OFF (inlet stop valve)
② Pressure gauge : Cooling water shall have a sign indicating the
prohibition of the use of cooling water
③ Water strainer : A device with fixed dimensional openings through
which cooling water is passed to partially remove
foreign matter held in suspension.
④ Water manifold : Cooling water device which provides multiple
connection ports.
⑤ Water flow indicator : See cooling water flowing at a controlled rate.
⑥ Ball V/V (Check V/V : 3/4") : Main cooling water line ON/OFF (outlet stop valve)
3-4 T/C Specification
3-4-1 Voltage and Frequency
. Welding power supply : Single phase, AC 440V ±25% / AC 220V ±25%
/ AC 380V ±25%
50 / 60Hz Automatic selection
. Control power supply : Unnecessary due to be fed from a voltage
dropped welding power supply.
. Power consumption : 50VA (Idling condition)

CHOWEL / PATC-150A-EU
  
3-4-2 Environment
. Temperature : -5 ℃ + 50 ℃ ( 23 ℉ 122 ℉ )
. Humidity : 90% or less without dewing
3-4-3 Cooling Condition
. Controller : Natural air cooling
. Thyristor : Water cooling
Temperature at water inlet : Less than 30 ℃
(Less than 86 ℉ )
Quantity of water : Thyristor - More then 4 ℓ /min
(More then 1.05gal/min)
Cooling water pressure : Max. 3Kgf/
Resistivity : More then 5000 Ω㎝
(More then 1969 Ω inch)
3-4-5 Control Element : Thyristor size D
(750A 100% duty cycle)
3-4-6 Current Control System : Synchronous phase control by Thyristor.
3-4-7 Weld current control method
. Constant current control : Loop control by means of primary current
feedback
. Voltage compensation control : Open-loop control by means of measuring
line voltage.
3-4-8 Control Range
. Firing angle control range : 20 - 135 degrees
. 1st current control range : 50 - 1500amps (It's subject to limitation by
Thyristor and duty factor)
. 2nd current control range : 2.0 KA - 25.5 KA
. Turn ration of transformer : 1.0 - 199.9
. Time range Initial squeeze time / 0 - 99 CYC
Squeeze time / 1 - 99 CYC
Up-slope time / 0 - 30 CYC
#1 weld time / 0 - 99 CYC
Cooling time / 0 - 99 CYC
#2 weld time / 0 - 99 CYC
Hold time / 1 - 99 CYC
Off time / 1 - 99 CYC

CHOWEL / PATC-150A-EU
  
Pulsation / 1 - 9 times