GF Welding Weld334m User manual

USER’S MANUAL
Weld334m
HC
HCM
HIC
HIM
Ed.5 – December 2004 Doc.39000326

Weld334m - User’s manual
II
GF WELDING S.p.A.
Strada del Portone, 18/24 – 10137 – TORINO (Italia)
Tel.:
Tel.:
Fax:
e-mail:
web:
011-3033.278 (Italy Sales dept.)
011-3033.270-279 (Foreign Sales dept.)
011-3033.277 (Italy After Sales)
011-3033.274 (Foreign After Sales)
011-3092046
[e-mail]
www.gf-welding.it
The information contained in this manual may be changed at any time without prior notice; in this
case, GF WELDING S.p.A. is relieved of any responsibility.
The information on the software and hardware tools contained herein are confidential and are
released in conformity with a licence contract.
It is absolutely prohibited to distribute or circulate the hardware and software documentation of
this product to third parties.
The purchaser is allowed to prepare the software safety backup copy in the quantity of one copy
only.
No part of this manual may be reproduced or distributed in any form or by any means or stored in
a database or retrieval system without the prior written permission of GF WELDING S.p.A.
All rights reserved to GF WELDING S.p.A.

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Table of contents
WHITE PAGE................................................................................................................................................. VI
1. SAFETY ..........................................................................................................................................................1
1.1 HAZARDS ASSOCIATED WITH THE USE OF RESISTANCE WELDING MACHINES ...............................................2
1.1.1 ! Prohibitions......................................................................................................................................2
1.1.2 ! Conditions to be respected to reduce the hazard .............................................................................2
1.1.3 ! Causes of hazard..............................................................................................................................2
1.2 OBSERVATIONS ON CONNECTIONS..............................................................................................................4
1.2.1 Earthing, insulation............................................................................................................................4
1.2.2 Safety criteria against short circuits ..................................................................................................4
1.2.3 Current sensor....................................................................................................................................5
1.2.4 Power supply ......................................................................................................................................6
1.2.5 Phase synchronising for welding........................................................................................................7
1.2.6 Programming unit ..............................................................................................................................7
1.2.7 Connecting the Weld334m with the WMS central network ................................................................7
2. CHARACTERISTICS AND GENERAL DESCRIPTION OF THE WELD334M ..................................9
2.1 GENERAL DESCRIPTION ..............................................................................................................................9
2.2 BLOCK DIAGRAM OF 334M.......................................................................................................................10
2.3 HARDWARE CONFIGURATION....................................................................................................................11
2.4 CHARACTERISTICS....................................................................................................................................12
2.4.1 Utilisation characteristics ................................................................................................................13
2.4.2 Dimensions, overall dimensions and fastening positions. ................................................................13
2.4.3 HHT4300 programming unit............................................................................................................14
2.4.4 Connection through Laptop .............................................................................................................14
3. POWER SUPPLY AND 24V FOR I/O .......................................................................................................15
3.1 CONTROL DEVICE POWER SUPPLY.............................................................................................................15
3.1.1 PS . Description of signals ...............................................................................................................15
3.1.2 Connections for main power supply. ................................................................................................16
3.1.3 Power consumption ..........................................................................................................................17
3.2 USE OF 24V - I/O .....................................................................................................................................17
3.2.1 Selecting 24V – internal or external.................................................................................................17
3.2.2 24V connections for discrete I/O......................................................................................................18
3.3 GENERAL PROTECTIVE DEVICES ON POWER SUPPLY..................................................................................20
3.4 SETTING THE EXTERNAL SYNCHRONISM ...................................................................................................21
4. F351-BUS INTERCONNECTION CARD ................................................................................................23
5. F384-CPU MICROPROCESSOR CARD ..................................................................................................25
6. F353-ADC ANALOGUE CARD .................................................................................................................27
6.1 P3 E P4 . DESCRIPTION OF THE ANALOGUE INPUTS...................................................................................27
6.2 P2 . DESCRIPTION OF THE SIGNALS FOR THE SOLENOID VALVE AND THE TFE ..........................................28
7. F364-SEV AND F385-SEV: PROPORTIONAL SERVOVALVE MODULES ......................................31
7.1 SERVOVALVE ADJUST: .............................................................................................................................31
7.1.1 Voltage outlet characteristics...........................................................................................................32
7.1.2 Current outlet characteristics...........................................................................................................32
7.2 CONNECTION OF THE F364 / F385-SEV MODULE ON THE F353-ADC CARD............................................32
7.2.1 Jumper function on connector J4 .....................................................................................................33
7.2.2 Jumper function on connector J5 .....................................................................................................33
8. F359-MCP MEMORY CARD AND PRINTER ........................................................................................35

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9. F360-IOB CARD – BASE I/O..................................................................................................................... 37
9.1 DESCRIPTION OF FUNCTIONS.................................................................................................................... 37
9.2 P20 24VDC - I/O .................................................................................................................................... 37
9.3 P22 - HSA – CIRCUIT BREAKER TRIP....................................................................................................... 37
9.4 P21 . DESCRIPTION OF SIGNALS ............................................................................................................... 38
10. F356-IOE I/O EXPANSION CARD ....................................................................................................... 41
10.1 P23 . DESCRIPTION OF OUTPUT SIGNALS .............................................................................................. 41
10.2 P24 . DESCRIPTION OF INPUT SIGNALS.................................................................................................. 44
10.2.1 List of program selection codes ................................................................................................... 47
11. F376-OPC FIELD-BUS INTERBUS-S CARD (PROFILE F-IBS/03)................................................. 49
11.1 CHARACTERISTICS ............................................................................................................................... 49
11.2 OPTICAL CONNECTORS INTERBUS-S .................................................................................................... 49
11.3 INTERBUS-S INTERFACE POWER SUPPLY .............................................................................................. 50
11.4 DESCRIPTION OF STATUS LEDS............................................................................................................ 50
IDENTIFICATION CODE (ID CODE) ...................................................................................................................... 51
11.5 ERROR CONDITIONS WITH THE CONTROL DEVICE SHUT DOWN.............................................................. 51
11.6 OPTICAL POWER REGULATION .............................................................................................................. 51
12. F386 ETHERNET 100BASE-T AND CANBUS COMMUNICATION MODULE............................ 53
12.1 TECHNICAL FEATURES ......................................................................................................................... 53
12.1.1 Ethernet section ........................................................................................................................... 53
12.1.2 CANbus section............................................................................................................................ 53
12.2 FRONT PANEL....................................................................................................................................... 53
12.2.1 P28 – CANbus connector............................................................................................................. 53
12.2.2 CANbus status LED’s................................................................................................................... 53
12.2.3 P10 Ethernet 100Base-T connector ............................................................................................. 54
12.2.4 Ethernet status LED’s .................................................................................................................. 54
12.3 ETHERNET CONNECTION CABLE ........................................................................................................... 54
12.3.1 Features ....................................................................................................................................... 54
12.3.2 Connection type ........................................................................................................................... 54
13. F383-COM RS422 SERIAL COMMUNICATION CARD .................................................................. 57
13.1 P15 – CONNECTION PORT .................................................................................................................... 57
14. INTERBUS-S PROFIL F-IBS/03............................................................................................................ 59
14.1 GENERAL DESCRIPTION ........................................................................................................................ 59
14.1.1 Control Words.............................................................................................................................. 59
14.1.2 Status Words ................................................................................................................................ 63
14.2 ROBOT DIRECTIVES UPDATE ................................................................................................................. 66
APPENDIX.......................................................................................................................................................... 67
APPENDIX A - MAINTENANCE ........................................................................................................................ 69
Maintenance operations ................................................................................................................................ 69
Replacing the modular cards.........................................................................................................................................69
Replacing the CPU card................................................................................................................................................70
Replacing the power feeder...........................................................................................................................................70
Replacing the welding control device ...........................................................................................................................71
Modifying a welding program:......................................................................................................................................71
Replacing the battery ....................................................................................................................................................72
APPENDIX B – DIAGRAMS AND NETWORK CONFIGURATIONS.......................................................................... 73
Operating diagrams....................................................................................................................................... 73
1 – START recognition with use in automated environment ........................................................................................73
2 – START recognition with use in manual environment.............................................................................................74
3 – EMERGENCY STOP condition : general diagram ................................................................................................75
4 – EMERGENCY STOP condition during or outside the welding pulse....................................................................76
5 – EMERGENCY STOP excluded with START still active .......................................................................................77
6 – START disabled condition during the welding pulse .............................................................................................77
7 – Proportional Servovalve operating diagram............................................................................................................78
8 – ENABLE function (Interbus-s)...............................................................................................................................79

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9 – Diagram of diagnostic pressure control .................................................................................................................. 80
Interbus-S –general architecture of I/O communications. .............................................................................81
Ethernet Tcp/Ip – Example of network architecture ..................................................................................................... 82
InterBus-S- Example of network architecture............................................................................................................... 83
WHITE PAGE.................................................................................................................................................84
APPENDIX C - WELD334M APPLICATION DIAGRAM .......................................................................................85

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WHITE PAGE

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1. Safety
To insure correct installation and operation of the WELD334m welding control device, it is
necessary to carefully read this chapter. Each operation on the machine is to be carried out
only by qualified personnel with good understanding of the information contained in this
manual; should the documentation not be perfectly legible and/or incomplete of any further
information required, please consult GF WELDING S.p.A. before undertaking any work on
the machine.
Inside the welding control, signals are generated which set parts of the machine in motion;
therefore, it is prohibited to open and tamper with the control and safety circuits. Live
metal parts, such as screws or similar parts, penetrating into the electric circuit may cause
malfunctioning as well as the generation of incorrect and hazardous conditions and events.
It should be remembered that any changes and/or modifications not expressly authorised
by the manufacturer or performed by unauthorised personnel or non-GF WELDING
personnel which modifies the machine operation makes the warranty void.
Check all cables and the relevant connections before using the welding control device in
order to see if there is any mechanical damage or failing insulation. Whenever a problem
arises such as to compromise the safety conditions, switch off the unit and cut out power.
Report the problem to GF WELDING After Sales Personnel.
To ensure the optimal performance of the device, the user must make sure that all
requirements for safety on the work site are strictly adhere to.

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1.1 Hazards associated with the use of resistance welding machines
Because of the presence of electric current and live parts in the machine, mounting,
maintenance work and replacement of genuine parts is only to be entrusted to Qualified
Personnel (electricians or authorised personnel). All work undertaken is to be done in safety
conditions. The non-observance of these requirements can cause death, injury to persons
or damage to machine and property.
1.1.1 ! Prohibitions
•It is prohibited to work on the live installation.
•It is prohibited to remove by-pass and modify the safety devices as this could cause
serious risks to personnel and equipment and could lead to death.
1.1.2 ! Conditions to be respected to reduce the hazard
•Always insure that the electric switchboard main switch is OFF.
•Work on the machine, equipment and the welding transformer only after breaking
the connection from the mains. This to be sure that no undesired switching of
electrical current occurs.
•Work on the spotgun and welding cable connections only after breaking the
connection from the mains power.
1.1.3 ! Causes of hazard
•The programming of the welding control is entrusted only to qualified personnel.
Incorrect parameter settings may cause damage or injury because of undesired
molten material splashes during welding.
•It is compulsory to wear protective goggles, non-flammable clothes and protective
shoes.
•Dangerous conditions may arise when, for example, electrodes are changed or
dressed and no current re-adaptation/re-setting takes place, especially when using
the stepper function (stepper reset).
•If 24V power supply is external to the machine or the control device, power may be
applied to the equipment even if the main switch connection is broken.
•During mounting, setting of work, maintenance and/or repair operations, hazards
may occur because of the exchange of leads, air/water pipes, etc…
•Unqualified personnel may be unaware of the risk that such changes/modifications
entail, therefore, all changes/modifications are only to be entrusted to and/or
performed by qualified personnel.
•Hazardous situations may arise because of mains voltage drops, or in case of tripping
of the machine emergency stop device, which causes the return to rest position of
the pneumatic valves in use during the operation (this situation affects the whole
plant).
•If during the welding process the cooling water flow is low or non-existent, it is
prohibited to bypass or inhibit the tripping of thermostats or the water flow control
device (if installed).

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•High magnetic fields, generating very close to the welding gun and the secondary
cable, represent a serious hazard to people and property (e.g.: watches, cables for
electric data transmission, magnetic devices, medical equipment and pace-makers).
•Welding is obtained through the periodical repetition of high single-phase, short-time
and low cosphi current pulses. These conditions of use may cause disturbances to the
power lines of the production plant and may be hazardous for other types of
operating machines or machine tools.
•Outputs of the welding control device solenoid valves are all protected by a series-
connected contact of the cycle start relay. This to prevent any faults or disturbances
of the electronic outputs from causing undesired controls. (The Start cycle function is
equipped with a time-dependant consent control at the plants and countries
demanding for it).
•In cases where local safety regulations require or prescribe such as for machine start
– for instance: two-hand cycle start controls with check of simultaneous operation –
these devices shall have to be implemented when installing the system.
•Outputs for the pre-stroke solenoid valves controlling the additional gun opening,
feature direct control as well as the output for the proportional solenoid valve.
•These two outputs do not cause any movement nor do they operate the gun to close
fully.

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1.2 Observations on connections
1.2.1 Earthing, insulation
This paragraph deals with the earthing of the equipment, please ensure that all earthing is
correctly carried out.
•The correct earthing of each part of the electric system is a compulsory precaution,
in order to ensure the plant workers/operators safety.
•Furthermore, earthing is of paramount importance to avoid damage to the
installation itself. Periodically check the status of earth connection of all cables and
terminal cards.
•Special care is to be paid to connections with moving and metal parts, making sure
there is no oxidation of connection and that the electrical connections are made
against painted areas.
•To have correct earthing, it is fundamental to avoid series connecting the whole earth
installation or part of it with only one cable. It is also important to check that, for
each machine, the earth is star connected at the fixing point of the earth cable.
•Some types of welding machines need for the earth connection of the transformer
secondary to be made outside of the machine.
•The Weld334m is a sophisticated, microprocessor controlled equipment which can
also be used in environments showing «electromagnetic field pollution». In the
design phase, systems have been adopted which respect the EMC requirements with
the surrounding ambient. It is recommended to scrupulously observe the conditions
of use (meaning by this that the Weld334m cabinet is to be closed and all its earth
leads must be connected).
•In compliance with the accident prevention Standards, the welding control does not
act directly on the SCR block; the SCR switching is operated through a special
external firing circuit which is isolated from high voltage present on the power circuit.
1.2.2 Safety criteria against short circuits
On a welding machine, the short circuit is likely to occur on the transformer primary side.
This may entail very serious consequences such as, for example:
•On a Robot or an automatic installation, the destruction of parts onto which the short
circuit current is discharged.
•On a manual station, the electrical shock of the operator and damage to the
equipment.
The short circuit may occur between the primary and ground or between the primary and
the secondary.
380/500V
TRS
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