Académique Documents
Professionnel Documents
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Programming Manual
Release 2.0
Code 39000425
Programming Manual
GF WELDING S.p.A.
Strada del Portone, 18/24 10137 TORINO (Italia)
Tel.:
Tel.:
Fax:
e-mail:
web:
II
011-3092046
mail@gf-welding.it
www.gf-welding.it
GF WELDING
Programming Manual
Warranty
All conditions of warranty as described in this section are general and
complete the specific purchasing conditions. In any case they refer to the
local 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 agreed
in the purchasing contract differently.
Furthermore Company GF WELDING S.p.A. guarantees the Weld 334m to
be free of any defects caused by manufacturing. In case an error should
occur during warranty period, which is caused by manufacturing, the maker
will carry out all necessary repairs or exchange defect parts. The maker
insists on the right to decide, whether to exchange or repair the defect
parts. The user has to pay for shipment costs.
Company GF WELDING S.p.A. will not take any responsibility for damages
or 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 or
hardware of the welding control to be free of errors or to be competitive
with each standard or in particular to comply with the special
manufacturing demands of the user.
In particular Company GF WELDING S.p.A. does not take responsibility for
the correctness of the weld- and current-increment programs, which were
created 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 by
electrostatic discharge, which occurs during connection or disconnection of
energized devices, tampering and/or executed reparations from staff nonauthorised from GF WELDING.
Keyboards, cables, trackballs, connectors or other consumable parts are not
covered by this warranty.
GF WELDING
III
Programming Manual
WHITE PAGE
IV
GF WELDING
Programming Manual
INDEX
1
1.1
1.2
Programming................................................................................... 1-1
Manual Keyboard HCM 4300 HHT..................................................... 1-1
1.2.1
1.2.2
1.3
2.1
2.1.1
2.1.1.1
2.1.1.2
2.1.1.3
2.1.1.4
2.1.2
2.1.2.1
2.1.2.2
2.1.2.3
3.1
3.1.1
Parameter of SETUP - WELD334M CONFIGURATION............................... 3-2
3.1.1.1
WMS-NET network address: ............................................................ 3-2
3.1.1.2
Device name:................................................................................ 3-2
3.1.1.3
Working mode:.............................................................................. 3-2
3.1.1.4
Preset Analog output:..................................................................... 3-2
3.1.1.5
Weld alarm threshold A: ................................................................. 3-3
3.1.1.6
Weld alarm threshold B: ................................................................. 3-3
3.1.1.7
Current transducer: ....................................................................... 3-3
3.1.1.8
N. current transducers: .................................................................. 3-3
3.1.1.9
Start code parity............................................................................ 3-4
3.1.1.10
Module address parity: .................................................................. 3-4
3.1.1.11
Execution in repeat: ...................................................................... 3-4
3.1.1.12
Execution with current:.................................................................. 3-4
3.1.1.13
Station type:................................................................................ 3-5
3.1.1.14
PRESSURE-OK Input mode:............................................................ 3-5
3.1.1.15
SVV Ang-Out 4-20mA check ........................................................... 3-5
3.1.1.16
End of sequence output minimum time (FINESEQ)............................. 3-5
3.2
3.2.1
3.2.1.1
3.2.1.2
3.2.1.3
3.2.1.4
3.2.1.5
3.2.1.6
3.3
3.4.1
3.4.1.1
3.4.1.2
3.4.1.3
3.4.1.4
3.5
3-6
3-6
3-7
3-7
3-7
3-7
3-7
3.3.1
3.3.2
3.4
3.5.1
3.5.1.1
3.5.1.2
3.5.1.3
3.5.1.4
GF WELDING
Programming Manual
4
4.1
4.2
4.3
4.4
4.4.1
4.4.2
4.4.3
4.4.4
4.4.5
4.4.6
4.4.7
4.4.7.1
4.4.7.2
4.4.7.3
4.4.7.4
4.4.7.5
4.4.7.6
4.4.7.7
4.4.7.8
4.4.7.9
4.4.7.10
4.4.7.11
4.4.7.12
4.4.7.13
4.4.7.14
4.4.7.15
4.4.7.16
4.4.7.17
4.4.7.18
4.4.7.19
4.4.7.20
4.4.7.21
4.4.7.22
4.4.7.23
4.4.7.24
4.4.7.25
4.4.7.26
4.4.7.27
4.4.7.28
4.4.7.29
4.4.7.30
4.4.7.31
4.4.7.32
4.4.7.33
4.4.7.34
4.4.7.35
4.4.7.36
5
5.1
5.2
5.3
5.4
5.5
5.6
5.6.1
5.6.2
5.6.3
5.6.3.1
5.6.3.2
5.6.3.3
5.6.3.4
VI
GF WELDING
Programming Manual
5.6.3.5
5.6.3.6
5.6.3.7
5.6.3.8
5.6.3.9
5.6.3.10
5.6.4
5.6.4.1
5.6.4.2
5.6.5
5.6.6
5.6.7
5.6.7.1
5.6.7.2
Prewarning__:..............................................................................5-12
Stop_______: ..............................................................................5-12
Dressing_:...................................................................................5-12
Offset_______: ............................................................................5-12
Pt. x Pieces _______:....................................................................5-13
P.x Emergency : ..........................................................................5-13
Parameter for Dressing 2 ..................................................................5-13
Pt.x Dressing_ : ...........................................................................5-14
Pt.x Emergency: ...........................................................................5-14
Stepper: Current - and pressure increment curve .................................5-15
Increment with Graphic method .........................................................5-16
Increment with Tabular method .........................................................5-18
Tabular stepper Menu....................................................................5-19
Programming the Tabular increment ................................................5-19
6
6.1
6.1.1
Parameter SPOT TRACE ..................................................................... 6-2
6.1.1.1
Program number [ P: ] ................................................................... 6-2
6.1.1.2
Program name [ : ]........................................................................ 6-2
6.1.1.3
Welding mode [ : ]......................................................................... 6-2
6.1.1.4
Welding time [ Cycles: ] ................................................................ 6-2
6.1.1.5
Nominal welding current [ I Prg.: ] .................................................. 6-2
6.1.1.6
Setpoint current [ I Nom: ] ............................................................. 6-3
6.1.1.7
Measured welding current [ I. Mis:
kA ]...................................... 6-3
6.1.1.8
Stepper number [ Stp : ] ................................................................ 6-3
6.1.1.9
Stepper counter [ Cnt : ] ................................................................ 6-3
6.1.1.10
Current increment in (%) [ INC% : ] .............................................. 6-3
6.1.1.11
Setpoint Electrode force 1 [ Prs1: ]................................................. 6-3
6.1.1.12
Setpoint Electrode force 2 [ Prs2: ].................................................. 6-4
6.1.1.13
CosPhi [ CosPhi: ] ....................................................................... 6-4
6.2
6.2.1
6.3
7
7.1
7.1.1
7.1.2
7.1.3
7.1.4
7.2
7-3
7-4
7-5
7-6
8
8.1
8.2
8.3
9.1
9.2
APPENDIX ...............................................................................................1
Appendix A
Operating
Operation
Operating
Operating
Operating
Operating
Operating
Operating diagrams.................................................................. 1
diagram
diagram
diagram
diagram
diagram
diagram
diagram
Appendix B
1
3
4
5
6
7
8
DIAGNOSTICS ALARMS............................................................ 1
Description of alarms............................................................................................ 1
GF WELDING
VII
Programming Manual
WHITE PAGE
VIII
GF WELDING
Programming Manual
PREFACE
This manual contains theoretical and technical details about the usage and
operation of the welding control Weld334m.
Mainly this is a programming instruction, which is useful for persons, who
are setting up the parameters of the control. Knowledge of electrotechnical
basics as well as experience about resistance welding are mandatory to use
and program the welding control.
Concerning safety, danger of resistance welding devices, safety rules, startup of the control and technical features please refer to the Hardware
Manual. The spot weld is the result of complex electrical, thermic,
metallurgic and mechanic processes, which are performed within a short
amount of time.
To use the welding control knowledge about technical correlations between
all 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 preceding
process steps. The operator, however specifies effective parameters of the
control - 5 out of more than 100. However, the 2 most important
parameters define the necessary thermal energy for successful welding. In
some cases inadequate conditions of preceding process steps like bad fitting
parts or insufficient design of devices can be compensated by efficient
combination of the control parameters.
The operator has to find the working point within the process window in
order to provide quality and safety of welding. The control carries out the
programmed parameters only. The errors issued by the control indicate
deviations from fixed settings. In any case the spot may not be of bad
quality.
Please notice, that state of the art controls like Weld334m, which offer
constant current control, stepper, error diagnostics, statistical functions and
more, will not guarantee perfect weldings in any case. The control repeats
the process with highest amount of precision, as it was programmed by the
operator. In case errors are issued by diagnostics of the control,
countermeasures must be done instantly. In most cases of abnormality the
current could not reach full amount because the secondary circuit does not
permit more or parts are far apart.
The actual welding quality results from the programming of the operator
and not from the control only.
This manual shall enable the user, to learn about how to program the
control and to look as a reference in order to perform the task quickly and
securely. 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 changed
without notice. Company GF WELDING does not have any obligations on
this item.
The soft- and hardware as described in this manual is part of a Licensing
agreement and all information must be kept confidential.
It is prohibited to pass the documentation of soft- and hardware to a third
party. The purchaser is allowed to make one copy of the software as a
backup.
Parts of this manual including copies or other notes may not be duplicated
or distributed by electronic or mechanic means without written permission
of Company GF WELDING S.p.A.
Copyright by GF WELDING S.p.A.
GF WELDING
IX
Programming Manual
WHITE PAGE
GF WELDING
Programming Manual
General Notes
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 is
connected to the control unit.
Via Main computer with WMS Software, which offers control function and central
programming of each welding control, which are connected to the main computer
via bus system.
Processor Pentium
10 MB HDD
The HHT has a liquid crystal display with 240x64 pixels. A text consisting of
8 lines with 40 signs each can be displayed.
Around the display there is an input area with 13 keys allocated.
GF WELDING
1-1
Programming Manual
General Notes
1.2.1
Keys
All kind of standard functions and related keys are described in the
following.
Arrow keys:
Are there any data displayed on the screen, the 4 arrow keys will move the
cursor into the 4 directions.
Soft keys: F1 F2 F3 F4 F5
These keys activate the functions above, which are displayed in the lower
bar.
Keys: + (plus)
- (minus)
These keys change the content or values of the fields, where the cursor is
located. In case of a numeric field, the number will be increased (+) or
decreased (-). In case of a character field, the predefined words will alter.
Remark:
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 will
perform the same function as the key. In order to confirm changes the
save function must be activated by pushing the related key. The displayed
star (*) in the upper bar will disappear, when changes are saved.
Upper bar
1-2
F2
OFF
000001
0000100
100
SET-B
ETC
F3
Data area
GF WELDING
F4
F5
ENT
Lower bar
Programming Manual
General Notes
1.2.2
Display
The display is divided into three different areas:
In case the star (*) does not disappear after saving some entry,
any faulty data entry is indicated. For example: the first sign of
an numeric field must be a number, the entry must be corrected.
The cursor jumps to the faulty or missing data field and indicates
where to correct the entry.
Data area
In the data area all operating parameters of the control, which can be
edited, are displayed. Furthermore statistical or dynamic information in the
fixed 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 arrow
keys to take a look at the remaining lines.
In the data area there are three different kinds of fields displayed:
In order to distinguish fields, which can be edited, from fields, which can
not be edited, just move the cursor using the arrow keys. The cursor will
appear on fields only, which can be edited.
There are three different kind of fields, which can be edited:
GF WELDING
1-3
Programming Manual
General Notes
Fields with numeric values
After selecting a field (use the arrow keys ), change the value
by 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 lower
limits are shown at the left side of the related fields.
Example: In the SETUP menu the number of current sensors can be
entered, which can be in the range between 1 and 6. On the
printout 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 be
edited, the + and - key can be used in order to find following signs:
ABCDEFGHIJKLMNOPQRSTUVWXYZ0*+-/012345689
EXAMPLE:
In case the F2 key is defined with the COPY function, the copy procedure
of a program will be initiated by pushing F2.
1-4
In case the F1 key is defined with Page+ (next page), the data area does
not show the whole content of the activated page. Use F1 key and the
remaining data in the next page will be shown.
In case the F5 key is defined with ETC , besides the 4 shown functions,
further functions exist. The further functions will be displayed by pushing
the F5 key.
GF WELDING
Programming Manual
General Notes
TRACE: Display of relevant information about each spot welds and status
of inputs and outputs in real time
CARD: Ensures storage of data. Displays functions for use of RAM card
GF WELDING
1-5
Programming Manual
General Notes
1-6
GF WELDING
Programming instructions
Language/Date/Time
2 Configuration
<F5-ETC F3 CONFIG>
language
Configuration
SoftwareRelease
Language
WELD334m
v.1.1
HCM
v2.00
4300 HHT
English
NETWORK
MODIFY
2.1.1
2.1.1.1
Configuration parameters
Release Software
Parameter:
Prog. Version:
Description:
GF WELDING
2-1
Programming instructions
Language/Date/Time
2.1.1.2
Prog. Version:
Description:
2.1.1.3
Language
Parameter:
Prog. Version:
Description:
2.1.1.4
Prog. Options:
Example: In order to shift the clock by one hour please follow this
procedure:
1. Press the F5 key in the CONFIG menu (MODIFY). The function
of the F5 key will change to SAVE.
2. Press the arrow key 4 times and the cursor will be positioned
on time.
3. Press the + key once. The hour will be increased by one
hour.
4. Press the F5 key once. All changes will be saved. The star in
the upper bar will disappear. The function of the F5 key will
change to MODIFY.
2-2
GF WELDING
Programming instructions
Language/Date/Time
2.1.2
On accessing the NETWORK CONFIGURATION menu (F5)(F3) you can define the IP
address, 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
SAVE
2.1.2.1
IP Address
An IP address consists of 4 numbers between 0 and 255 separated by fullstops. The address is free: however, if the centralized network is connected
to the company network, you must check that the IP addresses have not
already been used by other devices or PCs.
2.1.2.2
SubNet Mask
This number, together with the address, identifies the subnetwork in which
the welding control is situated. The protocol subnetwork is predefined
(Class C): normally all welding controls plus the WMS, that comprise a
system, 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 HOSTPORT
value of the welding control must be the same as that set in the WMS
application software.
GF WELDING
2-3
Programming instructions
Language/Date/Time
WHITE PAGE
2-4
GF WELDING
Programming instructions
Setup
3 Base settings
<F5-ETC F4 SETUP>
The base settings of the welding control are done in the SETUP menu.
The SETUP menu consists of 4 pages (masks). Following choices are
possible:
1. SETUP - WELD 334m CONFIGURATION: Main parameters of the
configuration
2. SETUP GUN PARAMETERS 0 (0-16): Specific configurations of used
guns = stepper
3. SETUP - ALARMS CONFIGURATION: Selection of error messages, which
will block restarts and will be reported in the errorlog (REPORT)
4. SETUP - CABLE WEAR: Setup of spot counters to specify maintenance
intervals (for example: exchange of gun cables)
5. SETUP TIP DRESSER WEAR: parameters
maintenance for dressing electrodes
concerning
the
tool
(0 32)
: 00
Device name
(8 digits)
: FASE 334m
Working mode
(0 100)
: 050
(1 20)
: 01
(1 20)
: 01
Current transducer
: ENABLED
N.current transducers
(1 6)
: 1
: OFF
: OFF
Execution in repeat
: OFF
: OFF
: Manual
: 24V=OK
: 00
GF WELDING
3-1
Programming instructions
Setup
Function keys of SETUP - WELD334M CONFIGURATION
F1 PAGE+:
F4 PRINT:
F5 SAVE:
Saves all changes. In case all entries were ok, the star in
the upper bar will disappear.
Key
Key + -:
3.1.1
3.1.1.1
(00 32)
Description:
3.1.1.2
Device name:
Parameter:
limits:
Description:
3.1.1.3
It
is
Working mode:
Parameter:
Range:
(WELD320 WELD334m)
Description:
3.1.1.4
(0 100)
Description:
3-2
GF WELDING
Programming instructions
Setup
3.1.1.5
Range:
(1 20)
Range:
(1 20)
Description:
3.1.1.7
Current transducer:
Parameter:
Presettings:
(ENABLED - DISABLED)
Description:
3.1.1.8
N. current transducers:
Parameter:
Range:
(1 6)
Description:
GF WELDING
3-3
Programming instructions
Setup
3.1.1.9
Description:
3.1.1.10
Settings:
Description:
3.1.1.11
Execution in repeat:
Parameter:
Settings:
(OFF ON)
Description:
Settings:
(OFF ON)
Description:
3-4
GF WELDING
Programming instructions
Setup
3.1.1.13
Station type:
Parameter:
Settings:
(MANUAL AUTOMATIC)
Description:
3.1.1.14
Settings:
(0V=ok
Description:
24V=ok)
(ENABLED DISABLED)
Description:
Enables/disables the analogue diagnostic output in 420mA current, used to control a proportional valve.
When enabled, if the control detects a discontinuity in the
servovalve command during execution of the welding cycle
(e.g. cable connection to servovalve disconnected or
discontinuous, servovalve failed) it will diagnose error
E098, of the blocking type.
This function is only available if servovalve command cards
that integrate the diagnostic circuit are used.
3.1.1.16
Range:
(0 99)
Description:
GF WELDING
3-5
Programming instructions
Setup
(00.00 30.00)
30.00
PAGE +
00.0
I min [kA]
Estimated
Parameters
:
(0.0 150.0) :
0.0
I max [kA]
(0.0 150.0) :
0.0
CosPhi
GUN -
GUN +
(0.0 1.0) :
PRINT
0.00
SAVE
F3 GUN+:
F4 PRINT:
F5 SAVE:
3.2.1
3.2.1.1
Range:
(00.00 30.00)
Description:
3-6
GF WELDING
Programming instructions
Setup
3.2.1.2
Description:
3.2.1.3
Sensitivity TF [V/kN]
Parameter type: Editable field with numerical value
Limits:
Description:
3.2.1.4
(00.00 30.00)
Parameter to be set with the conversion coefficient
declared by the manufacturer of the force transducer (TF).
The force transducers must generate an analog signal in
voltage proportional to the force to be measured.
Measured Parameter
I min [kA]:
Parameter:
Range:
(0.0 150.0)
Description:
3.2.1.5
Measured Parameter
I max[kA]:
Parameter:
Range:
(0.0 150.0)
Description:
3.2.1.6
Measured Parameter
CosPhi:
Parameter:
Range:
(0.0 1.0)
Description:
GF WELDING
3-7
Programming instructions
Setup
EXAMPLE:
Resistive load only, voltage and current with same phase, angle
= 0 cos = 1
Inductive with resistive load, current is 30 delayed to the voltage,
angle = 30 cos = 0,866
Inductive with resistive load, current is shifted by 45 later than
voltage, angle = 45 cos = =0,707
Inductive load only, current is 90 delayed to the voltage, angle
= 90 cos = 0
N09
E000-OK
N10
E000-OK
N11
E000-OK
N12
E000-OK
N13
E000-OK
N14
E000-OK
N15
E000-OK
N16
A
N06
N08
N07
N05
>
N04
N03
*
E000-OK
B
Column A:
Column B:
Order number
Column C:
3-8
GF WELDING
Programming instructions
Setup
Notes on previous table:
The error messages E005, E006, E031, E032, E001 and E002 are used in
the menu REPORT (See section 8)
The error messages E031, E032, E001 and E002 are configured with
abort function.
The error message is selected by the cursor > on position N05, which
refers to code E001.
F2 SELECT:
F3 ALL:
F4 PRINT:
F5 SAVE:
Usage of keys:
CONFIGURATION)
(ESC +
ENT
SETUP ALARMS
Key :
Keys + -:
ESC key:
ENT key:
GF WELDING
3-9
Programming instructions
Setup
3.3.1
>
N01
N02
N03
N04
N05
PAGE+
ALL
SAVE
3.3.2
*
>*
PAGE+
N01
N02
N03
N04
N05
ALL
SAVE
Example: To configure as an abort alarm the error message E032Nul 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.
3-10
GF WELDING
Programming instructions
Setup
ON
OFF
Prewarning(1-999999)
000001
000001
Stop
0000100
(100 999999)
Counter (0 999999)
100
PRINT
PAGE+
0000100
100
SAVE
ETC
RESET-B
SET-A
SET-B
ETC
F2 RESET-B:
F3 SET-A:
F4 SET-B:
F5 ETC:
F1 PAGE+:
F3 PRINT:
F4 SAVE:
GF WELDING
3-11
Programming instructions
Setup
3.4.1
3.4.1.1
Enable
Parameter:
Options:
(ON - OFF)
Description:
3.4.1.2
Prewarning
Parameter:
Range:
(1 - 9.999.999)
Description:
3.4.1.3
Stop
Parameter:
Range:
(100 - 10.000.000)
Description:
3.4.1.4
Counter
Parameter:
Range:
(0 10.000.000)
Description:
3-12
GF WELDING
Programming instructions
Setup
ON
000001
00001000
Counter (0 9999999)
PAGE+
RESET
PRESET
SAVE
F2 RESET:
F3 PRESET:
is
equal
F4 PRINT:
3.5.1
the
F5 SAVE:
to
GF WELDING
3-13
Programming instructions
Setup
Unlike the electrode wear management, the TIP DRESSER WEAR function is
not dependent on programs, special clamps and it has no dedicated
outputs.
* Only if configured as an Abort alarm on the Setup- Alarm Configuration
3.5.1.1
Enable
Parameter:
Range:
(ON - OFF)
Description:
3.5.1.2
Prewarning:
[%]
Parameter:
Range:
(1 - 100)
Description:
3.5.1.3
Stop:
Parameter:
Range:
(100 - 10.000.000)
Description:
3.5.1.4
Counter
Parameter:
Range:
(0 10.000.000)
Description:
3-14
GF WELDING
Programming instructions
Weld programs
<F2 PROG>
All kind of parameters of the 255 possible weld programs can be accessed
in the menu PROG (WELD PROGRAMS).
The menu PROG shows a list of all existing programs with the main
parameters 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
TEST111
Const. Cur
ON
S00
S.SP
P02
BODEN3
Normal
OFF
S00
S.SP
P03
PAVIM3
Const. Cur
ON
S00
S.SP
P04
SEITENT
Const. Cur
ON
S00
S.SP
P05
>
AAA
Const. Cur
ON
S01
RPT
COPY
.
CLEAR
EDIT
SS/RPT
WELD PROGRAMS
P01
Const. Cur
ON
S00
RPT
P02
TEST222
Const. Cur
OFF
S00
RPT
P03
BODEN3
Normal
ON
S00
RPT
P04
SEITENT
Monitor
ON
S00
RPT
P05
AAA
Const. Cur
ON
S01
SS
P06
BBB
Monitor
ON
S01
SS
P07
>
TEST111
CCC
Corr.Cos
ON
S02
SS
P08
P09
P10
A
COLUMN A:
COLUMN B:
COLUMN C:
COLUMN D:
COLUMN E:
COLUMN F:
COLUMN G:
COLUMN H:
GF WELDING
4-1
Programming instructions
Weld programs
REMARK: Column H is displayed in alternative to columns D E F G when
using arrow keys
The content of the columns can be changed by selecting the programs using
the arrow keys and pushing F1 EDIT. Column G can be changed by using F5
SS/RPT only.
Key + proceeds to the 5 succeeding, whereas key - proceeds to the 5
previous programs.
Function keys in the menu WELD PROGRAMS:
F1 EDIT:
Selects the program next to the cursor > for editing (see
section 4.4)
F2 COPY:
F3 CLEAR:
F4 PRINT:
F5 SS/RPT:
F2 COPY
In this menu programs will be copied. This means to transfer data of one
program to another program.
Page menu COPY WELD PROGRAMS
COPY WELD PROGRAMS
P01
TEST111
Const. Cur
ON
S00
SS
P02
TEST222
Normal
OFF
S00
SS
P03
PAVIM3
Const. Cur
ON
S00
SS
P04
FIANCATA
Const. Cur
ON
S00
SS
P05
>
AAA
Const. Cur
ON
S01
RPT
COPY
SELECT
4-2
Move the cursor to the program (target) using the arrows All
parameters of the source program will be transferred to the target
program.
GF WELDING
Programming instructions
Weld programs
5. Push F5 key COPY. All parameters of program 4 will be transferred to
program 8.
6. To go back to menu WELD PROGRAMS push ESC key.
F3 CLEAR
Cont.Cur
ON
S00
SS
TEST222
Normal
OFF
S00
SS
P03
BODEN3
Cont.Cur
ON
S00
SS
P04
SEITENT
Cont.Cur
ON
S00
SS
P05
SELECT
P01
P02
>
AAA
Cont.Cur
ON
S01
RPT
ALL
CLEAR
GF WELDING
4-3
Programming instructions
Weld programs
F5 SS/RPT
Const.Cur
ON
S00
SS
TEST222
Normal
OFF
S00
SS
P03
BODEN3
Const.Cur
ON
S00
SS
P04
SEITENT
Const.Cur
ON
S00
SS
P05
EDIT
P01
P02
>
AAA
Const.Cur
ON
S01
RPT
COPY
CLEAR
SS/RPT
4-4
GF WELDING
Programming instructions
Weld programs
F1 EDIT
4.4.1
Welding transformer
Input signal
HHT
Output signal
Control
WELD334m
Current
transducer
Line
4.4.2
Transformer
SCR
Electrodes
Welding mode
Six different welding modes can be selected within one program:
1. NORMAL
Normal welding. In the NORMAL mode, the user sets the percentage of
maximum current with which he wants to perform welding. There is no
verification of the actual welding current as no current transducer is
expected to be installed.
GF WELDING
4-5
Programming instructions
Weld programs
2. MONITOR
Same as Normal operation mode, however in addition it is possible to
monitor actual current. This makes process diagnosis easy (see section
4.4.7.20). A current transducer is mandatory.
3. CONSTANT CURRENT
Actual current in kA will be same as setpoint current. This is achieved by
the welding control, which sets the ignition angle of the thyristor.
Parasitic effects like change of impedance of the secondary circuit or
changes of voltage supply will be compensated and the welding current
will be kept constant. A current transducer is mandatory (see section
4.4.7.20).
4. SEAM NORMAL
Operation mode is for seam welding only. In this mode the active
parameters (see section 4.4.6) will be repeated until the start signal is
switched off. The welding program can be changed without
interrupting the Signal START. The Seam normal operation mode is
similar to Normal apart from the parameter downslope.
5. SEAM MONITOR
This operation mode is similar to Monitor apart from the parameter
slopedown.
6. SEAM CONSTANT CURRENT
This operation mode is similar to CONSTANT CURRENT apart from the
parameter slopedown.
7. HALF CYCLE:
This welding mode must be selected if the welding control is installed in
plant where the welding technology known as AL-S is applied.
For this type of application, the duration of welding is fixed and consists
of 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 halfwave, so as to avoid saturating the transformer. (See diagram in the
appendix for an example)
8. HALF CYCLE MONITOR: As for the HALF CYCLE mode, with the
possibility of monitoring the current and making any process diagnostics
required (see point 4.4.7.19). A current sensor is mandatory.
All operation modes mentioned above effect the menu EDIT WELD
PROGRAMS dynamically, where all displayed parameters will change in
dependency on the selected Welding Mode. See also Operating Diagram
3 of Appendix A page 4.
4-6
GF WELDING
Programming instructions
Weld programs
4.4.3
CODE0 - CODE 5
Programcode
CODE P
Parity code Program.
WELD
334m
EVSA
Weld valve channel A
EVPA
Pressure variation ch.A
EVSB
Weld valve channel B
STARTA
Cycle start ch. A
EVPB
Pressure variation ch.B
STARTB
Cycle start ch. B
I/VSERV
control servo valve
l
CONSSALD
Weld enable
RICHSALD
Weld request
REPEAT
Repeat mode
FINESALD
End of weld
SALDA SI
With weld current
FINESEQ
End of sequence
SOLOPR
Force only
STSERV
Status servo.valve
4.4.4
GF WELDING
4-7
Programming instructions
Weld programs
Stp_: 00
:ON
: Normal
VEE_: 00
PLS: N
: 00
Up_S : 00
1^Ang: 000
1Sqz
_: 00
CPV_: 00
Weld
Pwr
2Sqz
_: 00
MPV_: 0
Dw_S : 00
Hold
: 00
P1: 00.00
Wait : 00
Open
_: 00
P2: 00.00
PAGE +
SAVE
PROG -
: 00
I:
%:000
KA
PROG +
P:08 :
: Normal
:ON PLS: N
Up_S : 00
Weld : 00
: 00
1^Ang: 000
a
Pwr %: 000
Dw_S : 00
Wait: 00
CosPhi :
KA
0.80
SAVE
PAGE +
I:
PROG -
PROG +
Stp_: 00
1Sqz: 00
2Sqz: 00
Hold : 00
Open: 00
PAGE +
4-8
: Const.Curr. : ON
:
VEE_: 00
CPV_: 00
MPV_: 0
P1: 00.00
P2: 00.00
SAVE
Up_S: 00
Weld: 00
Dw_S : 00
Wait_ : 00
PROG -
GF WELDING
I:
PROG +
PLS:N: 00
1Ang : 000
Blank: 000
I.Prg : 000.0
KA
Programming instructions
Weld programs
: Const.Cur : ON
PLS:N:
00
Up_S : 00
Weld : 00
00
%I.max:
00
Rtr: 00
%I.lim:
00
Blank: 00
Dw_S : 00
%I.min:
1^Ang: 000
I.Prg: 000.0
Ang: 000
SAVE
PAGE +
Wait : 00
PROG -
I: KA
PROG +
: Const.Cur : ON
PLS:N:
00
Th.1 :
00.00
Up_S
: 00
1^Ang: 000
Th.2 :
00.00
Weld
: 00
Blank: 00
Th.3 :
00.00
Dw_S
: 00
Wait
: 00
PAGE +
SAVE
PROG -
I.Prg: 000.0
I: KA
PROG +
4.4.5
go to next page
F2 SAVE:
F3 PROG -:
go to previous program
F4 PROG +:
go to next program
REMARK: in case the special pulse mode is selected, the
function keys will modify:
F3 PULSE -:
F4 PULSE +:
F5 ETC:
Furthermore the right upper corner of the display shows the pulse number
(see section 4.4.6) which is actually selected.
GF WELDING
4-9
Programming instructions
Weld programs
4.4.6
Welding modes
Abbreviation
4-10
Monitor
Const.Cur.
Seam N.
Seam M.
Seam C.C.
Cycle N.
Cycle M.
Program Nr.
Program name
Welding mode
Enable programs
Pulse type
Number of pulses
Stepper/electrode parameter
Presqueeze time
squeeze time
Hold time
Open time
Equivalent energy value
Delay squeeze control
Squeeze variation mode
Electrode force 1.
Electrode force 2.
CosPhi nominal
maximum current tolerance
Minimum current tolerance
Limit current tolerance
Electrode force tolerance
Electrode force diagnostic mode
Repeating spots
Firing angle limitation
Sheet thickness
Upslope cycles
Downslope cycles
Cool time
Weld time
Delayed firing of first half-cycle
Welding current
Diagnostics current
Blanking cycles (Blank)
Welding current in kA
Measured welding current
Normal
Description
P:
:
:
:
PLS:
:
Stp_:
1. Sqz_:
2,. Sqz_:
Hold _:
Open_:
VEE_:
CPV_:
MPV_:
P1:
P2:
CosPhi:
%I.max:
%I. min:
%I. lim:
%T. Prs:
%T. Prs:
RTR:
Ang:
Th.
UpS:
DwS:
Wait_:
Weld:
1Ang:
Pwr %:
I.Dgs.:
Blank:
I.Prg.:
I: kA
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
no
no
no
yes
yes
no
no
yes
yes
yes
yes
yes
yes
yes
no
no
no
no
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
no
yes
yes
yes
yes
yes
yes
yes
yes
no
no
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
no
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
no
no
yes
yes
yes
yes
yes
yes
yes
no
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
no
no
no
yes
yes
no
no
yes
yes
no
yes
yes
yes
yes
no
no
no
no
yes
yes
yes
yes
no
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
no
no
yes
yes
no
yes
yes
yes
yes
yes
no
no
yes
yes
yes
yes
yes
no
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
no
yes
yes
yes
yes
yes
no
yes
yes
yes
no
yes
yes
yes
no
no
yes
yes
yes
yes
yes
yes
yes
no
1
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
no
no
no
yes
yes
no
no
yes
no
no
yes
no
no
yes
no
no
no
yes
yes
yes
yes
yes
no
1
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
no
no
yes
no
no
yes
no
no
yes
yes
no
no
yes
GF WELDING
Programming instructions
Weld programs
4.4.7
4.4.7.1
Program number
Parameter:
Range:
(01 255)
Description:
Order number
In case the cursor is placed in some other field, next
program can be shown by pressing F3 PROG- or F4
PROG+. All parameters of the new selected program are
displayed.
4.4.7.2
Program name
[:]
Parameter:
Limits:
Description:
4.4.7.3
Mode of welding [ : ]
Parameter:
Presettings:
Description:
4.4.7.4
Enable program [ : ]
Parameter:
Presettings:
(ON OFF)
Description:
GF WELDING
4-11
Programming instructions
Weld programs
4.4.7.5
Presettings:
Description:
I
[KA]
T [cycles)]
4-12
GF WELDING
Programming instructions
Weld programs
The first pulse (warm-up pulse) takes 4 cycles [Weld:04] and the cool
time, which separates it from the succeeding pulse, takes 2 cycles
[WAIT:02].
The second pulse (actual weld) takes 7 cycles [Weld:07] and the cool
time, which separates it from the succeeding pulse, takes 3 cycles
[WAIT:03].
The third pulse (postwarming) takes 3 cycles [Weld:03] and the cool
time, which separates it from the succeeding pulse, takes 0 cycles
[Wait:00].
I
[KA]
T [cycles)]
4.4.7.6
Number of pulses [ : ]
Parameter:
Range:
Description:
4.4.7.7
Range:
(0 16)
Description:
GF WELDING
4-13
Programming instructions
Weld programs
4.4.7.8
Presqueeze [ 1.Sqz: ]
Parameter:
Range:
(0 99)
Description:
4.4.7.9
(Unit = Periods)
Squeeze [ 2.Sqz: ]
Parameter:
Range:
(0 99)
Description:
4.4.7.10
This is the time given for the gun, to build up the electrode
force after the welding program has started. This time
value must be found out by experience.
(Unit = periods)
(0 99)
Description:
4.4.7.11
(Unit = periods)
Open [ Open: ]
Parameter:
Range:
(0 99)
Description:
4-14
This is the time for the gun to open, move to the new
position and close again. It applies for serial welds only.
This time value must be found out by experience.
(Unit = periods)
GF WELDING
Programming instructions
Weld programs
The input signal START remains until output signal FINESEQ (end of weld
cycle) on
STATUS = 1
STATUS = 0
START
1SQZ
2SQZ
WELD
HOLD
OPEN
Solenoid valve
End of sequence
T [cycles
GF WELDING
4-15
Programming instructions
Weld programs
Welding graph for repeated spot RPT
Following graph shows the sequence in repeat mode
The input signal START remains on till begin of second welding sequence
STATUS = 1
START
START
STATUS = 0
1SQZ
2SQZ
WELD
HOLD
OPEN
Prortional valve
End of weldsequence
T [cycles]
4-16
GF WELDING
Programming instructions
Weld programs
4.4.7.12
Range:
(0 10)
Description:
0= no spot counting
10= each spot will be counted
If one gun is driven by several welding programs, all
programs will have the same stepper parameters. The
highest amount of electrode wear (electrode alarm)
however is caused by the program, which commands the
highest amount of energy (current as a function of time).
Usually it will be the program, which is used for welding of
the biggest sheet thickness combination. The equivalent
energy value parameter [VEE_:] makes it possible, to
assign 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 electrode
wear, VEE_: is set to 10.
After execution of each weld the internal spot counter is
increased by 1. For programs which apply less energy for
welding, where VEE_: has a smaller value, the counter will
increase in proportion to this.
For instance another program which uses half of the
energy, the value for [VEE_:] will be set to 5. In order to
increase the counter by one, 2 spots have to be welded by
this 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
[ CPV_: ]
Parameter:
Range:
(0 99)
Description:
(Unit = cycles)
GF WELDING
4-17
Programming instructions
Weld programs
4.4.7.14
Presettings:
(0 5)
Description:
MVP=2
MVP=3
MVP=4
MVP=5
4-18
GF WELDING
Programming instructions
Weld programs
2SQZ
1SQZ
HOLD
OPEN
EVSA
Mode 0
EVSA+EVPA
EVSA+EVPA
EVSA
Mode 1
EVSA+EVPA
EVSA
Mode 2
EVSA+EVPA
EVSA
Mode 3
EVSA+EVPA
EVSA
EVSA
Mode 4
EVSA+EVPA
EVSA
Mode 5
CPV
GF WELDING
4-19
Programming instructions
Weld programs
In case of type C the two different force values P1 and P2, which are
applied by the welding gun, are programmable (see [P1:] and [P2:]). The
force after squeeze time is set with [P1:]. In case of no squeeze variations,
mode 0 must be selected.
MVP=1
MVP=2
MVP=3
Squeeze, initially equal to P1, goes to level P2 after the variation cycles
and remains during the hold cycles
MVP=4
Squeeze, initially equal to P1, goes to level P2 after the variation cycles
and returns to level P1 during the hold time.
MVP=5
4-20
GF WELDING
Programming instructions
Weld programs
2SQZ
WELD
HOLD
OPEN
P1
Mode 0
P2
Mode 1
P1
P1
P2
P1
Mode 2
P2
P1
Mode 3
P2
P1
P1
Mode 4
P2
P1
Mode 5
CPV
GF WELDING
4-21
Programming instructions
Weld programs
4.4.7.15 Electrode force 1. [ P1: ]
Parameter.
Range:
(00.00 30.00)
Description:
(Unit = kN)
(00.00 30.00)
(unit = kN)
Description:
4.4.7.17
Range:
(0.25 0.99)
Description:
4-22
GF WELDING
Programming instructions
Weld programs
In case CosPhi does not match perfectly the range of
current settings will be limited or the measured values by
the current transducer do not show actual current values
correctly.
4.4.7.18
Range:
(05 50)
Description:
4.4.7.19
(05 50)
Description:
GF WELDING
4-23
Programming instructions
Weld programs
4.4.7.20
It may occur during welding, that the average measured current does not
match the programmed setpoint current.
The actual measured current may be within one of the 4 ranges described in
the following:
Area A: The actual measured current is above 11.8kA and the message
E006 - Meas.curr.>max threshold will be issued.
Area B: The actual measured current is between 8.5kA and 11.8kA, current
is judged as OK.
Area C: The actual measured current is between 7.3kA and 8.5kA for 2
weldings in series and the error 'E005 - Meas.Curr.< min
threshold' will be issued.
In case the current is within area C one time, no error message
will be issued (Weld alarm threshold A = 2).
Area D: The actual measured current is below 7.3 kA and the error 'E031Meas.curr.<lim threshold' will be issued.
%I.max:18
I.Prg:10.0
Zone B: Weld OK
10.0 kA
8.5 kA
%I.min:15
Alarm Zone C: E005 Meas. Curr. < min threshold subordinate to alarm threshold (see 3.1.1.5)
7.3 kA
%I.lim:27
Alarm Zone D: E031 Meas. Curr. < lim. threshold
4-24
GF WELDING
Programming instructions
Weld programs
4.4.7.21
Range:
(05 50)
Description:
4.4.7.22
(00 50)
Description:
GF WELDING
4-25
Programming instructions
Weld programs
Use of this diagnostic function depends on an electrode
force sensor being included in the plant, and on the correct
parameter designation of the sensor characteristics in the
SETUP menu GUN PARAMETERS (see point 3.2).
In the software versions in which it is supported, this
parameter is present on the key-board for all welding
modes.
4.4.7.23
Range:
(00 10)
Description:
4-26
GF WELDING
Programming instructions
Weld programs
4.4.7.25
Range:
Description:
SCR firing
V[ V ]
180
20
angle.[ ]
100
area, where the firing
angle limitation can be
defined
GF WELDING
4-27
Programming instructions
Weld programs
4.4.7.26
(00.00 99.99)
Description:
4.4.7.27
Up-slope [ Up_S:]
Parameter:
Range:
Description:
4-28
GF WELDING
Programming instructions
Weld programs
4.4.7.28
Range:
Description:
GF WELDING
4-29
Programming instructions
Weld programs
Graph with applied up-slope and down-slope for pulse type Normal
Following graph shows a welding program, which consists of 3 pulses type
normal [PLS:N:03] in operation mode Normal, Monitor and Const.Current.
I
[KA]
T[cycles]
The cool time, which separates it from the next pulse, takes 2 cycles
[Wait:02]. The current is set to 6 kA [I.Prg:6.0].
The second pulse (actual welding) takes 7 cycles [Weld:07]. 4 cycles upslopes are specified [Up_S:04]. The cool time, which separates it from the
next pulse, takes 3 cycles [Wait: 04]. The welding current is set to 8kA
[I.Prg:8.0].
The third pulse takes 10 cycles [Weld:10]. 3 cycles up-slope [Up_S:03] and
2 cycles down-slope [Dw_S:02] are specified. The cool time, which separates
it from the begin of the hold time, takes 0 cycles [Wait: 00]. The welding
current is set to 4 kA [I.Prg:4.0].
I
[KA]
8
6
4
2
T [cycle]
4-30
GF WELDING
Programming instructions
Weld programs
Graph with up-slope for pulse type Special in seam-weld operation
Following graph shows a welding program, which consists of 3 pulses type
Special [PLS:S:03] in operation mode Seam weld. Down-slope does not
exist for seam-welding.
The first pulse takes 4 cycles [Weld:04]. 2 cycles up-slopes are specified
[Up_S:02]. The welding current is set to 6kA [I.Prg:6.0].
The third pulse takes 10 cycles [Weld: 10]. 3 cycles up-slopes are
specified [Up_S:03] and the cool time, which separates it from the next
pulse, is set 0 [Wait:00]. The welding current is set to 4kA [I.Prg:4.0].
I
[KA]
8
6
4
2
1st Impuls
4.4.7.29
2nd Impuls
3rd Impuls
T [cycle]
Range:
Description:
4.4.7.30
Range:
Description:
GF WELDING
4-31
Programming instructions
Weld programs
4.4.7.31
Range:
(030 135)
Description:
(Unit = degree)
Standard: 90
Sets an upper limit to the firing point of the thyristor for
the first half cycle. Any wrong setting will result in a wrong
current consumption from the mains which, in turn, might
cause the intervention of safety devices along the supply
line.
4.4.7.32
Range:
(000 100)
Description:
4.4.7.33
Diagnostics current
[ I.Dgs.:]
Parameter:
Range:
(000.0 150.0)
Description:
(Unit = kA)
(00 99)
(Unit = cycle)
4-32
GF WELDING
modes
Programming instructions
Weld programs
4.4.7.35
[ I.Prg.: ]
Parameter:
Range:
(000.0 150.0)
Description:
(Unit = kA)
modes
[ I: kA ]
Parameter:
Range:
(000.0 150.0)
Description:
(Unit = kA)
GF WELDING
4-33
Programming instructions
Weld programs
4-34
GF WELDING
Programming instructions
Stepper programs
<F3 STEPPER>
5 STEPPER Menu
16 steppers are available. Each stepper means one spot counter, which is
assigned to one welding gun or one pair of electrodes.
Following parameters have to be set in the stepper menu:
The electrodes wear due to welding and the quality of the spots
deteriorates.
Due to electrode wear the contact area of the electrodes increases, which in
results in less current density and less force per area.
To compensate, current and force are increased in dependency of the
number of spot welds and the electrodes will be dressed.
When executed, each welding program increments the value of current of
related stepper (see point 5.4) in a way proportional to the Equivalent
Energy Value stated in the program (see Art. 4.4.7.12).
In the stepper menu all parameters of the 16 current increment programs
(stepper) are defined. In the STEPPER menu a list of all steppers appear
together with all main parameters, date, time of last modification.
Following table shows a part of the menu STEPPER (only 7 out of 16
steppers):
STEPPER
S01
P 900
S 1000
S02
Gun 2
P 900
S 1000
C 124
Tu 10/02/1998 10:11:32
S03
Gun 3
P 1200
S 1400
22
S04
PART.33
P 700
S 1000
S05
PART.47
P 700
S 800
C 650
Tu 10/02/1998 09:21:44
S06
>
Gun 1
Gun 8
P 900
S 1000
C 342
17
Tu 16/02/1998 18:11:55
S07
GF WELDING
5-1
Programming instructions
Stepper programs
The content of the columns can be changed. To do this select a stepper by
using key F1 EDIT. Column F, the actual counter status, can be changed
with key F2 PRESET (see section 5.4)
Column G is displayed in alternative to columns D E F after pressing
the arrow keys .
The + and - keys shift the stepper, where the cursor > is located, by 5
positions.
Page of Stepper menu
STEPPER
>
S01
S02
S03
S04
S05
GUN 1
GUN 2
GUN 3
PART.33
PART.47
EDIT
COPY
95
S 1000
90
S 1000
C 124
95
S 1400
22
95
S 1000
95
S 800
C 650
ETC
CLEAR
17
PRESET
ETC
F3 CLEAR:
F4 PRINT:
F5 ETC:
F1 RESET:
F2 PRESET:
5-2
GF WELDING
Programming instructions
Stepper programs
F2 COPY
In this menu steppers can be copied. This means to transfer data from one
stepper to another stepper.
>
S01
S02
S03
S04
S05
GUN 1
GUN 2
GUN 3
PART.33
PART.47
95
S 1000
90
S 1000
C 124
95
S 1400
22
95
S 1000
95
S 800
C 650
SELECT
17
COPY
F3 CLEAR
>
S01
S02
S03
S04
S05
SELECT
GUN 1
GUN 2
GUN 3
PART.33
PART.47
95
S 1000
90
S 1000
C 124
95
S 1400
22
95
S 1000
95
S 800
C 650
ALL
17
CLEAR
GF WELDING
5-3
Programming instructions
Stepper programs
F1 RESET
S 1000
17
S02
GUN 2
S 1000
C 124
S03
GUN 3
S 1400
22
S04
PART.33
S 1000
S05
PART.47
S 800
C 650
S06
>
GUN 1
GUN 8
S 1000
C 342
S07
Column A: in this column the cursor is moved by using the arrow keys
to select the stepper, which shall be reset
Column B: Order number (from S01 to S16)
Column C: Stepper name (mnemonic)
5-4
GF WELDING
Programming instructions
Stepper programs
Column D: Lifetime (see section 5.6.3.6)
Column E: actual counter status (see section 5.4)
Column F: number of dressings executed (status of dressing counter, see
section 5.6.1)
PAGE RESET STEPPER PROGRAMS
>
S01
S02
S03
S04
S05
GUN 1
GUN 2
GUN 3
PART.33
PART.47
SELECT
S
S
S
S
S
1000
1000
1400
1000
800
C 17
C 124
C 22
C 0
C 650
ALL
DRESS
4
5
0
0
0
CHANGE
F2 ALL:
F4 DRESS:
F5 CHANGE:
The + and - keys shift the stepper where cursor > is located by 5 positions.
Example: Confirmation dressing
A gun (channel A) is assigned to stepper 2 (S02).
This gun works with Program 5 (P05) where the parameters are set as
follows :Stp_:02 and VEE_:10, each spot executed with P05 will increase
the counter S02 by 1.
Stepper 2 is configured with DRESS 1.
The lifetime of a new electrode is 1000 spots. After dressing it must be
started with a higher current, which is the same as for a new electrode after
30 weldings. Therefore offset must be set 30 (Stop_:1000 Offset___:30).
The electrodes are dressed 8 times before exchange (Dressing__: 8).
After execution of 1000 spot stepper 02 issues the message E049 and
dressing of the appropriate electrodes must be done.
In order to confirm, that dressing of the electrodes is finished, following
steps must be performed:
1. Press ESC key, to return back to main menu
2. Press F3 STEPPER
3. Press F5 ETC key
4. Press F1 RESET and menu RESET STEPPER PROGRAMS will be entered
5. Move the cursor to stepper S02 by using the arrow keys.
6. Push key F1 SELECT
7. Push key F4 DRESS
GF WELDING
5-5
Programming instructions
Stepper programs
In column E the offset value C 30 (actual counter status of stepper) will
appear. In column F '1' will appear (status of dressing counter).
F2 PRESET
The actual counter status of the stepper shows the number of executed spot
since:
Last dressing or last electrode exchange (in operation mode DRESSING 1)
Last electrode exchange (in operation mode DRESSING 2)
In case of changed electrode wear the actual counter status may have to be
adapted.
In menu STEPPER the counter status is shown in column F: 'C_____' (see
section 5).
Example: change of stepper counter content of Stepper S30
1. Push key F5 ETC in menu STEPPER. Key F1 is assigned to function
RESET. Key F2 is assigned to function PRESET.
2. Move the cursor to Stepper S03, which shall be modified.
3. Push key F2 PRESET and following window will appear
5-6
GF WELDING
Programming instructions
Stepper programs
Dressing 1: the dressing counter will be reset (see section 5.6.1) and
the actual counter status is set to 0.
RESALSA
(reset Counter A )
WELD
334m
RESALSB
(reset counter B)
WALLST.A
(Prewarning Stepper A)
WALLST.B
(Prewarning Stepper B)
ALLSTA
(Alarm Stepper A)
RAVOK
(Dressing done)
ALLSTB
(Alarm Stepper B)
CHGEOK
(Electrode exchange done)
ALARM2
(Alarm)
RICHRAVV
(Request dressing)
RICHEL
(Request Electrode exchange)
GF WELDING
5-7
Programming instructions
Stepper programs
Output ALLSTA (Alarm E049 Stepper alarm channel A) will be high as soon
as the lifetime is reached, which is defined in the stepper for the electrodes
of channel A (see section 5.6.3.7).
Output ALLSTB (Alarm E050 Stepper alarm channel B) will be high as soon
as the lifetime is reached, which is defined in the stepper for the electrodes
of channel B (see section 5.6.3.7).
Output ALARM2 (Hardware error) will be high as long as error E066
(dressing not done) or E067 ('Electrode not changed') is active.
Output RICHRAV (Request dressing) will be high dependant on the selected
dressing mode:
5-8
GF WELDING
Programming instructions
Stepper programs
F1 EDIT
The control allows, to configure the stepper for two kind of dressings:
1. Stepper with Dressing1: Dressing in cycles (saw tooth curve)
2. Stepper with Dressing2: Dressing in intervals
5.6.1
Dressing 1
Stepper page in Dressing 1 mode
S:09
: Dressing 1
:GFX
Prewarning__: 000
Stop_______: 00000
Pt.x Emergency : 00
Dressing____: 000
Offset_____ : 00000
: OFF
INC
SAVE
STEP -
STEP +
ETC
CLR I
CLR P
ETC
GF WELDING
5-9
Programming instructions
Stepper programs
5.6.2
Dressing 2
The menu for editing a stepper set to the DRESSING 2 mode looks as
follows:
S:09
: Dressing 2
:GFX
Prewarning__: 00000
Stop_______: 00000
INC
SAVE
STEP -
STEP +
ETC
CLR I
CLR P
ETC
5-10
GF WELDING
Programming instructions
Stepper programs
All the editable fields must be within the predetermined limits (if not, the
Save function of data will not be enabled).
Function keys in menu EDIT STEPPER:
F1 INC:
F2 SAVE:
F3 STP -:
F4 STP +:
F5 ETC:
F2 CLR I:
F3 CLR P:
F5 ETC
5.6.3
5.6.3.1
Stepper number [ S: ]
Parameter:
Range:
(01 16)
Description:
5.6.3.2
Stepper name
[:]
Parameter:
Range:
Description:
Dressing mode
[:]
Parameter:
Settings:
(Dressing 1 - Dressing 2)
Description:
GF WELDING
5-11
Programming instructions
Stepper programs
5.6.3.4
(GFX - TAB)
Description:
5.6.3.5
Prewarning__:
Parameter:
Range:
(1 100)
Description:
Unit: %
Stop_______:
Parameter:
Range:
(1 65500)
Description:
Dressing_:
Parameter:
Range:
(0 250)
Description:
5.6.3.8
Offset_______:
Parameter:
Range:
(0 65500)
Description:
5-12
GF WELDING
Programming instructions
Stepper programs
5.6.3.9
Range:
(1 - 100)
Description:
5.6.3.10
P.x Emergency :
Parameter:
Range:
(00 - 99)
Description:
5.6.4
Stepper name
Dressing mode
Prewarning
Pt.x Pieces_______:
GF WELDING
5-13
Programming instructions
Stepper programs
5.6.4.1
Pt.x Dressing_ :
Parameter:
Range:
(0 65500)
Description:
5.6.4.2
Pt.x Emergency:
Parameter:
Range:
(00 - 99)
Description:
5-14
GF WELDING
Programming instructions
Stepper programs
5.6.5
The increment trend during the electrode lifetime may be created either in
the Graphic form (GFX), by a curve, or managed in the Tabular form
(TAB). Both methods are programmed in the Increment page and each of
them features a specific programming procedure.
The Increment method can be selected directly in the Edit menu of the
Stepper program concerned. To do this, move the cursor to the field next to
the Dressing Mode and, by means of the or + keys, select the GFX or
TAB option (see figure below).
GFX
S:09
+
TAB
: Dressing 1
Prewarning__: 00000
:
Pt.x Pieces____: 000
Stop_______: 00000
Dressing_: 000
Pt.x Emergency: 00
Offset______: 00000
: OFF
INC
SAVE
STP -
GF WELDING
STP +
ETC
5-15
Programming instructions
Stepper programs
5.6.6
CURRENT
Programming page for
graphic stepper
CNT : 1
INC : 0
PAGE+
INTERP
Select current/pression
Cursor
Programmable step
Function keys in
incrementation)
F1 PAGE +:
stepper
menu
(Current
and
pressure
F2 INTERP:
keys :
keys +
-:
keys ::
ESC key:
REMARK:
5-16
GF WELDING
Programming instructions
Stepper programs
Example: Edit Stepper - Current increment curve
A Welding gun on channel A is assigned to stepper 2 (S02). This gun is
commanded by program 5 (P05) with the parameters Stp_:02 and VEE_:10
(each welding spot carried out by P05 will increase the spot counter of S02
by 1).
Stepper 2 is set in the DRESSING 1 Mode.
New electrodes carry out 1000 spot welds and 970 spot welds are defined
between each dressing (Stop____:1000 Offset___:30).
The welding current for welding program, which is assigned to stepper 2,
shall be increased.
The increment curve shall be linear and the maximum shall be 50% before
the electrodes need to be dressed (this means: after 1000 spots).
In order to input the increment mentioned above, perform following steps:
1. Press ESC key in order to return to the main menu.
2. Press key F3 STEPPER
3. Push arrow key and move the cursor next to Stepper S02.
4. Push key F1 EDIT and you will enter the STEPPER menu.
5. Push key F1 INC and you will enter the menu: CURRENT - PRESSURE
INCREMENT CURVE.
6. If necessary push key F1 to switch from the pressure to the current
increment curve.
7. Push arrow key to move the cursor to the end of the x-axis
(parameter CNT: 1000).
8. Push arrow key or + key to move the cursor along the y-axis to the
value 50% (parameter INC: 50%).
9. Press key F2 INTERP to interpolate the axes origin and the defined point
10.Press ESC key in order to return to the previous menu
11.Push key F2 SAVE in order to dedicate the increment curve to Stepper 2.
Following graph shows the page with the increment curve:
Current
CNT : 1000
INC : 50
PAGE+
INTER
GF WELDING
5-17
Programming instructions
Stepper programs
5.6.7
Tabular method may be applied both for Current and Pressure Increment.
A Tabular increment cannot be converted into a Graphic increment and vice
versa; if a stepper program is edited and the method is changed, when
saving the change, the increment curve will be cleared.
GFX
TAB
: Dressing 1
Prewarning__: 00000
:
Pt.x Pieces____: 000
Stop_______: 00000
Dressing____: 000
Pt.x Emergency_: 00
Offset______: 00000
: OFF
INC
SAVE
STP -
5-18
GF WELDING
STP +
ETC
Programming instructions
Stepper programs
5.6.7.1
00000
00%
(25)
------------------------
PAGE +
Programmable step
Select current/pression
5.6.7.2
Cursor
CURRENT
CNT :
INC :
02325
03%
5 6
3
2
1
PAGE +
-------------------------
1:
2:
3:
4:
5:
6:
CNT=
CNT=
CNT=
CNT=
CNT=
CNT=
2325
4600
4925
5100
7000
8000
INC=
INC=
INC=
INC=
INC=
INC=
GF WELDING
5-19
3%
5%
6%
7%
8%
9%
Programming instructions
Stepper programs
WHITE PAGE
5-20
GF WELDING
Programming instructions
Welding analysis and I/O status
<F4 TRACE>
6 TRACE menu
In the TRACE menu are displayed:
F2 I/O:
F3 TEST:
F4 PRINT:
F1 PROG
On this page to most important data of the last welding are shown.
The page SPOT TRACE looks as follows:
P :0 4 : S E IT E N T :
C o n s t. c u rr.
SPO T TRACE
C y c le s : 6
I P rg : 9 .0
I N o m : 9 .4
I . M is :
9 .4 k A
S tp :1
C n t :1 1 2 1
In c % :4
P rs 1 :0
P rs 2 :0
C P h i :0 .9 3
E000 - OK
N u m b e r o f th e
w e ld in g p u ls e
(m a x im u m 9 )
A re a w h e re a n e rro r
m e s s a g e w ill b e
d is p la y e d d u rin g
w e ld in g .
GF WELDING
6-1
Programming instructions
Welding analysis and I/O status
6.1.1
6.1.1.1
(01 255)
Description:
6.1.1.2
Program name
[:]
Parameter:
Range:
Description:
6.1.1.3
Welding mode
[:]
Parameter:
Presettings:
Description:
6.1.1.4
Description:
6.1.1.5
Range:
Description:
6-2
GF WELDING
Programming instructions
Welding analysis and I/O status
6.1.1.6
Range:
Description:
6.1.1.7
[ I. Mis:
kA ]
Parameter:
Range:
(000.0 150.0)
Description:
6.1.1.8
(Unit = kA)
(0 16)
Description:
6.1.1.9
(0 65500)
Description:
6.1.1.10
[ INC% : ]
Parameter:
Range:
(0 60)
Description:
6.1.1.11
[ Prs1: ]
Parameter:
Range:
(00.00 30.00)
Description:
(Unit = kN)
GF WELDING
6-3
Programming instructions
Welding analysis and I/O status
6.1.1.12
[ Prs2: ]
Parameter:
Range:
(00.00 30.00)
Description:
(Unit = kN)
6.1.1.13
CosPhi
[ CosPhi: ]
Parameter:
Range:
(0.25 0.99)
Description:
6-4
GF WELDING
Programming instructions
Welding analysis and I/O status
F2 I/O
On this page all logic states of all Inputs and Outputs of the control are
shown.
The page I/O TRACE looks as follows:
I/O Trace
Input
Start
0 0 000000 0
Valves
00 0
0 00 00
W.Cycle
00000 0000
000 0 0
Alarms
000 0
Stepper
00 0 0
00 00 00
Other
0 00 0 00 000
000
Output
Start
0
CEVASB
CODE4
CODE3
CODE2
CODE1
CODE0
CODEP
CEVASA
Valves
CODE5
STARTB
STSERV
W.Cycle
REPEAT
SOLOPR
SALDAJ
CONSALD
0
ENDCYCL
TSCR
PRESS
FLUSS
RESAH
Alarms
0
RESALSA
Stepper
RESALSB
RAVOK
CHGOK
Other
SAF. M
SAF. A
SAF. B
+24V
CONDUZ
PRESV
SPARE
SPARE
SPARE
Start
EVSA/B
Valves
EVPA
0
RICHSALD FINESALD
W.Cycle
EVPA
FINESEQ
EVASA
UNDCURR
OVRCURR
ALARM2
WALLSTA
Stepper
WALLSTB
0
ALLSTA
0
SPARE
RICHRAV
RICHEL
SPARE
ALLSTB
0
SPARE
Other
STATUS
ALARM1
Alarm
EVASB
Remark: The output EVS in the second line shows the logic state of the OR
of the outputs EVSA and EVSB.
GF WELDING
6-5
Programming instructions
Welding analysis and I/O status
6.2.1
Abbreviation Description
Typology
+24V
24Vdc present
Logic input
ADR0
Logic input
ADR1
Logic input
ADR2
Logic input
ADR3
Logic input
ADR4
Logic input
ADRP
Logic input
ALARM1
Weld alarm
Logic output
ALARM2
Hardware alarm
Logic output
ALLSTA
Lifetime A
Logic output
ALLSTB
Lifetime B
Logic output
CEVASA
Logic Input
CEVASB
Logic Input
CHGOK
Logic Input
CODE0
Logic Input
CODE1
Logic Input
CODE2
Logic Input
CODE3
Logic Input
CODE4
Logic Input
CODE5
Logic Input
CODEP
Logic Input
CONSICA
Release channel A
Logic Input
CONSICB
Release channel B
Logic Input
CONSALD
Weld enable
Logic Input
Logic Input
Logic Input
COSPHI
ENDCYCL
EVASA
EVASB
Logic output
Logic output
Logic output
EVPB
6-6
EVPA
Logic output
GF WELDING
Programming instructions
Welding analysis and I/O status
Abbreviation
Description
Typology
EVSA
Logic output
EVSB
Logic output
FINESALD
Logic output
FINESEQ
Logic output
I/VSERV
MODO320
Logic input
OVRCURR
E006 OVERCURRENT
Logic output
PRESV
VOLTAGE AT SCR
Logic input
RAVOK
Logic input
READY
READY
Logic output
REPEAT
REPEAT MODE
Logic input
RESAH
ERROR RESET
Logic input
RESALSA
Logic input
RESALSB
Logic input
RICHEL
Logic output
RICHRAV
Logic output
RICHSALD
Logic output
SALDA SI
WITH CURRENT
Logic input
SOLOPR
ONLY PRESSURE
Logic input
STARTA
START CHANNEL A
Logic input
STARTB
START CHANNEL B
Logic input
STATUS
Logic output
STSERV
PRESSURE OK SERVOVALVE
Logic input
TSCR
OVERTEMPERATURE SCR
Logic input
UNDCURR
E005 UNDERCURRENT
Logic output
WALLSTA
PREWARNING STEPPER A
Logic output
WALLSTB
PREWARNING STEPPER B
Logic output
GF WELDING
6-7
Programming instructions
Welding analysis and I/O status
F3 TEST
When a card type F388-IOE is present in the control, the special function "Test
lamp" is enabled.
This test enables the outputs:
Number
Description
P39-1
Gun 1 Warning
P39-2
Gun 2 Warning
P39-3
P39-4
P39-5
P39-6
P39-7
P39-8
These are enabled for 5 seconds, after which they return to their pre-test
status.
The Test lamp function is performed after confirmation, with the ENT key on
the mini-keyboard.
After the test, the TRACE menu screen appears on the mini-keyboard.
6-8
GF WELDING
Programming instructions
Diagnostic and alarm history
<F1 Alarms>
7 ALARMS menu
A logfile is written in the menu ALARMS.
P00
Tu 10/02/1998 14:35:32
39
P02
Tu 10/02/1998 09:54:44
38
P08
37
P04
36
P05
35
P00
E074-Card on/reset
34
P00
Fri06/02/1998 14:23:56
33
P08
Fri06/02/1998 10:43:03
32
P08
Fri06/02/1998 09:56:54
31
P04
Fri06/02/1998 05:32:32
Column A:
Column B:
Column C:
Column D:
GF WELDING
7-1
Programming instructions
Diagnostic and alarm history
ALARM HISTORY
40
39
38
37
36
RESET
P00
P02
P08
P04
P05
F1 RESET:
RES-RS
F3 RES-RS:
7-2
GF WELDING
Programming instructions
Diagnostic and alarm history
7.1.1
is
cis
pr
Software parameters
GF WELDING
7-3
Programming instructions
Diagnostic and alarm history
7.1.2
Description
Activated output
Reset
E001
WALLSTA
cis - is
E002
WALLSTB
cis - is
E003
cis
E004
cis
E005
UNDCURR - ALARM1
a-c-i
E006
OVRCURR - ALARM1
a-c-i
E007
E011
ALARM1
a-c-i
E015
ALARM1
a-c-i
E031
UNDCURR - ALARM1
a-c-i
E032
UNDCURR - ALARM1
a-c-i
E045
cis
E046
cis
E047
cis
E048
ALARM1
E049
ALLSTA
cis - is
E050
ALLSTB
cis - is
7-4
cis
GF WELDING
Programming instructions
Diagnostic and alarm history
7.1.3
Description
Activated
output
Reset
Abort
E052
ALARM2
c-i
E053
E055
E056
E057
E058
E059
E060
E061
E062
E063
E065
E066
E067
E070
E073
E074
E075
E076
E077
E078
E079
E080
E081
E082
E083
E084
E085
E086
E087
E088
E089
E091
E092
ALARM2
ALARM2
ALARM2
ALARM2
ALARM2
ALARM2
ALARM2
ALARM2
ALARM2
ALARM2
ALARM2
ALARM2
ALARM2
ALARM2
ALARM2
ALARM2
ALARM2
ALARM2
ALARM2
ALARM2
ALARM2
n
c-i
c-i
a-c-i
a-c-i
a-c-i
a-c-i
a-c-i
a-c-i
a-c-i
a-c-i
cis - is
cis - is
n
a-c-i
a
a-c-i
a-c-i
c-i
a-c-i
a-c-i
a-c-i
a-c-i
n
a-c-i
a-c-i
c-i
c-i
c-i
c-i
c-i
pr
c-i
Y
Y
Y
Y
Y
N
Y
Y
Y
Y
N
N
Y
N
N
Y
N
Y
N
Y
N
N
Y
N
N
Y
Y
Y
Y
Y
Y
Y
E093
Output overcharge
ALARM2
c-i
ALARM2
ALARM2
ALARM2
E094
ALARM2
c-i
E095
ALARM2
c-i
E098
ALARM2
c-i
E099
E100
ALARM2
ALARM2
c-i
c-i
Y
Y
GF WELDING
7-5
Programming instructions
Diagnostic and alarm history
7.1.4
Description
7-6
Activated output
Reset
Abort
SGDNC-SGDNO
SGDNC-SGDNO
GF WELDING
Programming instructions
Diagnostic and alarm history
RESAH
(Error Reset)
WELD
334m
ALARM1
(Abnormal welding)
ALARM2
(HW Alarm)
UNDCURR
(E005 Meas. Curr.< min threshold)
OVRCURR
(E006 Meas. Curr.< max threshold)
SGDNC
SDCOM
SGDNO
GF WELDING
7-7
Programming instructions
Diagnostic and alarm history
WHITE PAGE
7-8
GF WELDING
Programming instructions
Report
8 Menu REPORT
<F5-ETC F2-REPORT>
Menu REPORT offers the option, to display and statistically collect certain
error messages and the number of spot welds during the last 24 hours.
For improvement of product quality interruptions should be statistically
analysed.
This analysis is done for each program within a defined range of time.
This analysis refers to the frequency of specified errors (see section 3.3)
and refers to the assigned welding programs.
A good understanding of the reports is necessary to correct the welding
parameters, which are cause of the errors.
The reported data must be printed out after completion, because the old
data will be deleted by the data of the new report the day after.
In menu REPORT following settings can be done:
input name of 3 programmable reports
input begin and end of 3 programmable reports
Following data are displayed, which refer to the defined time range:
number of spots executed by each welding program
total number of welds executed by each welding program (the welding
control counts the execution of only one weld also for programs
consisting of several impulses)
number of messages 'Process diagnostics', which was programmed for
each welding program.
Total number of error messages, which were configured.
Bar graph with the number of messages 'Diagnostics' configured during
the running of the single program
Date and time of the reported events
GF WELDING
8-1
Programming instructions
Report
8.1
Define Reports
If no inputs have been done, the REPORT page where the 3 configurable
reports are entered, looks as follows:
REPORT
Name
> First Shift
Second Shift
Third Shift
Start
06:00:00
14:00:00
22:00:00
End
13:59:59
21:59:59
05:59:59
F4 PRINT:
F5 MODIFY:
Arrow keys : Moves the cursor (>) up or down, to select the report,
which shall be edited by using the keys F1, F4, F5.
ESC key:
F5 MODIF
arrows :
keys + -:
F5 SAVE:
ESC key:
8-2
GF WELDING
Programming instructions
Report
F1
VIEW
Check date and time displayed on the control (see section 2.1.1.4)
Set time for start and end of the report (see section 8.2)
Set the Diagnostics messages, which shall be analysed, in menu SETUP ALARMS CONFIGURATION (see section 3.3.2).
Some error messages (E001 - E002 - E003 - E004 - E046 - E047 - E049 E050) will not increase the counter, even they are shown in menu SETUP ALARMS CONFIGURATION. For these messages no bar graphs will be
created.
Referring to electrode- and cable wear these error messages have no effect
on the statistical analysis of the abnormal weldings.
These error messages are found in the SETUP ALARM CONFIGURATION
Menu only because they must be configured as Abort functions (refer to
section 3.3.2).
Page VIEW REPORT may look as following:
Example: REPORT
The box shows the program, which relates to the bar graph.
CNT: number of welds, executed by the welding program during the specified
range of time.
TOT: number of welds, executed by all welding programs during the specified
range of time
Name of the report (1-2-3) date and time of start, date and time of
the end of the report.
REPORT 2
P:01:TEST 111
Start
28/04/98
14:00:00
End
28/04/98
21:59:59
FINISHED
Actual status of the report.
3 states are possible:
FINISHED
RUNNING
EMPTY
CNT:52
TOT:239
E005:15
GF WELDING
8-3
Programming instructions
Report
Now it can be compared, how often the error messages occurred, which
were specified in the menu SETUP - ALARMS CONFIGURATION (only 4 with
increased counter).
The analysis is done 16 hours after 21:59:59 of 28/04/98, because
REPORT2 is finished and not deleted yet.
Program P:01, which is called TEST111, has executed 52 spots out of totally
239 spots.
The star (*) selects the first bar of the graph, which is assigned to error
message E005, which occurred 15 times in the given time range.
Further information about the messages, which must be selected by the
star, can be shown using the ENT key. A window will overwrite the
displayed report.
REPORT 2
Start
28/04/98
14:00:00
End
28/04/98
21:59:59
FINISHED
P:01:TEST 111
CNT:52
E005:Meas.curr.< min
threshold TOT:73 TOT:239
E005:15
keys + -:
arrows :
ENT key:
ESC key:
8-4
back to REPORT
GF WELDING
Programming instructions
Memory Card Menu
<F5-ETC F1-CARD>
The control offers a plug, where e Memory card type PCMCIA can be
inserted. This card is delivered by Co.GF WELDING S.p.A.
Memory card is an ancillary device which allows saving or loading 2 types of
data concerning the welding control operation.
The operational limitations of the Memory Card (battery, temperature,
magnetic field) are provided by the maker and must be considered.
Following data deal with the Memory Card:
The window MEMORY CARD looks as following (in case no MEMORY CARD is
inserted into the control):
MEMORY CARD
WELD 334m
CARD
Module Name
FASE 334m
Card name
???????????
GF WELDING
9.1
Programming instructions
Memory Card Menu
MEMORY CARD
Module - name
FASE 334m
WELD 334m
Card name
Rel 1.1
CARD
UPGRADE
FORMAT
The arrow indicates the
direction of data
transfer (from Mem ory
card to the control )
The indicates,that
the Mem ory Card is
write protected.
F4 FORMAT:
formats the card and all data on the Memory Card will be
deleted.
ESC key:
on
the
control
(see
menu
insert the Memory Card into the control (Card name must be Rel 1.1)
9.2
GF WELDING
Programming instructions
Memory Card Menu
Example: Format Memory Card
During format all data on the Memory Card will be deleted. After format,
the Memory Card is prepared for new applications.
The write protection switch on the Memory Card shall not be in position
WRITE PROTECT.
To format the Memory Card proceed as following:
Confirm?
[ ENT = YES / ESC = NO ]
Weld program
Stepper
Setup
Report
Loading the programs from the memory card to the welding control allows
resetting all of operational data to the original situation when Save function
was performed.
MEMORY CARD
Module Name
FASE 334m
WELD334m
Card Name
CARD
SAVE
Rel 1.1
LOAD
FORMAT
RUN
GF WELDING
9.3
Programming instructions
Memory Card Menu
Function keys of menu MEMORY CARD with Program Card
If a Memory Card with program is inserted in the control, following keys are
available:
F1 SAVE:
F2 LOAD:
F4 FORMAT:
formats the card and all data on the Memory Card will be
deleted.
F5 RUN:
Start of operation.
ESC key:
Key :
insert the Memory Card into the control (No card name )
Press key F1 SAVE. The arrow, which shows the direction of dataflow
,looks to memory card symbol (see section 9.1).
Press key F5 RUN .Operation is started (at the end of Save function, the
Card name is the same as Module Name).
insert the Memory Card into the control (card name occurs)
Press key F2 LOAD. The arrow , which shows the direction of dataflow
,looks to control symbol (see section 9.1).
Press key F5 RUN .Operation is started (at the end of Save function, the
Module Name is the same as Card Name).
9.4
Reset the welding control at the end of operation (to do this, press the
push button located on the front part of the control or power off).
GF WELDING
Programming instructions
APPENDIX
APPENDIX
GF WELDING
Programming instructions
APPENDIX
GF WELDING
Programming instructions
Appendix A - Operating diagrams
Appendix A
Operating diagrams
GF WELDING
Programming instructions
Appendix A - Operating diagrams
OFF STATE 0V
SQUEEZE
PRESSURE
1 HALFCYCLE TRIGGERS AT 90
WELDING
N6 WELDING-R CYCLES
NORMAL
N3 WELDING-R CYCLES
N 1 CYCLE-R INTERVAL
N 2 CYCLES-R WELD.
N 3 CYCLES-R WELD.
N 2 CYCLES-R INTERVAL
N 1 CYCLE-R INTERVAL
N 1 NETW.CYCLE
WELDING
ALARMS
HOLD
OPEN
PRESSURE TEST
RIPEAT ?
DIAGRAM
N 2
SI
NO
END OF SEQUENCE
WELDING
REQUEST
10 mSec before
END OF
WELDING
ELVS A / B
SOLENOID VALVE GUN
CLOSING
IMPULSE
=TIME = 160mSec
File 32021820.ds4
GF WELDING
Programming instructions
Appendix A - Operating diagrams
CYCLE START
PROGRAM
CODES
ON STATE +24V
OFF STATE 0V
SQUEEZE
PRESSURE
1 HALFCYCLE TRIGGERS A
NORMAL WELDING
N6 WELDING CYCLES-R
N3 WELDING CYCLES-R
N 1 INTERVAL CYCLE-R
N 2 CYCLES-R WELD.
N 3 CYCLES-R WELD.
N 2 INTERVAL CYCLES-R
N 1 INTERVAL CYCLE-R
N 1 NETWORK CYCLE
WELDING
ALARMS
HOLD
OPEN
YES
RIPEAT ?
YES
NO
START?
NO
END OF SEQUENCE
WELDING
REQUEST
10 mSec before
END OF
WELDING
ELVS A / B
CLOSE ELECTROVALVE
GUN
file:32021821.DS4
GF WELDING
Programming instructions
Appendix A - Operating diagrams
PRESSURE
WELDING
N6 WELDING R-CYCLES
STANDARD TYPE
ONE PULSE
N3 CYCLES-R SLOPE-UP
STANDARD TYPE
WITH SLOPE UP AND DOWN
N 1 CYCLE-R INTERVAL
NORMAL PULSES TYPE (N4)
N 3 WELDING R-CYCLES
N 1 CYCLE-R INTERVAL
N3 CYCLES -R DI SLOPE-DOWN
N 5 WELDING R-CYCLES
N 3 CYCLES -R SLOPE-UP
1 IMPULSE:
- N3 WELDING R-CYCLES.
- N 1 CYCLES -R INTERV.
-6400 Aeff WELDING CURRENT
2 IMPULSE:
-N7 WELDING R-CYCLES
-N4 CYCLES -R SLOPE-UP
-N2 CYCLES INTERVAL
- 9500 Aeff WELDING CURRENT
3 IMPULSE
-N 10 WELDING R-CYCLES
-N 3 CYCLES SLOPE-UP
-N 3 CYCLES SLOPE-DOWN
-N1 CYCLES -R INTERVAL
- 5500 Aeff WELDING CURRENT
HOLD
OPEN
END OF SEQUENCE
ELVS A / B
ELECTROV. CLOSE
GUN
File:32021822 DS4
GF WELDING
Programming instructions
Appendix A - Operating diagrams
PREWARNING
MACHINE STOPPED
Current increment
Program Parameters
Offset = 12
Prewarning = 95%
Warning = 2000
Emergency spots = 20
Number of dressing = 2
CNT OFFSET
CNT OFFSET
Prewarning (E01&02)
Outs = PREALLSTA,B
100 mSec
SPOT COUNTER
2001
2000
DRESS COUNTER
2001
12
2020
2000
2010
CYCLE OK
CYCLE NOK
12
1701
2020
1700
2001
2010
2000
CYCLE OK
File:32021823.ds4
GF WELDING
Programming instructions
Appendix A - Operating diagrams
MACHINE STOPPED
STEPPER ALARM
Current Increment %
PREWARNING
Program Parameter
Offset = 12
Prewarning = 95%
Warning = 2000
Emergency Spots = 20
Number of dressing = 2
CNT OFFSET
CNT OFFSET
Prewarning (E01&02)
Outs = PREALLSTA,B
Warning (E49 &E50)
Outs = ALLSTA/B
Tip dressing request
Out = RICHRAVV
Confirmation tip dressing
Input = RAVOK
xxxxxxxx
100 mSec
100 mSec
SPOT COUNTER
100 mSec
12
2001
2000
DRESS COUNTER
12
1701
2010
CYCLE OK
1700
2001
2000
2020
CYCLE NOK
0
2000
12
2001
2020
2010
CYCLE OK
GF WELDING
Programming instructions
Appendix A - Operating diagrams
WARNING
PREWARNING
Program Parameters
Prewarning = 1900
Warning = 2000
Emergency spot = 20
Spot x dress = 200
Prewarning (E01&02)
Outs = PREALLSTA,B
Warning (E49 &E50)
Outs = ALLSTA/B
Tip dressing request
Out = RICHRAVV
Confirm. tip dressing
Input = RAVOK
100 mSec
100 mSec
SPOT COUNTER
211
201
200
401
400
210
420
420
421
1901
1900
2000
2001
2010
DRESS COUNTER
CYCLE OK
CYCLE NOK
CYCLE OK
In case of situation "confirmation electrode exchange" timing & procedure are the
same of type dressing 1
GF WELDING
Programming instructions
Appendix A - Operating diagrams
START CYCLE
SQUEEZE.
PRESSURE
1 HALF CYCLE TRIGGERS AT 90
WELDING
STANDARD TYPE
ONE PULSE
N3 CYCLES-R SLOPE-UP
STANDARD TYPE;
WITH SLOPE UP
N 2 CYCLE-R INTERVAL
NORMAL PULSES TYPE
N 1 CYCLE-R INTERVAL
N3 welding cycles
1 is SLOPE-UP
SPECIAL PULSES
MODE (MAX n 4)
1 IMP.S.
3 IMP.S.
4 IMP.S.
2 IMP.S.
WITHOUT
SLOPES
Program code
UNTIL END
OF WELDING
Progr # 1
Progr # 3
Progr # 1
Progr # 4
CODE
CHANGE
PGM
WITH SLOPE
BETWEEN CURRENTS
CODE
CHANGE
PGM
HOLD
OPEN
160 mSec
END OF SEQUENCE
ACTIVATION ALARM
WELDING DIAGNOSIS
Example of
Moment of event generation
ELVS A / B
ELECTROV. GUN
CLOSE
GF WELDING
Programming instructions
Appendix A - Operating diagrams
GF WELDING
Programming instructions
Appendix A - Operating diagrams
10
GF WELDING
Programming instructions
Appendix B Diagnostics Alarms: causes and remedies
Appendix B
DIAGNOSTICS ALARMS
GF WELDING
Programming instructions
Appendix B Diagnostics Alarms: causes and remedies
GF WELDING
Programming instructions
Appendix B Diagnostics Alarms: causes and remedies
Description of alarms
Code
message
remarks
activities
Indication that tip change or
dress on channel A must be done
soon
E003 Warning
E004 Warning
The measured current value was ntimes between %I.min and %I.lim
( n = programmed numbers of weld
alarm threshold )
The red LED LOW CURR on frontpanel
is on.
Possible reasons :
channel A
channel B
threshold cable
channel A
threshold cable
channel B
threshold
Possible reasons:
prewarning threshold
reached.
Possible reasons:
Too high stepper incrementation
High voltage drop
Tips damaged., wear in secondary
loop ,
cable wear , bad contacts.
Power of transformer insufficient.
Wrong cosphi programming
( not in cc mode )
GF WELDING
Programming instructions
Appendix B Diagnostics Alarms: causes and remedies
Code
message
remarks
activities
Check air pressure and electrode
force system
Do maintenance
Reset dressing tool counter in
HHT
channel A
channel B
weld channel B
configuration
channel A
E052 Communication
anomaly with
remote CPU
An error or a complete
Check connection between
communications failure has been
control and remote CPU
found with the remote CPU. This alarm
Check possible communication
is only diagnosed in systems in which
configurations (jumpers,
the welding control is in
parameter settings, etc.)
communication with another process
Check correct operation of
control (eg. a robot)
remote CPU
GF WELDING
Programming instructions
Appendix B Diagnostics Alarms: causes and remedies
Code
message
remarks
Battery is low.
The device remain on alarm condition
permanently (the red LED on the CPU
card is on).
No alarms outputs are activated ; a
message is sent to the WMS ; the
control continue its activity.
Resistance of current sensor too high
( >30 )
Possible reasons :
Broken cable
Sensor defect
Control defect
activities
Check
value :
Check
Check
Check
Check
Check
Check
Sensor defect
Earth fault
Control defect
Wrong polarity
This message blocks start.
Null current detected on one or both
the conduction half-cycles.
Possible reasons
Wrong polarity
This message blocks start.
The signal PRESENZA
DISGIUNTORE is absent (only for
controls responding to CNOMO
normative.)
Check wiring
Check firing board
short circuit
missing
coil resistance
cable and connectors
control
sensor
E062 InterbusS
Check connection
fails
communication
fail
internal reasons.
Possible reasons:
Board broken
Break down on optical transmission
line
GF WELDING
Check program
Programming instructions
Appendix B Diagnostics Alarms: causes and remedies
Code
message
remarks
For the used Stepper, after Stop
threshold has been reached, the
number of emergency spot has been
expired, without confirmation of the
required tip maintenance operation
(Tip Dressing Request).
activities
Execute tip maintenance activity
as required, and confirm
operation activating Tip Dressing
Done confirmation.
alarm on
E073 Initialized
module
ON (Reset)
corrupted
data
corrupted
GF WELDING
Programming instructions
Appendix B Diagnostics Alarms: causes and remedies
Code
message
remarks
activities
Check correspondence
between device address set
in the setup and the address
set by dip-switch or
jumpers.(see the
documentation for the 334
network card).
Set Parity to OFF (Warning :
in this case, an error reading
the card code is not
detected).
corrupted
data corrupted
synchronization
input
Check voltage
If the error persists, contact
technical assistance at GF
WELDING S.p.A.
data corrupted
corrupted
Inverter
The inverter detected a failure in its
system
E086 SCR
Possible reasons :
Defective thermostat.
Defective thermostat.
GF WELDING
Check waterflow
Check cable and connections
Programming instructions
Appendix B Diagnostics Alarms: causes and remedies
Code
message
remarks
activities
Check waterflow
Check cable and connections
Ensure that the flowmeter is
functioning properly. (Check
that the H2O green led on
front panel is on)
not active
active
enabled
modules.
E094 Spot-Index data The autodiagnostic function that runs If the error is repeated contact
corrupt
E095 Spot-Index
valid
E098 4-20mA
E099 Electrode
servovalve
command
anomaly
maintenance
anomaly
E100 Emergency
activated
GF WELDING
Programming instructions
Appendix B Diagnostics Alarms: causes and remedies
Code
message
remarks
SCR defect
Broken cables
Earth fault
Wrong connections
Defect control
time is out-of-range.
activities
GF WELDING