VEMA PCN110ZP User manual

Programmable welding controller PCN110ZP
Bulgaria, Pleven 5803, 16 Nikolay Haytov str.
tel.: [phone]
e-mail: [email protected] https://vema-bg.com
Industrial electronic systems
OPERATION MANUAL

2
Five independent timers in the are provided to parameters of the controller
facilitate the process of welding: pressing time (T), weld time (T), pause between
off on
multiple sparks (T), cooling time (T) and delay time between welds (T) for repetitive
p e d
welding only.
Parameters and work of the controller
Introduction
Multi-spark welding is implemented in order to achieve the best quality of
welding, especially for rounded items.
The controller can work in a direct mode of continuous welding.
The parameters of the controller are accessed via serial interface RS485 using
the Modbus RTU protocol. The welding sequence can be triggered by an external
PLC output, making it possible to integrate the welding controllers PCN110ZP in
automatic welding machines with several welding transformers and a complex
sequence of welding operations.
PCN110ZP power controller is used to regulate the phase angle of AC loads,
such as spot welding machines, both single or two-phase. When used with two-
phase loads ( ), a phase matching transformer 400/230V is needed, unless it is Fig.5
not provided in the controlled device. Without such a transformer as a power supply
to PCN110ZP, there will be a 30 degrees phase shift between controller and loads,
thus real control will not be possible.
The internal parameters of the controller are listed in the , along with their table
meaning and Modbus addresses. They can be accessed via Modbus functions 0x3,
0x4, 0x6 and 0x10 on RS485 (38400 bps, 8-N-1). Modbus ID can be selected bitwise
by the DIP-switch under the front panel of the controller.
The welding controller works in the standard sequence of processes: pressing,
welding current in sparks/impulses, cooling off. The digital input In triggers one such
cycle. At the beginning of welding, the output for pressing and the (OUT) LED will
switch ON, the (RUN) LED will flash during initial pressing time T and then remain
off
illuminated during the actual welding T. The flashing of (RUN) will occur also during
on
the pauses between impulses T and during the final cooling stage T. After welding is
p e
finished, the output and the two LEDs will switch OFF.
Powering up the controller with the digital input ON will invoke collision and the
input should be switched off before any further operation. Collision will occur also if
the input is re-enabled during the cooling phase of the previous welding.
he output power, regulated by the PCN110ZP, is divided to 100 units
(percentage of the full power). The value of 0 means that the power output of the
controller is off, whereas 100 means that it will transmit the full input power. The
parameters for output power for each impulse are SP, SP and SP .
2 3

3
bit15 - first spark of current weld finished (0- no, 1- yes)
bit06 - pressing is finished (1- yes, 0 - not yet)
bit03 - state of the digital output Out (0- OFF, 1- ON)
bit05 - established connection with Modbus master(1- ОК, 0 - problem)
bit14 - second spark of current weld finished (0- no, 1- yes)
bit07 - the delay T between two welds in repetitive welding at the moment
d
bit09 - N/A
bit10 - repetitive welding at the moment (0- no, 1- yes)
bit01 - internal EEPROM error (0-no, 1- yes)
bit08 - input collision (0- collision, 1- OK)
bit12 - a welding sequence is underway (0- no, 1- yes)
bit02 - state of the digital input In (0- OFF, 1- ON)
bit04 - status of the power supply net (1- ОК, 0 - problem)
bit11 - end of weld (0- from pressing to beginning of cooling, 1- afterwards)
bit13 - welding current present with time T (0- no, 1- yes)
on
* the unit for measuring time is 5/96 ms, i.e. @50 Hz the length of the semi-periods would be around 192, @60 Hz -
around 230
** Bitwise meaning of flags (bit00 LSB, bit15 MSB):
bit00 - N/A
Modbus
address
Name
Meaning
Format
/ Write
Read
0x1000
SP
Output power value for the first spark(impulse)
XXX %
RW
0x1001
SP2
Output power value for the second spark(impulse)
XXX %
RW
0x1002
SP3
Output power value for sparks 3-99
XXX %
RW
0x1003
Toff
Pressing time before actual welding
XX.X s.
RW
0x1004
Ton
Weld time for each spark
X.XX s.
RW
0x1005
Tp
Pause between sparks
X.XX s.
RW
0x1006
Ni
Number of sparks for multi-spark welding
0-99
RW
0x1007
Te
Cooling time after weld
XX.X s.
RW
0x1008
Td
Delay between two welds in repetitive welding
XX.X s.
RW
0x1009
Sb
Welding mode according to the digital input
0,1,2,3
RW
0x2002
PCN flags bitwise **
R
0x2003
ID
Modbus ID
0-15
R
0x2004
Amin
Minimal phase angle *
XXX
R
0x2005
A
Present phase angle *
XXX
R
0x2006
T
Remaining time (of T , T, T,T or T)
off on p e d
same as Tx
R
0x2007
N
Index of the present spark at the moment
0-Ni
R
0x2008
P+
Length of a positive semi-period of the power supply *
XXX
R
0x2009
P-
Length of a negative semi-period of the power supply *
XXX
R
0x200А
P
Length of a semi-period of the power supply *
XXX
R
Parameters of the welding controller

Welding control modes
The following four welding modes with respect to the digital input are available,
depending on the value of S parameter:
b
The option for multi-spark welding is available for all modes except for
continuous welding. It can be used by setting parameter N to a value, greater than
i
1, for the number of sparks(impulses) when welding non-flat items. In this case, the
user can set different values for the power of the second (SP ) and third (SP ) sparks.
2 3
0 - (Trigger on initial pressing) It is necessary to keep digital input ON for the
whole phase of pressing (T), after that the welding process will continue straight to
off
the final cooling phase regardless of the input state. A new welding will be triggered
only from ready state of the controller, i.e. previous welding finished and digital input
OFF:
1 - (Repetitive welding) It is necessary to keep digital input ON for the whole
process of welding. Releasing the input will stop the repetitions and bring the
controller to ready state. After one weld is completed, there will be a delay of T
d
seconds before the next one starts:
Fig.1 Timing diagram for welding trigger on initial pressing, N=4 and S =0
i b
* The second input triggering does not start real welding
SP
Toff Toff
TpTp TpTp TpTp
TeTe Ton Ton Ton Ton Ton Ton Ton Ton
input In
Toff
output
4
*
*
*
Fig.2 Timing diagram for repetitive welding mode, N=4 and S =1
i b
the digital input is released at the end of third spark of the second weld
delay
input In
output
SP3
SP2
Toff Toff
TpTp TpTp TpTe
Ton Ton Ton Ton Ton Ton Ton
SP
SP3
SP2
Td

2 - (2-step welding) It is necessary to keep digital input ON for the whole
process of welding. Releasing the input will stop the process and bring the controller
to ready state. A new welding will be triggered only from ready state of the
controller, i.e. previous welding finished and digital input OFF:
3 - (Continuous mode) In this mode the welding process continues without
sparks with output power of SP. Releasing the input will stop the weld and finish the
cooling phase of the process. A new welding will be triggered only from ready state
of the controller, i.e. previous welding finished and digital input OFF:
* When in continuous welding mode with the digital input ON, the value of the
output power SP can be changed directly via Modbus RTU command. This helps the
user find the suitable values in this welding mode, especially in the process of seam
sealing.
5
Fig.3 Timing diagram for 2-step welding mode, N =3 and S =2
i b
The second release of the digital input will stop welding at the third spark
input In
output
SP*
input In
Fig.4 Timing diagram for continuous welding mode, S =3
b
SP
output
*changing value of SP via Modbus
SP
Toff Toff
TpTp TpTp Te
Ton Ton Ton Ton Ton Ton
SP3
SP2
Toff TeToff Te

For the communication with a master device on RS485, the signals A and B
must be routed by a twisted-pair.
The following diagrams illustrate two-phase connections to a standard dual
thyristor module:
The connecting wires must be isolated and have minimal cross sectional area
of 0.35-0.75 mm² for G1;K1 and G2;K2 control circuits. The rule to remember for the
2
power wiring is 6А/mm .
The digital input In can be driven by PLC outputs, PNP or NPN logic. When
using PNP, the input In should be tied to 0V, and the +24V input must be connected
to the PNP output of the PLC. On the other hand, when NPN is used, the +24V input
should be tied to the external +24V, and the input In must be connected to the NPN
output of the PLC.
PCN110ZP is designed for DIN mounting in electrical cabinets. The connector
pinout of the controller is pictured on the front panel.
Mechanical installation and wiring
6
230 V
AC
10 11 12 13 14 15
K2 G2 K1 G1 +24V In
1 2 3 4 5 6 7 8 9
RS485
A B
ID
PCN110ZP
U 230 /50 Hz;P н=1,8 VA
2021 г.
IP 2 0 TC
04 П27 058 - 04
N
o
RUN
OUT
VEMA
400VAC
Fuse
~
-
+
Weld transformer
230VAC
to PLC output(NPN) or 0V(PNP)
to PLC output(PNP) or +24V(NPN)
Fig.5 Connections diagram for two-phase power supply
Make sure the thyristor module is well ventilated for power rates above 500W!!!