05en - FiliusACS X Multi IQ - Operating Instructions PDF

Welding Control System
FiliusACS
FiliusACS-B-Multi-IQ | FiliusACS-C-Multi-IQ
Operating instructions
35174-05en
Imprint
Harms & Wende GmbH & Co. KG
Grossmoorkehre 9
D-21079 Hamburg
Germany
Tel.: +49 40 766 904-0

Fax.: +49 40 766 904-88
E-mail: hwh@harms-wende.de
Internet: www.harms-wende.de
Representative managing director:

Ralf Bothfeld
All rights reserved.

Reproduction of this technical documentation, including excerpts, regardless of the method,
is prohibited without prior written agreement by Harms & Wende GmbH & Co. KG. Violations
obligate the perpetrator to damage compensation payments. All rights reserved in the event
of patent issue or utility model registration.
We reserve the right to make changes to the content of the documentation and the availa-
bility of the products without prior notification. The original document is in German (national
language of the manufacturer). All translations are copies of the original document. Technical
changes reserved.
Liability exclusion
All data refer to systems and machines with average utilisation. In case of doubt, contact our
HWH service department, tel.: +49 40 766 904-84.
Harms & Wende accepts no liability for damage caused through the installation and ope-
ration of other software applications.
2 35174-05en | 2016-01 | FiliusACS-B-Multi-IQ | FiliusACS-C-Multi-IQ | Operating instructions

Contents
1 Introduction 9
1.1 About this documentation 9
1.2 Typographical conventions 10
2 Description of the device family 13

3 Device description 15
3.1 Proper use 15
3.2 Labelling 16
3.3 Structure 17
3.4 Operating elements 19
3.5 Status LEDs 19
3.6 Display 20
3.7 USB connection 21
3.8 Operating conditions 21
4 Safety 23
4.1 Basic notes 23
4.2 Personal protection 24
4.3 Safety instructions for service and maintenance work. 24
4.4 Device protection 25
5 Delivery 27
5.1 Delivery scope 27
5.2 Delivery 27
6 Transport 29
6.1 Internal 29
6.2 Return transport/shipping 29
7 Assembly 31
7.1 Installation 31
7.2 Supply voltage 32
7.3 Solenoid valve voltage 32
7.4 Functional earth connection 32
7.5 Connection of the plugs 33
7.6 Interference suppression 33
8 Commissioning 35
9 Operation 37
9.1 Switching on the module 37
35174-05en | 2016-01 | FiliusACS-B-Multi-IQ | FiliusACS-C-Multi-IQ | Operating instructions 3

9.2 Mains frequency detection 37
9.3 Status display 38
9.4 Display elements 38
9.5 Menu structure overview 41
9.6 Menu selection 42
9.6.1 Parameter menu selection 42
9.6.2 Selecting the configuration menu 42
9.6.3 Selecting a sub-menu 42
9.7 Value input 42
9.8 Text input 43
9.8.1 Inputting text 44
9.8.2 Ending text input and discarding the change 45
9.8.3 Ending text input and saving the change 45
10 Configurations 47
10.1 Program administration 47
10.2 Process configuration 50
10.2.1 Electrode management 50
10.2.2 Settings forwelding parameters 52
10.2.3 Squeeze time configurations 53
10.2.4 Start of squeeze time 54
10.2.5 Start interlock 55
10.2.6 Program selection 55
10.2.7 Electrode exchange configuration 56
10.2.8 Stepping contact function 56
10.2.9 Configuration of the travel sensors 57
10.2.10 Proportional valve value for calibration 58
10.2.11 Configuration for proportional valve values 58
10.2.12 Configuration of interlock addition/mains load limitation control 59
10.2.13 Pre-stroke solenoid valve 60
10.2.14 Power settings 60
10.2.15 Select time basis 62
10.2.16 Maximum time inputs 62
10.2.17 Control system behaviour in the event of welding errors 63
10.3 Comparison and service 65
10.3.1 Calibrate travel sensor 1 65
10.3.2 Force calibration 67
10.3.3 Reset controller 70
10.3.4 Measuring coil comparison 70
10.3.5 Mains voltage comparison 71
4 Operating instructions | FiliusACS-B-Multi-IQ | FiliusACS-C-Multi-IQ|2016-01 | 35174-05en

10.4 Module configuration 72
10.4.1 Set date/time 72
10.4.2 Select language 72
10.4.3 Keyboard lock 73
10.4.4 Set contrast 73
10.4.5 Module name 74
10.4.6 Delete log book 74
10.4.7 Define CAN node 74
10.5 Filius information 74
10.6 Firmware update 75
11 Parameterising the welding process 79

11.1 General information on resistance welding 79
11.2 Welding process 82
11.3 Sequence program 84
11.4 Selecting a program 85
11.5 Edit program 85
11.6 Program configuration 86
11.6.1 Order 86
11.6.2 Regulation type 86
11.6.3 Operating mode 87
11.6.4 Proportional valve 90
11.7 Parameters 91
11.7.1 First extended squeeze time 91
11.7.2 Squeeze time 92
11.7.3 Pre-heating 93
11.7.4 Main current time 94
11.7.5 Post-heating 100
11.7.6 Hold time 102
11.7.7 Open time 103
12 Device functions 105

12.1 Constant current regulation (KSR) 105
12.2 With current 106
12.3 IQ monitoring function IQ monitoring function 106
12.3.1 Parameterise IQ monitoring function 106
12.3.2 IQ parameters 107
12.3.3 Current measurement 107
12.3.4 Measuring time 108
12.3.5 Delay 108
12.3.6 Tolerances 108

12.4 Travel measurement 109
12.4.1 General information on travel measurement 110
12.4.2 Prerequisite 111
12.4.3 Component control 111
12.4.4 Sink-in travel monitoring 112
12.4.5 Final dimension monitoring 113
12.4.6 Profile indexing 115
13 Pin assignment 119

13.1 Pin assignment 1 120
13.2 Pin assignment 2 121
13.3 Position of the connections 122
13.4 Notes on the connections 123
13.4.1 24 V input connection wiring diagram 123
13.4.2 24 V output connection wiring diagram 123
13.4.3 Connection wiring diagram for proportional valve outputs 124
13.4.4 Connection wiring diagram for current sensor 124
13.4.5 Connection wiring diagram for voltage supply and power stages 125
13.4.6 External CAN bus connection 125
14 Input/output signals 127

14.1 Emergency stop 127
14.2 Start 1 and 2 127
14.3 Operational message 127
14.4 Stepping contact 128
14.5 Pressure contact 128
14.6 Current end 128
14.7 Temperature 128
14.8 Water flow OK 128
14.9 With current 128
14.10 Pre-stroke 129
14.11 Program selection 129
14.12 Solenoid valve 129
14.13 Deleting a spot counter 129
14.14 Error reset 129
14.15 Max. spot number reached 129
14.16 VZ = interlock addition/NBS = mains load limitation control 130
14.17 Limit value error 130
14.18 Pre-stroke solenoid valve 130
15 Data back-up 131

16 Maintenance 133
16.1 Maintenance 133
17 Storage 135
18 Disposal 137
19 Technical data 139
19.1 Basic settings on delivery 140
19.2 Default settings 141
19.3 Dimensions 142
20 Module messages 145

20.1 Flow monitor 145
20.2 Thyristor / transformer temperature 146
20.3 Controller error upper stop 147
20.4 Electrode exchange 148
20.5 Upper limit value 148
20.6 Lower limit value 149
20.7 Withdraw Start1 149
20.8 Withdraw Start2 150
20.9 Synchronisation error 150
20.10 No current measurable 151
20.11 Withdraw external current end 151
20.12 Emergency stop 152
20.13 Mains voltage error 152
20.14 Component error during travel measurement 153
20.15 Measuring coil comparison 153
20.16 Sink-in travel error during travel measurement 154
20.17 Final dimension error during travel measurement 154
20.18 No pressure contact/NBS 155
20.19 Acknowledging module messages 156
21 Appendix 157
21.1 Update service 157
21.2 EU declaration of conformity 158
21.3 Abbreviations 161
21.4 Table of figures 165
21.5 List of symbols 170
21.6 Index 173

8 Operating instructions | FiliusACS-B-Multi-IQ | FiliusACS-C-Multi-IQ | 2016-01 | 35174-05en
1 Introduction
1 Introduction
1.1 About this documentation

These operating instructions are intended to help you use your Harms & Wende module.
This documentation must be constantly available at the module's operating location.
Complete documentation
These operating instructions form part of the FiliusACS-B-Multi-IQ | FiliusACS-C-Multi-IQ
scope of delivery. The two welding control systems differ only as regards the design of their
fronts. In the following text, "FiliusACS"- is written for both welding control systems. For the
different dimensions, see Dimensions, p. 142.
The complete documentation (depending on equipment) is comprised as follows:
l Operating instructions
The complete documentation is available in the download section at www.harms-wende.de
or will be provided upon request. Registration is required to use the download area.
Target group
These operating instructions are aimed at trained personnel – specialist electricians or per-
sons with electrical engineering training as per DIN VDE 1000-10 – with knowledge of handling
welding system control systems. These operating instructions are not a substitute for trai-
ning.
Standards
Harms & Wende does not undertake to provide any guarantee for the completeness or cor-
rectness of laws, standards and guidelines which are mentioned or cited in these operating
instructions. Obtaining the complete, relevant, valid version of the laws, standards and gui-
delines is recommended.
Service
If you have any further questions on the content of these operating instructions or operation
of your module, contact Harms & Wende GmbH & Co. KG.
HWH Service, tel.: +49 40 766 904-84.

1 Introduction
1.2 Typographical conventions
Safety instructions
In these operating instructions, four signal words indicate different degrees of hazard.
Hazard source
Non-observance will result in death or serious injury.
l Avoidance measure
Hazard source
Non-observance may possibly result in death or serious injury.
l Avoidance measure
Hazard source
Non-observance may lead to moderate to slight physical injury.
l Avoidance measure
Hazard source
Improper handling or non-observance may lead to material damage.
l Avoidance measure
Other instructions
Certain points of these operating instructions provide separate information which is iden-
tified with the following symbol:
Note
Indicates additional important information.

1 Introduction
Danger symbols
The following symbols can be found in these operating instructions:
Danger point
Hazardous electrical voltage
Explosive substances
Warning regarding magnetic fields
Emphasised text sections

To emphasise them, I/O signals, parameters and process variables are shown within angled
brackets:
<Input signal>
Operating elements, in their function as part of the operating unit, are shown in square
brackets:
[Operating element]
The path with which a specific menu item can be selected in the operating unit is shown as fol-
lows:
M ENU LEVEL > SUB-MENU LEVEL > PROGRAM LEVEL > VALUES LEVEL.
Designation of Harms & Wende products

All Harms & Wende products are referred to generically as "modules". If reference is made to
specific products, these are designated according to their function, e.g. as "welding control
system" or "welding inverter".

1 Introduction

2 Description of the device family

The Filius control system family consists of a welding control system with operating unit.
Filius welding control systems can be combined with a variety of output stages in 10 kHz high-
frequency technology, 1 kHz medium-frequency technology and 50/60 Hz AC technology,
whereby the power stage/power unit can be set up separately from the welding control sys-
tem.
The welding control systems can be combined with the various welding technologies' power
stages to form a unit and can then be supplied as welding inverters for control cabinet instal-
lation. Using Filius RC (Remote Command) operating units and a simple connection cable,
parameterisation can also be carried out anywhere in the system.
The system designation indicates the technology for which the module is configured.
System Description
HF High-frequency (10 kHz)
MF Medium-frequency (1 kHz)
AC Mains frequency system (50/60 Hz), 1-phase
Design forms
Variant Description
I Power inverter with integrated control system and operation
S-B Welding control system without power unit (in beta format design)
S-C Welding control system without power unit (in compact format design)
In those products in which the welding control system is integrated into a power unit, the
design form of the device is determined by the construction. These welding control systems
are particularly suitable for installation in control cabinets, and are also intended for this pur-
pose. On selection of this type, specification of the power, the primary supply voltage and
the type of cooling is necessary. The function type and monitoring type must be defined in
the welding control system's characteristics.


3 Device description
The FiliusACS-B-Multi-IQ | FiliusACS-C-Multi-IQ welding control systems are microprocessor
control systems for controlling the welding process and for current regulation in combination
with a thyristor power stage.
The welding control systems are equipped with integrated control software with para-
meterisation options.
Function scope
l 2*1-16 programs
l Input of times in periods, half cycles or milliseconds (time basis configurable)
l Mains voltage compensation
l 2 start inputs
l 2 solenoid valves
l 2 proportional valves, force calibration
l Constant current regulation (KSR)
l IQ functionality
l Travel measurement
3.1 Proper use

The module controls welding tasks in the field of resistance welding.
This includes:
l Spot welding on one and two sides
l Projection welding on one and two sides
l Flash butt welding
l Upset welding
l Seam welding
l Heating.
The module is intended to be used as a component in industrial systems and machines which
are in technically flawless condition.
The modules are intended for operation in control cabinets.
The limit values specified in the technical data may not be exceeded at any time.
Any other use is not intended and is improper.

Improper use, unauthorised conversion and spare part purchasing

Improper use of and/or modifications to the hardware or software of the module, which
have not been verified and approved by Harms & Wende, may result in unforeseeable
damage.
Risks which arise in the event of improper use are the responsibility of the operator.
3.2 Labelling
On the rear of the module a type plate is mounted:
Fig. 3-1: Type plate
This specifies the name, serial number and article number of the module plus the address
and telephone number of Harms & Wende GmbH Co. KG.

3.3 Structure
Front view
Fig. 3-2: Front view of FiliusACS-C-Multi-IQ
01 Display
02 LED [Mains voltage]
03 LED [Welding current]
04 LED [Status message]
05 LED [With current]
06 Button [With current]
07 USB stick connection
08 [Folder] button
09 [Jog wheel]
10 [Cancel] button

Fig. 3-3: Front view of FiliusACS-B-Multi-IQ
01 Graphical display
02 LED [Mains voltage]
03 LED [Welding current]
04 LED [Status message]
05 LED [With current]
06 Button [With current]
07 USB stick connection
08 [Folder] button
09 [Jog wheel]
10 Button [Cancel]

3.4 Operating elements
Jog wheel
The [jog wheel] is used for navigation within the operating unit:
l Turning: moves through the menu structure or changes values
l Pressing: selects a menu item or confirms an input
Cancel
The [Cancel] button has two tasks:
l Calling the configuration menu in the status display
l Exiting a sub-menu or cancelling an input
Folder
The [Folder] button has two tasks:
l Switching between higher and lower case letters and numbers during text input
l Calling a sub-menu when backing-up programs
With current
The [With current] button switches the <With current> function on or off:
l When the <With current> function is switched on, the welding process is performed with
welding current if the input signal <With current> is also active. A welding process takes
place.
l When the <With current> function is switched off, the welding process is performed
without welding current; no welding process takes place.
3.5 Status LEDs
Mains voltage
Mains voltage
Green LED lights: mains voltage is present.
Welding current
Welding current
Red LED lights: welding current is flowing.

Status message
Status message
Red LED lights: message is available. The message can be called via the operating unit.
With current
With current
LED off: <With current> is inactive.

Yellow LED lights: <With current> is active.
Yellow LED flashes: <With current> is inactive due to an external signal.
3.6 Display
Fig. 3-4: Display
xx1 Time, see Time, p. 38.

xx2 Operating status, see Operating status, p. 39.
xx3 Welding program information, see Program information, p. 39.
xx4 Main display, see Main display, p. 40.
xx5 General information, see General information , p. 40.
xx6 Spot counter, see Display elements, p. 38.

3.7 USB connection

As the welding control system has a USB connection and an interface, data can be exchanged
with external PC software. It is also possible
l To install software updates with a USB stick
l To control access approval for specific parameter levels and functions
l To save or load welding programs
l To transfer log books on completed welding processes to a PC.
Only communication via a USB stick is supported at present. The USB stick being used may
have a maximum memory capacity of 6 GB and must be FAT32 formatted. The USB stick may
only contain files and file names which are used by the Filius welding control system. Sub-
directories are not permissible.
A file with these operating instructions in all available languages is on the USB stick as well as
the language files for setting the language, see Select language, p. 72.
3.8 Operating conditions

The module should only be operated in dry, dust-free rooms. The room temperature must
be between 5° and 50°C. The module must not be exposed to severe vibrations.


4 Safety
4 Safety
Read the safety instructions prior to installation and commissioning under all circumstances.
The operating instructions must be read and understood. Inadequately informed operators
my endanger themselves and other persons.
Note
The system's internal working, operating and safety regulations must also be observed.
4.1 Basic notes
Operator
The operator is responsible for adhering to the safety regulations. The operator is any natural
or legal person who uses the system or on whose behalf the system is used. The operator
may appoint an officer to assert his rights and perform his duties as his representative.
National safety regulations

In Germany, the requirements for persons employed in the area of electrical engineering as
per DIN VDE 1000-10 and the accident prevention regulations for electrical systems and ope-
rating equipment (DGUV-V3) must be observed.
Country-specific safety regulations, e.g. from professional associations, social insurance com-
panies, authorities for occupational safety and others must also be heeded.
Electrical safety
Work on the module may only be carried out by specialist electricians or persons with elec-
trical engineering training as per DIN VDE 1000-10.
The work that may be performed by persons who are neither specialist electricians nor per-
sons with electrical engineering training must be decided by a responsible, specialist elec-
trician.
Specialist electrician
A specialist electrician is a person who, due to his specialist training, knowledge and expe-
rience, can assess the work given to him and recognise possible dangers.
Person with electrical engineering training

A person with electrical engineering training has been instructed by a specialist electrician on
the tasks given to him and the possible dangers of improper behaviour and, if necessary, trai-
ned as well as instructed as regards the necessary safety devices and protective measures.

4 Safety
Dangers resulting from disregarding safety instructions

Failure to follow the safety instructions may pose a danger to persons as well as result in
damage to the module and/or system. Failure to follow the safety instructions renders any
damage claims null and void.
Operation in residential areas
Note
In a residential area, this module can cause high-frequency interference which may require
suppression measures.
4.2 Personal protection

All persons who install, operate or maintain or handle the module in any other manner must
observe the safety instructions contained in this documentation.
Work on the module may only be performed by specialist electricians.
Danger due to contact with electrical parts

The contact guard for live parts must not be removed.
Hazardous voltage
Electric shock with potentially fatal result.
l Maintain a safe distance.
l De-energise the system for service activities.
4.3 Safety instructions for service and maintenance work.

Service and maintenance work may only be performed by authorised and qualified specialist
electricians.
Work on the system and its components must only ever be performed when they are swit-
ched off and thus de-energised.
Hazardous voltage
Electric shock with potentially fatal result.
l Maintain a safe distance.
l De-energise the system for service activities.

4 Safety
Prior to the start of service work on electrical systems, observe the following rules under
all circumstances:
l Power down
l Secure to prevent unintentional reactivation
l Ensure that the system is de-energised
l Earth and short-circuit (at U > 1000 V)
l Cover or enclose any adjacent live parts
4.4 Device protection
Incorrect connection
The module may be damaged due to incorrect connection.
Only connect inputs with voltage corresponding to the technical data.
Module incorrectly connected

Damage to the module
l Only connect inputs with voltage corresponding to the technical data.
l Do not connect outputs to external voltages.

l Mains, intermediate circuit and transformer cables must not be connected to the +24 V
low voltage. Ensure adequate insulation.
High-voltage or insulation test

If the system's electrical equipment is subjected to a high-voltage or insulation test, all
module connections must be disconnected or removed.
System high-voltage or insulation test

Damage to the module's electronic components.
l Disconnect or remove the module's connections.

4 Safety
Electrostatic charging
Electrostatic discharging (ESD) may cause damage to the modules, .
ESD protection is required for electrostatic sensitive components (EGB)
l during packaging, transport and storage
l during work with personnel, workplaces, devices and tools coming into contact with elec-
trostatic sensitive components.
Electrostatic charging
Damage to the module's electronic components.
l Discharge persons and objects which come into contact with module components
through earthing (e.g. with ESD shoes) or they must have the same voltage potential.
Emergency stop
Ensure the possibility of emergency stop to avoid damage to the system and the module,
e.g. through integration into the emergency stop chain.

5 Delivery
5 Delivery
The module should remain in the original packaging until it is finally installed. As a result, it is
optimally protected against mechanical damage and harmful electrostatic voltages (ESD).
5.1 Delivery scope

The delivery scope includes:
l FiliusACS-B-Multi-IQ | FiliusACS-C-Multi-IQ
l Operating instructions
l A USB stick
l 9 mating connectors for inputs/outputs 1X2, 1X3, 1X4, X3, X7, X8, X9, X10 and X19
5.2 Delivery
The module is delivered in a reinforced box with double base and interior foam lining. The box
is also secured on a pallet.
Note
On delivery, please check the following points:
l Immediately after receipt, check the delivery against the delivery note to determine com-
pleteness and any transport damage.
l Notify the transport company and the Harms & Wende GmbH & Co. KG service depart-
ment immediately of any damaged parts.
l The system may not be commissioned until the damaged parts have been repaired or
replaced.

5 Delivery

6 Transport
6 Transport
6.1 Internal
After checking the delivery condition, transport the module to the installation location.
Transport damage to the module

Parts of the housing and power connections may be damaged due to improper transport.
l Do not use electrical power connections as carrying handles.
l Use a suitable means of conveyance.
6.2 Return transport/shipping

If it is necessary to return/ship the module, it must be packaged properly and securely.
Improper packaging
Parts of the housing and power connections may be damaged or destroyed during shipping.
l Always package the module in a reinforced box with a double base.
l Line the interior of the box with foam.

l Do not use power connections as carrying handles.
l Seal the box securely and secure to a pallet.

6 Transport

7 Assembly
7 Assembly
Improper installation or assembly work

Non-observance may possibly result in a reduction of personal or system safety. Mal-
functions and functional limitations are possible.
l Make sure that installation and assembly are performed by a specialist who also has spe-
cialist knowledge in the field of electromagnetic compatibility.

l Observe all of the specifications in the technical data.
l Observe the valid safety and accident prevention regulations.
l Do not disable any of the safety systems.
Data on dimensioning and the cable length can be found in the technical data chapter.
See Technical data, p. 139.
Connection is carried out as per the enclosed connection diagrams.
Data on pin assignment can be found in the pin assignment chapter.
See Pin assignment, p. 119.
7.1 Installation
Installation of the module

The modules are designed as built-in devices. Operation when not built in is impermissible.
Installation should take place in dry, dust-free rooms.
On installation , minimum distances from other components must be adhered to:
l 05 mm to the left and right
l 50 mm up and down
l 50 mm on the rear side for the electrical connections
No devices which emit a great deal of heat may be installed beneath the module.

7 Assembly
Electrical installation
Hazardous electrical voltage

Non-observance may possibly result in death or serious injury.
l Electrical connection must only be performed by a specialist electrician under con-
sideration of the valid safety regulations, the mains voltage and the maximum current con-
sumption of the system parts.
l Use suitable, insulated electrician tools for all electrical connection work.
l Make sure that the relevant part of the system and the relevant device are de-energised
and secure them to prevent unintentional reactivation.
l Dimension all line cross-sections according to the connected power.
l Make sure that no connection cables can come loose unintentionally.
l Make sure that the connection cables' insulation is not damaged.
7.2 Supply voltage

The module is operated with 24 VDC voltage. The supply must be planned for a current con-
sumption of 500 mA. For the switch-on load of the 24 V supply, see Technical data, p. 139.
The synchronising voltage must still be available for welding control system operation.
The signal inputs must also be supplied with 24 VDC voltage. These are routed potential-free
in the device so that the inputs and outputs can e.g. be supplied from a PLC (Programmable
Logic Controller).
On manual systems or machines, the signal input supply can also be taken from the supply
voltage.
7.3 Solenoid valve voltage

The solenoid valve voltage has the task of actuating DC solenoid valves . It is 24 V.
7.4 Functional earth connection

Functional earth
An EMC-friendly cable which is as short as possible with a cross-section of at least 4 m2 must

be connected between the flat plug contact and the system's common earthing point for ear-
thing.
The connection must be established with a flat connector sleeve 6.3 x 0.8 mm.

7 Assembly
7.5 Connection of the plugs

At least the following plugs must be connected for operation:
l Plug X3 establishes the connection to the power stage.
l Plugs X7 and X8 are command inputs, e.g. for start, program selection.
l Plug X9 establishes the connection to the solenoid valves and message outputs.
Depending on the functionality used, it may be necessary to connect the following plugs:
l Plug 1X2 for current measurement.
l Plug X19 for proportional valves 1 and 2.
l Plugs 1X3 for travel measurement 1 and 1X4 for travel measurement 2.
In FiliusACS-B-Multi-IQ | FiliusACS-C-Multi-IQ, plug X10 is not assigned.
To start the welding process, the inputs <With current>, <Pressure contact> and
<EMERGENCY STOP> plus <Water flow monitor> must be switched. If these signals are not
provided from the system, they must be connected to 24 V. An emergency stop button with
lock must be used as an emergency stop switch.
For the precise assignment of the plugs, see Pin assignment, p. 119.
7.6 Interference suppression

Interference suppression measures are required to suppress interference from external
sources.
Modern inverter and welding control systems are built using highly integrated components
packed tightly together. Due to undesired heat development, these modules work at a low
level of performance and high clock frequency. For this reason, if no suitable coun-
termeasures are taken, they can be affected by magnetic and/or electrical interference ori-
ginating from sources of interference such as voltage peaks and conducted via connection
lines.
As a general rule, anything producing interference (relay coils, other inductive switching ele-
ments, etc.) must be suppressed at the source.
The suppression element must be mounted directly at the source of the interference. If this is
not possible, it must be mounted in a connection housing as close as possible to the inter-
ference suppression device. The connection lines must be twisted tightly.
The suppression elements (resistors, capacitors and diodes) must be securely mounted using
mechanical means in order to prevent breakage due to vibration.
Examples of interference suppression

The following table shows examples of suppression measures. In addition, the industry offers
a range of components for interference suppression; these are tailored specifically to your
products and are also usually easy to install.

7 Assembly
Source of inter-
ference:
Additional
Contactor, Component types Remarks
wiring
relay, solenoid
valve
Advantages:
Diode Uncritical dimensioning
Type 1N4005 Lowest possible induction voltage
or 1N5060 Disadvantages:
to 60 V = Very high release delay
Application:
xl Small DC voltage relays
Advantages:
Uncritical dimensioning
Diode
Lowest possible induction voltage
Type 1N4005
Disadvantages:
or 1N5060
No suppression below
Zener Diode
Zener voltage U ZD
ZL22 to 48 V= or
Application:
xl ZL66 to 60 V=
Large DC contactors
Advantages:
Uncritical dimensioning
VDR
High energy absorption
Varistor
Disadvantages:
e.g. SIOV S14 K25
No suppression below U UDR
for 24 V= or
VDR voltage > peak value U
SIOV S14 K230
Application:
for 230 V=
xl Alternative to diode or RC
RC wiring Advantages:
Resistance; 220 Ω/5 W Good high-frequency damping
Capacitor: Disadvantages:
0.1 µF 1000 V Requires precise dimensioning
at 230 V~ to 440 V~ or High inrush current
0.5 µF 1000 V at 110 V~ or Application:
xl ready to install interference AC relays and motors
protection
RC wiring Advantages:
Resistance: Good high-frequency damping
load-dependent Contact protection against spark erosion
capacitor: Disadvantages:
0.01 µF to 0.1 µF 1000 V Requires precise dimensioning
Greater relay release delay
Application: Surge voltage suppressor
xl for inductive load
Fig. 7-1: Examples of interference suppression

8 Commissioning
8 Commissioning
Module incorrectly connected or parameterised with incorrect settings

The module may be damaged or destroyed.
l Only authorised, specialist personnel may perform commissioning.
The wiring diagrams always apply to connection, see Pin assignment, p. 119.
Prior to the first welding process:
Prerequisites
o The set supply voltage matches the voltage provided by the power stage.
o The solenoid valve voltage has been checked.
o The functional earth is connected.
o Power stage plug connectors and input and output plug connectors are connected.
o The welding control system is connected to the external sensor system.
o The USB stick with administration rights is inserted.
o The supply voltage is switched on.
o The welding control system is ready for operation and the parameters have been
input.
For optimum operation, we recommend:
o Adaptation to the actual cos phi power factor, see Power settings, p. 60
o Comparison of the ignition time point of the 1st delayed half cycle depending on the
welding transformer which is used
o Comparison of mains voltage compensation.
The welding control system is properly connected and ready for the first welding process.

8 Commissioning

9 Operation
9 Operation
9.1 Switching on the module

A self-test is performed after switching on. During this time, the type and firmware version
are displayed.
After the self-test, the mains frequency is determined Once this process has been completed
successfully, the main display area shows the current measured during the last welding pro-
cess. If no welding process has been performed yet after switching on, "0.00 kA" is displayed.
Note
The start contact inputs and the pre-stroke input must be inactive before switching on the
module. Otherwise, a message to this effect will be displayed after start up.
If a USB stick is inserted on switching on, the procedure depends on the content of the USB
stick. If the USB stick contains firmware files, the update options are queried on the display,
see Firmware update, p. 75.
9.2 Mains frequency detection

Possible messages: xxxx- 50 Hz
xxxxxxxxxxxxxxxxxxxxx- 60 Hz
xxxxxxxxxxxxxxxxxxxxx- ?? Hz
After the start screen, the detected mains frequency is reported for approx. 2 s.
If the detected mains frequency lies within the permissible ranges
l 46 – 55 Hz xxxx for 50 Hz or
l 56 – 65 Hz xxxx for 60 Hz
the module switches to the main display.
If the detected mains frequency does not lie within these ranges, question marks are dis-
played instead of the Hz value and a synchronisation error is then reported, see Module mes-
sages , p. 145.
After confirming/deleting the synchronisation error by pressing the [jog wheel] twice, the wel-
ding control system restarts.
This process must be repeated until a permissible mains frequency is detected.

9 Operation
9.3 Status display

DISPLAY AFTER INITIALISATION
xx
Fig. 9-1: Status display
The display is shown after initialisation. Information on the active program is provided here.
The configuration menu and the parameter menu can be called from here:
The configuration menu is called with [Cancel].
The parameter menu is called by pressing the [jog wheel].
9.4 Display elements
Display
Time
Time
Display of the current time

9 Operation
Operating status
Display of the current operating status (from left -> right)
No malfunction
(Flashing) malfunction
(Flashing) editing active
Keyboard lock
Keyboard lock via USB stick:
Counter group warning

Counter 1/2 pre-warning threshold reached
Counter group 1/2 maximum spot value reached
Start inputs
Start1 active
Start2 active
Pressure contact
Pressure contact active
Stepping contact
Stepping contact active
Program information
The following information on the current welding program is displayed:
l The selected welding program.
l Depending on the configuration, the program number is given an "i" prefix with internal
program selection and an "x" with external program selection.
l The number before the slash indicates the program which is started with <START1>.
l The number after the slash indicates the program which is started with <START2>.
Program selection
i Internal program selection
x External program selection
Selected program
xx/ Program for Start1
/yy Program for Start2

9 Operation
Spot counter
The display of spot counters varies depending on the configuration of the module and the
current status of the messages. The display always refers to the spot counter last updated
and is only displayed when the monitoring function <Max. spots> is switched on:
l White font on blue background: spot counter last updated, each for <START1> or
<START2>,
l White font on blue background in frame: counter value ≥ pre-warning threshold
l Blue font on white background in frame: counter value ≥ max. spot value
Spot counter
99999 Counter status for Start1
99999 Counter status for Start2
Main display
Display of the following information:
l Sub-menus
l Parameters symbolised through pictograms
l Current parameter values
l Text input
Main display
Menu for operating and setting up the control system
General information
Display of the following information, depending on situation:
l Sub-menu to which the user jumps by pressing the [jog wheel]
l Value changed after pressing the [jog wheel]
l On inputting the welding parameters, a graphical representation of the position in the wel-
ding process which can be edited after pressing the [jog wheel]
Additional information on current operation
E.g. as text
E.g. graphically

9 Operation
9.5 Menu structure overview

Status menu
Configuration menu Parameter menu

With internal program selection only:
See Program administration, p. 47 See Sequence program, p. 84
See Process configuration, p. 50 See Edit program, p. 85
See Data back-up, p. 131 See Program configuration, p. 86
See Module configuration, p. 72

With travel measurement activated only:
See Filius information, p. 74
See Filius information, p. 74
See IQ parameters, p. 107

With travel measurement activated only:
See Travel measurement, p. 109
Fig. 9-2: Menu structure
On selecting a menu again, the sub-menu last selected is shown on the display.

9 Operation
9.6 Menu selection

The various options for calling menus are described in the following.
9.6.1 Parameter menu selection

Prerequisites
o The display shows the status display.
Procedure
1. Press [jog wheel].
Result
l The parameter menu is called.
9.6.2 Selecting the configuration menu

Prerequisites
o The display shows the status display.
Procedure
1. Press [Configuration menu/Cancel].
Result
l The configuration menu is called up.
9.6.3 Selecting a sub-menu

Prerequisites
o The display shows the configuration menu or the parameter menu.
Procedure
1. Select the desired sub-menu by turning the [jog wheel].
2. Press the [jog wheel].
3. Select the further desired sub-menu by turning the [jog wheel].
Result
l The desired sub-menu is called.
9.7 Value input

Prerequisites
o A sub-menu in which values can be changed has been selected.

9 Operation
Procedure
1. Set the desired value by turning the [jog wheel].
Result
l The value has been input and accepted.
UNDO function
The parameter change can be undone by pressing the [Cancel] button as long as the input
has not been completed by pressing the [jog wheel].
RESET function
On delivery of the devices, the program parameter sets are set to basic values as default (see
Basic settings on delivery, p. 140). If a parameter is to be reset to the basic value, this can be
done by pressing the [Folder] button.
9.8 Text input

Texts can be input in various areas of the menu.
Fig. 9-3: Text input display
The main display is subdivided into two areas for text input:
l The upper framed text field with insertion mark
l The lower character selection field
The original text (e.g. the name of the welding control system) is displayed as default in the
text field. The insertion mark is on the left.
In the centre of the character selection field, a character is highlighted by a frame and enlar-
ged representation.
All upper case letters are available for selection at the start of the character selection field.
[Folder] can be used to select the following character ranges in succession:
l Lower case letters
l Numbers and special characters
l Control characters - delete left character , delete right character and move insertion
mark
l Upper case letters

9 Operation
Move insertion mark
Procedure
1. Select the control character range with [Folder].
2. Turn [jog wheel] until is marked.
3. Press the [jog wheel] and move the insertion mark to the desired position by turning the
[jog wheel].
4. Press the [jog wheel] to accept the current insertion mark position.
Result
l The insertion mark is in the desired position.
Delete characters
Procedure
1. Select the control character range with [Folder].
2. Move the insertion mark to the desired position, see above.
3. Turn the [jog wheel] and select the deletion direction:
l Delete to the right
l Delete to the left
4. Press the [jog wheel] to delete the character to the left or right of the insertion mark.
l Repeatedly pressing the [jog wheel] deletes further characters according to the
selected deletion direction.
Result
l The desired character has been deleted.
9.8.1 Inputting text

Prerequisites
o A sub-menu in which text can be input has been selected.
Procedure
2. Select the correct character range with [Folder].
3. Turn the [jog wheel] until the desired character is marked in the frame,
l Press the [jog wheel]. The selected character is inserted at the insertion mark position.
4. Repeat steps 1 to 3 if necessary.
Result
l The text is input.

9 Operation
9.8.2 Ending text input and discarding the change

Prerequisites
o Text has been input.
Procedure
1. Exit text input with [Configuration menu/Cancel].
–-– Pressing [Configuration menu/Cancel] again takes you back to the text input.
2. Select [Discard and End] by turning the [jog wheel].
3. Confirm by pressing the [jog wheel].
Result
l Text input is ended and the change is not saved.
9.8.3 Ending text input and saving the change

Prerequisites
o The desired text has been input.
Procedure
1. Exit text input with [Configuration menu/Cancel].
-– – Pressing [Configuration menu/Cancel] takes you back to text input.
2. Select [Accept and Exit] by turning the [jog wheel].
3. Confirm by pressing the [jog wheel].
Result
l Text input is ended and the change saved.

9 Operation

10 Configurations
10 Configurations
The module can be adapted to different statuses or behaviour.
The configurations refer to different levels. Values arising from the design of the system or
which change the sequence of the welding process can thus be adapted. You have the option
of switching functions on or off in order not to overload the user with superfluous setting
options.
Note
Configurations are usually only carried out once. As modifications immediately change the
welding process and are adapted to the system circumstances, special authorisation is requi-
red for these. The USB stick with the administrator rights must be inserted to enable para-
meters to be changed.
Administration and configuration options are edited in the sub-menus:

l Program administration
l Process configuration
l Module configuration
l Filius information
Additional menu items can appear depending on the device configuration:
l Travel measurement offset
10.1 Program administration

Program administration enables you to comfortably input the parameters for the welding
programs. If e.g. a higher welding current is required for a job but the other process remains
the same, an existing welding program can be used to derive a parameter set for a new wel-
ding job.
CONFIGURATION MENU >
xx
Fig. 10-1: Program administration
Program administration offers you the following functions:
Copy program
Delete program (only available with a USB stick inserted)
Back-up program(s) (only available with a USB stick inserted)
Load program(s) (only available with a USB stick inserted)

10 Configurations
Copy program
CONFIGURATION MENU > PROGRAM ADMINISTRATION >
xx
Fig. 10-2: Copy program
Copying is carried out by selecting a source program and then selecting the target program.
xx xx xx
Fig. 10-3: Select source and target programs
Before the target program has been selected, copying can be aborted with [Cancel].
Once the program has been copied, an order name consisting of the order name of the
source and a bracketed number corresponding to the program number of the target pro-
gram is entered in the target program.
xx
Fig. 10-4: Order name after copying
Delete program
xx
Fig. 10-5: Delete program
This menu item is only available with a USB stick inserted.

Programs can be selected from a list for deletion here.
If a program is deleted, the parameters in the selected program space are overwritten with
the default values.
Back-up program(s)
xx
Fig. 10-6: Back-up program(s)
This menu item is only available when a USB stick is inserted.

10 Configurations
After selecting this menu item, all programs stored in the welding control system are backed-
up to the USB stick. The file name is formed according to the pattern <Modulname>.fmod. A
security prompt is output before overwriting existing files.
xx
Fig. 10-7: Overwrite program
Load program(s)
xx
Fig. 10-8: Load program(s)
This menu item is only available when a USB stick is inserted.

After selecting this function, a list of the programs stored on the USB stick is displayed.
All of the programs available on the USB stick can be loaded into the welding control system
here.
xx
Fig. 10-9: Select program
Select by turning the [jog wheel] to the desired program; confirm by pressing the [jog wheel].
Selected program is loaded into the welding control system.
The selection process can be aborted with [Cancel].
xx
Fig. 10-10: Abort program loading

10 Configurations
10.2 Process configuration

Counter group
Welding parameters
Comparison + service
10.2.1 Electrode management

Welding electrodes are subject to severe wear and must be regularly maintained or exchan-
ged. To avoid long down times and poor quality welding, the welding control system is equip-
ped with an electrode management system. To control electrode wear, the die
Schweißsteuerung can count certain events in individual counters. To enable this wear to be
assigned to the tools, the programs which work with a tool are grouped into counter groups.
Spot counter or tool groups

The welding programs are assigned to certain spot counter or tool groups <Counter group>.
Each counter group encompasses a spot counter, a pre-warning threshold and an electrode
exchange threshold. The Filius offers two counter groups. Programs 1-16 of the welding con-
trol system are assigned to counter group 1 and thus <START1>, and programs 17-32 to coun-
ter group 2, and thus <START2>.
CONFIGURATION MENU > PROCESS CONFIGURATION >
xx
Fig. 10-11: Counter group
After selecting this function, counter group 1 or 2 is first selected.

The spot counter value, the pre-warning threshold and the electrode exchange threshold can
then be defined for the selected counter group.
Spot counter
Spot counters continuously count all welding cycles undertaken with current. Counter group
selection is given by the program assignment. Counting is always carried out when the wel-
ding process has been ended (with stepping contact). After incrementing the spot counter, a
check is performed to determine whether the pre-warning or the maximum number of spots
has been reached. In this case, the message output is activated. The spot counter can be
reset using a digital input (simultaneously for both counter groups) or via the operating unit.
The value range for the spot counter lies between 0 and 99999.

10 Configurations
Pre-warning function
On the operating unit, the pre-warning can be used to indicate that the end of the nominal
final dimension value will be reached soon. If the spot counter status exceeds the pre-war-
ning value, the spot counter status is shown on the display with a white frame (with moni-
toring activated only). With suitable parameterisation, the electrode can be exchanged in
production-free periods based on this information.
CONFIGURATION MENU > PROCESS CONFIGURATION > COUNTER GROUP >
xx
Fig. 10-12: Setting the pre-warning value
The pre-warning value can be selected between 1..99999.
Electrode exchange programming

The electrode caps are subject to abrasion during welding. Due to this physical change, wel-
ding quality can no longer be guaranteed after reaching the nominal final dimension value.
The nominal final dimension value is dependent on the welding job.
Electrode exchange programming enables the welding control system to monitor the spot
counter. After exceeding the nominal final dimension value, the welding control system sets
the "Electrode exchange threshold reached" output. When the spot counter status exceeds
the electrode exchange threshold, the spot counter status is displayed in inverse form (with
monitoring activated only). The value is shown at the bottom left of the display and the refe-
rence to counter group 1 or 2 in the middle field of the top line.
This module message can only be deleted by deleting the spot counter or changing para-
meters (maximum number of spots greater than spot counter), see Module messages , p.
145 and see Acknowledging module messages, p. 156.
However, the welding control system can be configured so that it restarts the program on rea-
ching the maximum number of spots.
CONFIGURATION MENU > PROCESS CONFIGURATION > COUNTER GROUP >
xx
Fig. 10-13: Setting electrode exchange
The electrode exchange threshold can be selected between 1..99999.

10 Configurations
10.2.2 Settings forwelding parameters

This sub-menu is only available when a USB stick is inserted. It can only be edited with admi-
nistration rights. The "Filius.adm" file must be available on the USB stick.
For details on the settings, see Parameterising the welding process, p. 79.
The following welding parameters can be defined:
Immediately
Start VHZ
After pressure contact = DK
Immediately
Start interlock
Start of main current time = SZ
Internal program selection

Select program
External program selection
Switch off
Stop electrode exchange
Switch on
At start of NHZ
Stepping contact FK
After NHZ
FK pulse duration 0…10 per
No electrode holder assigned

Function of distance measuring system
Electrode holder 1 assigned
1
No electrode holder assigned
Function of distance measuring system
2
Proportional valve 1 basic value 0 - 100%, def. 20%
Proportional valve 2 basic value 0 - 100%, def. 20%
Switch off
Electrode holder 1 force input
Switch on
Switch off
Electrode holder 2 force input
Switch on
Switch off
Mains load limitation
Switch on

10 Configurations
Constant
Static
Pre-stroke output
Scanning
Cos phi 0.44…0.93 in 16 stages (00 .. 15)
Periods
Select time basis
Milliseconds or seconds
Periods
Max. time input
Seconds
Min. squeeze time 1…99 per

MV
Max. welding time 0.5…99.0 per
Min. hold time 1…99 per
MN
Min. open time 1…99 per
First delayed half cycle 600…999 Skt
1st delayed half cycle after pause 600…999 Skt
Max. faulty welding 0…5, def. 0
Max. SKT 1…999 Skt, def. 999 Skt
Max. current 1.00…99.99 kA, def. 20.00 kA
Error class IQ 2.3, def. 2
FIQ
Controller error class 2.3, def. 2
FRG
10.2.3 Squeeze time configurations

Squeeze time behaviour depends on the start interlock configuration:
Start interlock at start of main current time
On cancelling triggering start, the current welding cycle and squeeze time are immediately
cancelled. Renewed starting of a welding process is then subject to the general start con-
ditions and start times. The welding process can no longer be interrupted when squeeze time
comes to an end.
Immediate start interlock
Following start recognition, the welding process is performed without further consideration
of <Start>.
The start of squeeze time may be dependent on the pressure contact due to configuration:
Start squeeze time after pressure contact

10 Configurations
Pressure contact control prior to the start of squeeze time counting:

In this case, the time sequence only starts after a pressure input signal has been detected. If
this signal is not available, the start of the time sequence is extended in each case by one unit
of time until the pressure input signal becomes active. Only then is the specified time pro-
cessed.
Immediate squeeze time start
Pressure contact control after to the end of squeeze time counting:

In this case, the time sequence starts immediately. Before the end of squeeze time the pres-
sure contact is polled. If this signal is not available, the start of squeeze time is extended in
each case by one unit of time until the pressure input signal becomes active.
Further operating statuses are triggered during the squeeze time.
NBS function (mains load limitation control):

The NBS polling signal is set one half cycle prior to the calculated end of the squeeze time. The
NBS release signal (pressure contact) is checked at the end of time counting. If NBS release is
not issued, continued running of the welding cycle is delayed by one unit of time.
Note
In the case of immediate start interlock, a missing pressure input signal and missing NBS
release, the welding process will pause. It can only be interrupted through external status
changes such as <EMERGENCY STOP> or by pressing [Cancel].
10.2.4 Start of squeeze time

CONFIGURATION MENU > PROCESS CONFIGURATION > WELDING PARAMETERS >
xx
Fig. 10-14: Start interlock VHZ
This function determines the behaviour of the <Squeeze time> and is parameterised through
[Start VHZ], see Process configuration, p. 50.
The following selection options are available:
l Start VHZ immediately:
The <Squeeze time> begins immediately after start detection.
l Start VHZ after DK:
<Squeeze time> only starts once <Pressure contact> is active.

10 Configurations
10.2.5 Start interlock

xx
Fig. 10-15: Start interlock
The start interlock determines the behaviour of the welding control system after the <START>
signal has been activated. The function is parameterised through <Start interlock>.
l Immediate start interlock:
Following start recognition, the welding process is carried out without further con-
sideration of <Start>. If there is no pressure contact, the welding process can be inter-
rupted by [Cancel].
l Start interlock after VHZ:
The welding process can be aborted during the squeeze time by an inactive <Start>.
10.2.6 Program selection

Programs can be selected either internally or externally.
Internal
xx
Fig. 10-16: Internal program selection
The programs are selected via the operating unit.
External
xx
Fig. 10-17: External program selection
The programs are selected externally in binary format via the inputs <BIT 1>...<BIT 4>.
The valency of the inputs is:
<BIT 1> = 01 xxxxxxxxx <BIT 2> = 02 xxxxxxxxx <BIT 3> = 04
<BIT 4> = 08 xxxxxxxxx <BIT 5> = 16 xxxxxxxxxxxxxxxxxx

10 Configurations
10.2.7 Electrode exchange configuration

This function can be used to determine the behaviour of the control system on reaching the
set spot counter value (see Electrode management, p. 50). After exceeding the nominal final
dimension value, "Electrode exchange limit reached" is output.
If no electrode monitoring is to be performed, this configuration must be set to "off".
CONFIGURATION MENU > PROCESS CONFIGURATION >
xx
Fig. 10-18: Continued running on electrode exchange
xx
Fig. 10-19: Stop electrode exchange
If monitoring is active, the spot counter status is shown on the display with a white frame
when it has exceeded the pre-warning value.
If the spot counter exceeds the nominal final dimension value value, the "Electrode exchange
limit reached" output is set. In this case, the spot counter status is displayed in inverse form.
10.2.8 Stepping contact function

The <Stepping contact> (FK) signal is used by transport facilities in the building as a command
to continue running. It can signal to an higher-level control system that a welding process
and possible evaluations have ended. Its function depends on the configuration, the ope-
rating mode selected and possibly the type of error which has occurred.
xx
Fig. 10-20: FK after hold time
xx
Fig. 10-21: FK at the start of the hold time
In this menu, the stepping contact can be configured to determine whether it

l is to be output after the end of the hold time
(NHZ) or
l at the start of the hold time.

10 Configurations
Stepping contact pulse duration

xx
Fig. 10-22: FK pulse duration
The pulse duration for stepping contact output can be set with this parameter. Activation of
the stepping contact is started depending on the above described configuration. If the pulse
duration is programmed to "0", the contact remains active until active start is withdrawn. If
start on FK output is passive, the FK is output as a pulse.
If a time is specified, the stepping contact is automatically deleted after the specified time has
expired, irrespective of start.
Note
If the stepping contact has been deleted and start remains active, it cannot be seen that the
activated program has already welded.
10.2.9 Configuration of the travel sensors

The Filius is equipped with two analogue travel measurement inputs for connecting poten-
tiometric travel sensors on the current measurement assembly.
In PROCESS CONFIGURATION > WELDING PARAMETERS, both travel sensors can be optionally assi-
gned to electrode holder 1, electrode holder 2 or no electrode holder.
This also enables two travel sensors to be configured for one electrode holder.
xx
Fig. 10-23: Selection of the travel sensor's electrode holder assignment
The following settings can be selected in the CONFIGURATION MENU > TRAVEL SENSOR:
Travel measurement deactivated
Travel sensor assigned to electrode holder 1
Travel sensor assigned to electrode holder 2
When travel monitoring is deactivated, no parameters are available for references, linea-
risation or monitoring. The corresponding menu items in the program parameters are not
then displayed.
For travel sensor calibration see Calibrate travel sensor 1, p. 65.

10 Configurations
10.2.10 Proportional valve value for calibration

To calibrate the travel sensor or for force input, the electrode holder must be addressed by
activating the start signal. As no active program is selected at this point in time, the pro-
portional valve must provide air pressure for electrode holder movement. These settings are
undertaken here
xx
Fig. 10-24: Nominal value of proportional valve 1 for calibration
xx
Fig. 10-25: Nominal value of proportional valve 2 for calibration
10.2.11 Configuration for proportional valve values

The Filius control system has two proportional valve outputs for setting the electrode holder
pressure force of the two electrode holders, which are activated with <Start 1> or <Start 2>.
This configuration enables the behaviour of the control system to be changed such that the
setting is carried out at the same point as before but as a nominal value specification in the
force unit dN (decanewton). Force setting calibration is required for this.
If the value is to be input in %, this configuration must be set to <x>.
xx
Fig. 10-26: The proportional valve nominal value is specified in %
xx
Fig. 10-27: The proportional valve nominal value is specified in [dN]

10 Configurations
10.2.12 Configuration of interlock addition/mains load limitation control

The interlock addition (VZ)/NBS contact function is configurable. Either as an interlock addi-
tion only or in combination with the pressure contact as mains load limitation control (NBS).
xx
Fig. 10-28: Selection as VZ function
xx
Fig. 10-29: Selection as NBS function
l Configured as VZ:
The VZ output is activated throughout the entire current-conducting time.
l Configured as NBS:
Activation of the VZ output starts during the last squeeze time period. The signal can
be used as a welding request signal for mains load limitation control so that the <Pres-
sure contact> can be used for welding release through NBS.
With the NBS function, the <VZ_NBS output> is set in the last squeeze time period. Only then
is the pressure contact polled.

10 Configurations
10.2.13 Pre-stroke solenoid valve

If the <Pre-stroke> function is configured to static or scanning, the <Pre-stroke> output is swit-
ched on and off via the <Pre-stroke ON/OFF> input.
If the <Pre-stroke> function is configured to continuous, the <Pre-stroke> output is switched
on continuously (24 VDC pulsing).
xx
Fig. 10-30: Selection of the travel sensor's electrode holder assignment
The following settings can be selected in the configuration menu:
Pre-stroke output constant
Pre-stroke output static
Pre-stroke output scanning
10.2.14 Power settings

The power setting for the welding spot arises from the input components of time and current
flow angle 1 up to 999‰. The current flow angle control range is oriented towards the set cos
phi value.
Adjustment of the power factor cos phi

xx
Fig. 10-31: Cos phi
Due to the inductivity of the welding transformer and the secondary circuit, the current
always lags behind the voltage. On setting the power, this results in an adjustment range limi-
tation, which is expressed by the factor cos phi. The delayed deletion of the thyristor which
also results from this is referred to as inductive overhang. This inductive overhang may lead
to the achievement of the maximum power at just e.g. 800 scale divisions. In order to take
advantage of the full adjustment range (999 scale divisions), cos phi adjustment is necessary.

10 Configurations
Fig. 10-32: Cos phi setting
01 Power setting range

02 Cos phi = 0.93
03 Cos phi = 0.45
The power factor cos phi is set to 0.93 as default in the factory. Adaptation to the relevant sys-
tem may be sensible. In the majority of cases, however, immediate functional readiness is
guaranteed with the basic setting.
If the setting has to be changed, the cos phi value can be set between 0.45 and 0.93 in the
configuration menu.
The value of 0.93 and 999 Skt current corresponds to the maximum ignition time point of 8.8
ms.
The maximum ignition time point is limited by setting the cos phi to 115.9°el. (0.45) or
158.4°el. (0.93).
The minimum ignition time point is a constant 27°el.
The available setting range of 999 Skt is subdivided such that a linear current change arises.
The following table shows example guideline values for single spot mode, mains frequency 50
Hz, nominal current 999 Skt.
Cos phi setting Cos phi value Ignition time point in ms Ignition time point in °el
0 0.44 6.44 115.9
1 0.48 6.60 118.8
2 0.53 6.76 121.7
3 0.57 6.92 127.6
4 0.60 7.04 126.7
5 0.64 7.20 129.6

10 Configurations
Cos phi setting Cos phi value Ignition time point in ms Ignition time point in °el
6 0.68 7.36 132.5
7 0.70 7.48 134.6
8 0.75 7.68 138.2
9 0.78 7.84 141.1
10 0.81 8.06 144.0
11 0.84 8.16 146.9
12 0.86 8.32 149.8
13 0.89 8.48 152.6
14 0.91 8.64 155.5
15 0.93 8.80 158.4
10.2.15 Select time basis

The time specifications for the mains frequency control systems are usually input in [Per]. In
more recent welding parameter proposals, these times are increasingly being specified in
[ms]. To be able to enter the proposals directly, the time basis can be selected between [Per]
and [ms].
Configuration menu > Process configuration > Welding parameters >
xx
Fig. 10-33: Selection of the unit of time in which the parameters are input.
10.2.16 Maximum time inputs

Time input for the welding process is limited. This limitation can be changed through the con-
figuration. Depending on the time basis, the limitation is undertaken either in [Per] or in [ms].
xx xx xx
Fig. 10-34: Limitation of time input in per
xx xx xx
Fig. 10-35: Limitation of time input in s

10 Configurations
Time limitation function

The current time value is displayed in the program during parameterisation. This may also be
higher than the value programmed for the maximum time setting. The time limitation only
applied if the parameter is adjusted, and an input greater than the time limitation is not pos-
sible. The parameter change can be reset to the old value with the [Cancel] button. This
enables the <Maximum time input> parameter to be corrected without changing parameter
set data.
Note
All times of all programs are set to 1 ms if the <Maximum time input> with 1 ms is input.
The times are checked at the start of the program. As times which are greater than the <Maxi-
mum time input> can be programmed in the parameter sets, the times are checked and limi-
ted to the <Maximum time input> for program operation. This limitation does not apply to
the minimum time values, e.g. the <Minimum squeeze time>, etc. As soon as any parameter
is limited, the information <Time limitation active> is generated and the program runs with
the limited times. Deviating values in the parameter sets are not automatically corrected in
order to avoid damage on incorrectly entering the <Maximum time input> parameter.
xx
Fig. 10-36: Time limitation "Tlim" display
10.2.17 Control system behaviour in the event of welding errors

Various errors can occur in controller and monitoring mode. The control system's behaviour
on occurrence of these errors can be configured by activating a specific error class.
The behaviour in the event of limit value errors is determined through the set FIQ error class
and through the selected FRE error class for controller errors.
FIQ configuration
The welding spot is evaluated during the <Hold time> (NHZ). Two error classes are available:
xx
Fig. 10-37: Selection of the error class for monitoring errors
Effects of error class 2:

l The <Operational> message goes off.
l The stepping contact is output after the NHZ has expired.
l The solenoid valve is shut off at the start of the NHZ.

10 Configurations

l The stepping contact is not output after the NHZ has expired.
l The solenoid valve is not shut off at the start of the NHZ.
An existing message can be acknowledged via the <Error reset> signal or by deleting the error
using the keyboard and the <Operational> message goes on. In error class 3, the stepping
contact is then output and the solenoid valve is shut off.
FRG configuration
The welding spot is evaluated during the <Hold time> (NHZ). Two error classes are available:
xx
Fig. 10-38: Selection of the error class for regulation errors

l Stepping contact l is output after the NHZ has expired.
l The solenoid valve is shut off at the start of the NHZ.
l Stepping contact is not output after the NHZ has expired.
l The solenoid valve is not shut off at the start of the NHZ.
An existing message can be acknowledged via the <Error reset> signal or by deleting the error
using the keyboard and the <Operational> message goes on. In error class 3, the stepping
contact is then output and the solenoid valve is shut off.

10 Configurations
10.3 Comparison and service

This sub-menu is only available when a USB stick is inserted. It can only be edited with admi-
nistration rights. The "Filius.adm" file must be available on the USB stick.
Calibrate travel sensor 1
Force calibration electrode holder 1
Force calibration electrode holder 2
RR1 Reset controller 1 or 2

RR2
Measuring coil comparison
Mains voltage comparison
10.3.1 Calibrate travel sensor 1

Calibrate travel sensor
This function defines the working range of travel sensor 1 and simultaneously serves to cali-
brate the travel sensors using a linear equation. Travel measurement calibration is carried out
using the teach-in method
The electrode holder force active during comparison can be defined in the submenus which
follow the menu items > travel sensors and > electrode holder assignments. The electrode hol-
der force is input in percent.
The electrode holder forces for moving the electrode holder during calibration can be defined
by the set values of the proportional valves.
If the travel sensor is assigned to electrode holder 1, the force for electrode holder 1 is assi-
gned with the set value. If the travel sensor is assigned to electrode holder 2, it is necessary to
input the set value for electrode holder 2. , see Configuration of the travel sensors, p. 57..
CONFIGURATION MENU > COMPARISON AND SERVICE >
xx
Fig. 10-39: Calibrate travel sensor
l Pressing the [jog wheel] accesses the input menu for REFERENCE POINT 1, TRAVEL SENSOR 1

10 Configurations
xx
Fig. 10-40: Calibrate travel sensor 1, reference point 1
l Pressing <Start 1> or <Start 2> (according to the electrode holder assigned to travel sensor
1) activates the solenoid valve (MV) for the relevant electrode holder. The welding elec-
trodes move together
Note
No welding current is output.
l Pressing <Start 1> or <Start 2> again opens the electrodes again.
Value input is not possible when the electrode holder is open. The request to close the elec-
trode holder is displayed (with attention symbol and reference to <Start 1> or <Start 2>). If
the electrode holder is closed, input mode for the calibration value starts.
If the menu item CALIBRATE TRAVEL SENSOR1 is exited, the welding electrodes open automatically
(without pressing <Start 1> or <Start 2>).
l By pressing the [jog wheel] again, reference point value 1 is displayed in inverse form and
can be changed by turning the [jog wheel].
l Pressing the [jog wheel] takes over the input value.
The smallest measured and possible electrode distance must be input here.
Note
It must be noted that the smallest measurement travel can become smaller than the input
reference point 1 in the event of cap wear or cap exchange.
These measuring ranges must still be registered by the travel sensor under all circumstances.
At the same time, this is also the first linearisation point (1st linear equation support point).
l Turning the [jog wheel] accesses the input menu for REFERENCE POINT 2, TRAVEL SENSOR 1.
xx
Fig. 10-41: Calibrate travel sensor 1, reference point 2
The largest reference and linearisation point used is input here (procedure as for reference
point 1).
A corresponding spacer (e.g. thick material) must be placed between the welding electrodes.
l Pressing <Start 1> or <Start 2> (according to the electrode holder assigned to travel sensor
1) activates the solenoid valve (MV) for the relevant electrode holder. The welding elec-
trodes move together.

10 Configurations
Note
No welding current is output.
l Pressing <Start 1> or <Start 2> again opens the electrodes again.
If the menu item CALIBRATE TRAVEL SENSOR1 is exited, the welding electrodes open automatically
(without pressing <Start 1> or <Start 2>).
At the same time, this is also the second linearisation point (2nd linear equation support
point).
l The [Cancel] returns you to the menu item COMPARISON + SERVICE.
l Turning the [jog wheel] takes you to the menu item CALIBRATE TRAVEL SENSOR 2.
Note
Each time a travel sensor is calibrated, it is vital to perform "cap offset reference" for the cali-
brated travel sensor
Travel measurement offset
Travel measurement offset

Calibrate travel sensor
Travel sensor 2 is calibrated in the same manner as described in the above section for travel
sensor 1.
10.3.2 Force calibration

Force calibration
Filius has two proportional valve outputs for setting the force of the two electrode holders,
which are activated with <Start 1> and <Start 2>.
The settings for the proportional valve are carried out in the see Proportional valve with force
specification, p. 90. However, the value should be entered in the force unit daN (deca-
newton). Force setting calibration is required for this.
xx
Fig. 10-42: Force calibration
Calibration is carried out through the definition of two work points (force % pairs) X1 and X2.

10 Configurations
xx
Fig. 10-43: Support point 1, electrode holder 1
xx
Fig. 10-44: Support point 2, electrode holder 1
On entering the calibration menu, the welding current is shut off and the LED display <With
current> goes off. The electrode holder calibration function is only available if force input in
daN is activated for the relevant electrode holder in the Process configuration > Welding para-
meters menu. After selecting the force calibration function for an electrode holder, support
point X1 or X2 is selected.
xx
Fig. 10-45: Force specification in daN
xx
Fig. 10-46: Force specification in %
xx
Fig. 10-47: Input confirmation
Support point 2 is set in the same way after selecting the menu item.
xx
Fig. 10-48: Force specification in daN
xx
Fig. 10-49: Force specification in %

10 Configurations
xx
Fig. 10-50: Input confirmation
Example of force % calibration

Calibration is carried out through the definition of two work points (force % pairs) X1 and X2.
First measurement: If 5% of the set voltage are applied to the proportional valve, the force
applied on the connected electrode holder can be measured; in this case, a force of 8 daN,
point X1.
Second measurement: If 60% of the set voltage are applied to the proportional valve, 60 daN
are measured, point X2.
The control system uses these two measurements to calculate all other necessary force %
pairs.
Fig. 10-51: Calibration curve with example data
X1 First measurement
X2 Second measurement

10 Configurations
10.3.3 Reset controller

RR1 Reset controller 1 or 2
RR2
The current controller converts the measured current to scale divisions. The necessary data
are obtained during the first welding process after controller reset; this is called the teach-in
welding process. A teach-in welding process must be performed
l On initial commissioning
l After power unit exchange
l In the case of faulty welding due to changed conditions
l After a cos phi setting change
Resetting can be carried out separately for electrode holder 1 and electrode holder 2.
Reduced welding quality / welding performance if parameters are not synchronised opti-
mally
Perform this synchronisation under all circumstances on initial commissioning or exchanging
the power unit/synchronisation transformer. This also applies if the voltage values have not
changed.
10.3.4 Measuring coil comparison

Measuring coil comparison
Current measurement is calibrated here for the Rogowski measuring coil.

This is sensible if the Rogowski measuring coil being used deviates from the standardised
value of 150 mV/kA.
Before inputting a value, a longer welding process of between 5 and 20 ms should be per-
formed. Weld in short-circuit without material. During this welding process, the current must
be recorded with an external measuring facility. The determined measured value can be
input.
This function changes the measured current value display. The 150 mV/kA setting is adjusted.
The [Folder] button can be used to reset the control system to the 150 mV/kA setting.

10 Configurations
10.3.5 Mains voltage comparison

This function adapts the module to the current mains voltage.

The following values are input to do this:
Uac nominal value Mains voltage nominal value
Current Uac Mains voltage actual value
Uac minimum value Permissible minimum value whose undershoot leads to a message.
Reduced welding quality / welding performance if parameters are not synchronised opti-
mally
Perform this synchronisation under all circumstances on initial commissioning or exchanging
the power unit/synchronisation transformer. This also applies if the voltage values have not
changed.
Mains voltage compensation

Mains voltage compensation is used to compensate current changes due to mains voltage
fluctuations. Both long-term fluctuations over the day and short-term dips due to load chan-
ges are taken into consideration. If the input voltage changes within a range of –10%/+10%,
the current conduction angle is adjusted so that the current on the secondary side changes
by less than ±3%.
The welding control system is compared against a control stage input voltage of 27 VAC in the
factory; i.e. when a voltage of 27 VAC is present, the ignition angle is not corrected (display:
±0%).
A new comparison is necessary when the actual voltage on site deviates from the rated vol-
tage. If e.g. the synchronising voltage is 29 VAC with a primary welding transformer voltage of
400 V, the welding control system detects an overvoltage of 29 V vs. 27 V = + 7%. This voltage
is regulated by withdrawing the ignition time point. The result is a welding current which is
too low.
Mains voltage compensation can be shut off in the configuration menu.

10 Configurations
10.4 Module configuration

Set date/time
[Language] Select language
Keyboard lock
Keyboard lock via USB stick
Set contrast
[Module name] Input module name
Delete log book
Define CAN node
10.4.1 Set date/time

CONFIGURATION MENU > M ODULE CONFIGURATION > SET DATE/TIME >
xx
Fig. 10-52: Set date/time
The individual digits of the date and time are selected and set here in succession.
10.4.2 Select language

CONFIGURATION MENU > M ODULE CONFIGURATION > SELECT LANGUAGE >
xx
Fig. 10-53: Select language
Three languages are offered here for selection.

Three languages can be administered. German and English are already available. A further lan-
guage can also be loaded.
For further foreign languages, contact HWH, tel.: +49 40 766 904-0.
The language is selected by turning the [jog wheel] and confirmed by pressing the [jog wheel].
The switch takes place immediately after selection.
The setting is retained after restarting.

10 Configurations
10.4.3 Keyboard lock

CONFIGURATION MENU > M ODULE CONFIGURATION > KEYBOARD LOCK >
XX
Fig. 10-54: Set keyboard lock
The keyboard can be locked to prevent unintentional or unauthorised changes to para-

meters or other process variables. Two types of keyboard lock are available for this:
Keyboard lock (simple) After a defined time has passed without actuation of the
[jog wheel] or the buttons, the keyboard is auto-
matically locked.
The time is configurable from 60 s to 3600 s.
The lock can be withdrawn by simultaneously pressing
the [Folder] and
[Cancel] buttons. The buttons must be kept pressed
for 3 seconds.
This function is used to prevent unintentional changes.
Keyboard lock via USB stick: After a defined time has passed without actuation of the
[jog wheel] or the buttons, the keyboard is auto-
matically locked.
The time is configurable from 60 s to 3600 s.
The lock can only be withdrawn by simultaneously pres-
sing the [Folder] and
[Cancel] buttons if a USB stick containing the
<KEY.adm> file is inserted at the same time.
This function is used to prevent unauthorised changes.
10.4.4 Set contrast

CONFIGURATION MENU > M ODULE CONFIGURATION > SET CONTRAST >
xx
Fig. 10-55: Set contrast
The display contrast can be adjusted here.

The value can be set in the range from 0 to 15.

10 Configurations
10.4.5 Module name

CONFIGURATION MENU > M ODULE CONFIGURATION > M ODULE NAME >
xx
Fig. 10-56: Module name
A name can be assigned for the welding control system here, see Text input, p. 43.
10.4.6 Delete log book

CONFIGURATION MENU > M ODULE CONFIGURATION > DELETE LOG BOOK >
xx
Fig. 10-57: Delete log book
The log book can be deleted here.

Deletion is carried out with a preceding security prompt.
10.4.7 Define CAN node

CONFIGURATION MENU > M ODULE CONFIGURATION >DEFINE CAN NODE>
xx
This is only possible for modules with a CAN bus connection.
The address for communication via the CAN bus is defined here.
The address can be set from 0 to 15.
10.5 Filius information

CONFIGURATION MENU > FILIUS INFORMATION
xx
Information on the welding control system's hardware and software equipment is displayed
here.
The information area covers more lines than can be displayed in the main display area. The
[jog wheel] can be used to scroll through the information area.

10 Configurations
10.6 Firmware update

Firmware updates are offered automatically when the module is started with the USB stick
inserted.
If the welding control system's firmware deviates from that on the USB stick, the cor-
responding updates are offered:
l Bootloader B update
l Feature update
l Graphics processor firmware update
l Welding control system firmware update
All updates or only the desired ones can be carried out. Updates are started by selecting
"yes" or "load", and are skipped by selecting "no" or [Cancel].
Running updates can be aborted with [Cancel].
Once the relevant update is completed, the status display is shown.
Bootloader update
Prerequisites
o A bootloader update is offered on the display.
Fig. 10-58: Update bootloader display
Procedure
1. For "yes" = press the [jog wheel]
2. For "no" = select [Cancel] or press [Folder]
3. Press the [jog wheel] to start the update
Update sequence
l Check file: validity of the update file is checked.
l Program flash: the corresponding file is overwritten in the welding control system.
l Verify: the two files are compared.
Once all 3 steps have been successfully completed, the now updated bootloader B is started
with the [jog wheel] or [button].
Result
l Bootloader update has been performed.
Feature update
Feature updates can be used to enable or extend functions. For information on this, contact
HWH service, specifying the serial number of your module, tel.: +49 40 766 904-84.

10 Configurations
Prerequisites
o A corresponding file is on the USB stick.
o A feature update is offered on the display.
Fig. 10-59: Feature update display
Procedure
1. For "yes" = press the [jog wheel]
2. For "no" = select [Cancel] or press [Folder]
3. Press the [jog wheel] to start the update
Once feature update has been completed successfully, further available updates are offered
on the display or restart with the available firmware is performed.
Graphics processor firmware update

If a firmware update is contained on the stick, it is offered after pressing the [button]. The
right [Folder] button shows the next graphics processor update which may be available.
Prerequisites
o A corresponding file is available on the USB stick.
o A graphics processor firmware update is offered on the display.
Fig. 10-60: Graphics processor firmware update display
Procedure
1. Select "load" by turning the [jog wheel].
2. To cancel, press [Cancel]; to display the next file, press [Folder].
3. Press the [jog wheel] to start the update.
Update sequence
Once all steps have been completed successfully, the update is ended with the [jog wheel] or
[button].
If further updates are available, they are offered on the display or restart with the available
firmware is performed.

10 Configurations
Firmware update
If a firmware update is contained on the stick, it is offered after the preceding update. The
right button [Folder] shows the next version which may be available.
Prerequisites
o A corresponding file is on the USB stick.
o A welding control system firmware update is offered on the display. The file ending is .FAC.
.
Fig. 10-61: Welding control system firmware update display
Procedure
1. Select "load" by turning the [jog wheel].
2. To cancel, press [Cancel]; to display the next file, press [Folder].
3. Press the [jog wheel] to start the update.
Update sequence
Once all 3 steps have been completed successfully, the newly loaded firmware is started with
the [jog wheel], the [Cancel] button or [Folder].

10 Configurations

11 Parameterising the welding process
11.1 General information on resistance welding

Resistance welding is a joining procedure for electrically conductive materials based on the
Joule current heat of an electrical current flowing through the connection point.
This heats the connection partners until they melt. After the current has flowed, once the mol-
ten material has solidified again, a mechanically resilient welded connection results.
The mechanical part of pressing is joined by the task of pressing the workpieces together with
such a high force that the resistance for the same material is virtually always the same.
In resistance pressure welding, pressing together during welding and after current flow sup-
ports the formation of a firm joint.
The major advantage of this welding technique is the possibility of concentrating high energy,
in the form of electrical current, onto a very small area of a workpiece within a very short
space of time, resulting in an insoluble joint under the application of high pressure (pneu-
matic or electromechanical).
The welding parameters previously input which are dependent on the type and thickness of
the workpieces being welded, their number, their fit to each other and their surface, are cru-
cial as regards the durability and size of the welding spot. Welding electrode cooling, the tem-
perature of the cooling water and its flow rate also exert an influence.
Typical procedures
The typical resistance welding procedures are:
l Spot welding
l Projection welding
l Butt welding
l Flash butt welding
Welding processes not fully listed here can only be discussed in part in these operating
instructions. Further information is available in the relevant literature.

Principle of a welding system

The following illustration schematically shows the principle of a welding system.
Fig. 11-1: Principle of a welding system

Typical welding process in resistance welding
Fig. 11-2: Typical welding process in resistance welding
Squeeze time
Welding time
Hold time
Welding current
Electrode force
I Current
F Force
t Time

11.2 Welding process

Resistance spot welding
Resistance spot welding (short form: spot welding) is used to join steel sheets in the auto-
motive industry, in body building and vehicle construction and generally in manufacturing
involving sheet metal processing. To be able to perform a welding process, the workpiece
must be clamped with a welding tool (electrode holder, etc.). This clamping is carried out
by means of the working stroke through the module or, in automated systems, through a
PLC or a robot. Once the compression force has built up on the workpiece, current flow is
introduced by the module. Molten material forms. So that a firm joint can be formed, the
workpiece must remain clamped for a certain time after melting to enable the formation
of a solid structure.
The welding process describes the course of the welding current over time. A program's wel-
ding process is defined through a variety of parameters. The parameters for a welding pro-
cess are stored as a program. The parameters are input via the operating unit.
Filius offers the option of optimally setting the process with up to five different times plus an
additional pre-heating and current increase function.
Improper parameterisation of the module

Material damage to the system and/or component
l Make sure the module is correctly parameterised.

Phases in the welding process
Fig. 11-3: Phases in the welding process
1 Strength of the main current (kA)

2 Strength of the post-heating current (kA)
3 Strength of the pre-heating current (kA)
a Squeeze time
b Pre-heating time
c Heat compensation time
d Main current time (main current)
e Current increase time
f Current decrease time
g Pause time
h Recooling time
i Post-heating time
k Hold time
l Number of pulses
m Welding time
n Welding process
The welding process is initiated by program selection and the presence of the start signal; it
ends with the stepping contact.
The welding unit is closed at the beginning of the welding process and welding force builds
up. Closing and the build-up of force take place in the squeeze time, or in the first extended
squeeze time.
See First extended squeeze time, p. 91
See Squeeze time , p. 92
After the welding unit is closed and the desired nominal force is achieved, the input of heat
into the workpiece begins with welding time (see Fig. 10-1).

To achieve an optimal welding result, it may be necessary to not introduce heat uniformly
but in the form of current profiles. Welding profiles individually tailored to the welding job
can be parameterised using the <Pre-heating>, <Main current> and <Post-heating> para-
meters.
See Pre-heating time, p. 94
See Main current, p. 96
See Post-heating, p. 100
Current increase and decrease, pulse and pause times can also be configured.
See Current increase time, p. 95
See Current decrease time, p. 98
See Pulses, p. 98
See Pause time, p. 97
The current-conducting times are followed by the hold time. During hold time the welding
spot cools down and is mechanically resilient afterwards. The stepping contact is set when
hold time ends, and the welding process is completed.
See Hold time, p. 102
11.3 Sequence program

Programs are used to set parameters with which a welding job can be processed. With auto-
mated systems which e.g. process several welding jobs in succession using a PLC, it is
necessary for the PLC to inform the welding control system which parameter set is required
for the job via the program selection inputs. Otherwise, it may be sensible to specify the pro-
grams via the operating unit in the case of bench devices.
The programs can be selected in two ways.
Welding program selection with internal program selection is performed under this menu
item. This function is only available if [ProgSelection] is set to <Internal program
selection>,see Process configuration, p. 50.
CONFIGURATION MENU > PROGRAM >
xx
Fig. 11-4: Program
xx
Fig. 11-5: Selecting a program

11.4 Selecting a program

32 programs are available. Programs 1 to 16 are assigned to <START1>. Programs 17 to 32 are
assigned to <START2>.
Assignment is carried out according to the following pattern:
l Programs 1 and 17
l Programs 2 and 18
l Programs n and n+16, whereby n is no greater than 16
Prerequisites
o The configuration menu is called.
Procedure
1. Call [Program] sub-menu.
2. Select programs.
3. Confirm selection by pressing [jog wheel].
Result
l Programs are selected.
l Status display is called.
11.5 Edit program

PARAMETER MENU >
xx
Fig. 11-6: Edit program
The individual programs can be selected here for editing.

The parameter menu appears after selection.

11.6 Program configuration

Order
Regulation type
Operating mode
Proportional valve
11.6.1 Order
To enable the welding program to be identified, a work or task designation can be defined for
the program.
PARAMETER MENU > PROGRAM CONFIGURATION > ORDER >
xx
Fig. 11-7: Order
A plain text designation can be assigned to the sequence program here, see Text input, p. 43.
11.6.2 Regulation type

PARAMETER MENU > PROGRAM CONFIGURATION > SKT MODE >
xx
Fig. 11-8: Current regulation
The following settings are possible:
Current setting in scale divisions without mains compensation
Current setting in scale divisions with mains compensation
Constant current regulation (KSR)
?? Voltage regulation
?? Power regulation

11.6.3 Operating mode

You can choose between three operating modes: single spot mode, series spot mode and
seam, whereby seam mode corresponds to continuous current with a programmed pause
time of 0.
The mode in which the individual welding processes are processed is defined using the ope-
rating unit.
PARAMETER MENU > PROGRAM CONFIGURATION > SINGLE SPOT >
xx
Fig. 11-9: Operating mode

Single spot
Series spot
Seam
The operating modes can be executed with various regulation types.

l Without mains voltage compensation
l With mains voltage compensation (only 50 Hz and 60 Hz)
l With constant current regulation (KSR)
Spot mode
In spot mode, a distinction is made between a single spot and a series of single spots (series
spot mode).
In series spot mode, the tool opens after the <Hold time>. This is followed by an <Open
time>, and a new welding process is performed. This process is repeated until the start is with-
drawn.
Single spot
The <Single spot> mode is typically used for automated systems.
In single spot mode, a welding process is performed when a start signal is detected. The wel-
ding process is completed with a stepping contact, see Stepping contact, p. 128. It results in
one welded joint.
l After starting, a welding process runs as programmed.
l The welding process is repeated after opening the start contact and closing it again.
l A start signal activated prior to the stepping contact does not result in a renewed wel-
ding process. It can only be started after the completion of the previous welding pro-
cess.
The welding process requirements are read by activating the <Start> input. The module the-
refore detects the order, prepares the welding program defined by the program selection and

works through the parameters in succession up to the <Hold time>. When the program
sequence is completed, the stepping contact <FK> signal is activated and process control is
returned.
The welding process in single spot mode can also be influenced by:
l Emergency stop
l Pre-stroke function
l Pressure contact
l Current end
l Monitoring functions
l Control functions
l Travel monitoring
Series spot
<Series spot> mode is typically used for hand electrode holders.
The continuous sequence of welding processes for the duration of the applied start is called
series spot mode. A start thus results in a series of welding processes, i.e. multiple welded
joints.
In series spot mode, a welding process is repeated following the output of the stepping con-
tact signal and expiry of open time for as long as the <Start> signal is also present.
In series spot mode, the welding process normally begins with the first extended squeeze
time, see First extended squeeze time, p. 91.
This is required because more time is needed to close the electrode holder and for power to
build up during the first welding process.
Note
In series spot mode, the <Start interlock at start of current time> configuration is recom-
mended. This enables the welding process to still be aborted during the squeeze time
without current if necessary.
If the welding process is not cancelled, it runs as programmed to the end of hold time.
See Hold time, p. 102.
This process is repeated as long as start signal is still being applied. Series spot mode is nor-
mally ended in open time by cancelling the start signal.
See Open time, p. 103.
In series spot mode, a welding cycle is repeated if the start signal, which was already active
prior to the <FK signal>, is still applied after the <FK signal>.
l The sequence is extended by <Open time>.
l After starting, a work cycle runs as programmed.
l If the start contact remains closed, the working cycle is repeated cyclically until the
start contact is opened.
l After the end of the last current pulse with <Hold time>, the module ends the process.
If the start input signal is

l cancelled during <Open time>, the welding process ends immediately.

l cancelled during <Squeeze time>, the welding process ends depending on the con-
figuration of the start interlock.
In series spot mode, squeeze time in the first cycle can be extended by <First extended
squeeze time> to compensate for cylinder lag on the machine or the electrode holder.
The series spot mode welding process can also be influenced by:
l Emergency stop
l Pre-stroke function
l Pressure contact
l Current end
l Monitoring functions
l Regulation functions
l Travel monitoring
Seam mode
The parameters active during seam mode are the same as those for spot welding. Only the
<Pulse> parameter is not used. The start input is checked constantly during the main current
time process. If this remains active, current output is maintained until start is withdrawn. If a
value is entered in the <Pause time> parameter in the main current time, the interaction bet-
ween current and pause time is repeated until the start input is passive.
Current and pause times can also be programmed for seam mode.
l In seam mode, the <Main current time> starts following the <Squeeze time> or after a
programmed pre-heating time.
l This is followed by the <Main current time>, alternating with the <Pause time>.
l A programmed current increase is executed.
If the start input signal is
l is withdrawn during the <Pause time>, it ends immediately and the hold time is com-
pleted with the programmed values. The stepping contact signal is output (depending
on the configuration).
l is withdrawn during the <Main current time>, the main current time ends immediately
and the hold time is completed with the programmed values.
l A programmed current decrease is not executed.
The process is executed until the start signal is withdrawn. Any programmed <Post-heating
time> does not run after withdrawal of the start signal.
Continuous current mode

Continuous current mode is a special form of seam mode; it only differs because the value 0
is assigned to the pause time.

11.6.4 Proportional valve
Proportional valve with percentage input

Proportional valve
PARAMETER MENU > PROGRAM CONFIGURATION > PROPORTIONAL VALVE >
xx
Fig. 11-10: Proportional valve, percentage input
Actuation of the proportional valve is set here. The value range is 0…100%, corresponding to
0...10 V.
Proportional valve with force specification

Proportional valve
PARAMETER MENU > PROGRAM CONFIGURATION > PROPORTIONAL VALVE >
xx
Fig. 11-11: Proportional valve, force specification
Actuation of the proportional valve is set here. The value range can be between 0…999 daN,
corresponding to 0...10 V.
If daN is used in the force input area, the proportional valve must be calibrated, see Con-
figuration for proportional valve values, p. 58.

11.7 Parameters
11.7.1 First extended squeeze time

PARAMETER MENU > TIMES >
xx
Fig. 11-12: First extended squeeze time = first vVHZ
Parameterisable 0 ..99 per
The <First extended squeeze time> (1st vVHZ) is permissible in all operating modes. It is used
primarily in series spot mode. During the first electrode stroke, first vVHZ enables reliable
pressure build-up when pressing the electrode onto the workpiece. The electrode holder has
to close over a longer distance in the case of the first welding spot and requires more time for
this. During the welding process, first vVHZ is the first process time; however, it may also
have the value 0.
When <Immediate start interlock> is configured, the welding process runs without external
influence.
If start interlock is set to <Start interlock at start of main current time>, the ongoing welding
cycle and 1st vVHZ are cancelled immediately upon cancelling the triggering start. The general
starting conditions and starting times then apply to renewed starting of a welding process.
Normal completion of the first vVHZ, it is followed by squeeze time.
The <First extended squeeze time> is used primarily in series spot mode.
See Series spot , p. 88.
It begins with the input signal <Start> and ends with the beginning of squeeze time. During
the first extended squeeze time, the welding unit closes and permits safe pressure build-up
when pressing the electrode onto the workpiece.
In series spot mode, use of the first extended squeeze time permits a more efficient welding
process, because the welding unit needs more time to close during the first welding spot than
with subsequent spots. This time can be parameterised beyond the first extended squeeze
time.
The fist extended squeeze time is always the first time expiring in the welding process; it can
also have the value 0.

11.7.2 Squeeze time

xx
Fig. 11-13: Squeeze time = VHZ
Parameterisable [Min. squeeze time] 0 ..99 per

The squeeze time (VHZ) value range can be limited by configuring the minimum squeeze time.
Squeeze time (also called pre-clamping time) is a time without current at the start or after the
first extended squeeze time, see First extended squeeze time, p. 91. Squeeze time is used to
bridge the closing time of the welding electrode holder and for the safe build-up of force
when the welding unit is closed but no current is flowing.
Squeeze time must be set so long that the desired pressure can build up over the workpiece.
If this time is set too short, this may result in initial spatter.
The pressure contact can be used to indicate whether nominal force is reached. The squeeze
time only ends when the pressure contact is closed. If the pressure contact is missing,
squeeze time is extended, simultaneously followed by the message:
l DK/NBS
Note
In the systems, air pressure is used to trigger electrode holder arm movements via solenoid
valves and cylinders. When the electrode holder arms come together, a force acts on the
workpiece. In the cylinder, this pressure builds up force, which can be evaluated with a pres-
sure switch.
Note
If the <Pressure contact> input is not used, the input must have a fixed 24 V connection.
The squeeze time follows on from

l the 1st extended squeeze time on the first passage through a welding cycle or
l open time in series spot mode.
Note
In the case of immediate start interlock, a missing pressure input signal and missing NBS
release, the welding process will pause. It can only be interrupted through external status
changes such as <EMERGENCY STOP> or by pressing [Cancel].
Component control and sink-in travel monitoring

Component control is evaluated one unit of time prior to the end of the squeeze time. The
reference mark for sink-in travel monitoring is formed at this point in time.
The current program starts on completion of the squeeze time.

11.7.3 Pre-heating
Pre-heating determines how long the component is heated by the <Pre-heating current>
prior to the welding process. Pre-heating can e.g. be used to join the material (poor fit), over-
come transition resistances in coated materials (galvanised sheets) and burn alloys off elec-
trode caps (to reduce transition resistances).
The duration and amperage are always dependent on the welding job.
The following parameters are available:
l Pre-heating time
l Pre-heating current
l Heat compensation time
The pre-heating time can be switched off (= 0 ms). If pre-heating time = 0 is set, no pre-heating
occurs. In this case, the nominal pre-heating current value has no effect on the initial value of
the current increase in the main current time. The heat compensation time is not then carried
out either.
The nominal current value setting can be specified in SKT for SKT mode or kA with current
regulation.
Pre-heating 1 .. [Max. Skt] xxx or xxx 0.01 ... [Max. current] [kA]
Pre-heating current
PARAMETER MENU > NOMINAL VALUES >
xx
Fig. 11-14: Pre-heating current
The parameter determines the value of the current which heats the component during the
<Pre-heating time>.
Pre-heating current is output with no current increase or decrease.
The framework of values for the nominal pre-heating current value is defined from 1...999 SKT
and is checked and ensured by the module.
For pre-heating time > 0, the nominal pre-heating current value is simultaneously the initial
value of the framework of values for the current increase during welding.

Pre-heating time
xx
Fig. 11-15: Pre-heating time

The parameter determines the length of time for which the component is heated by the <Pre-
heating current> prior to welding.
Pre-heating time is a current conducting time; it can be switched off (= 0).
For pre-heating time > 0, the nominal pre-heating current value is simultaneously the initial
value of the framework of values for the current increase during welding.
Heat compensation time

xx
Fig. 11-16: Heat compensation time

To avoid excessive heating, heat compensation time can be parameterised after pre-heating
time. During this time, cooling at the welding spot takes place through the electrodes which
are applied.
The parameter determines the duration between the end of <Pre-heating time> and the start
of <Main current time>. No current flows during this period of time.
11.7.4 Main current time

The parts to be welded are joined during the main current time.
In order to execute the welding job with the best possible quality, it may be necessary to not
continuously input heat into the material. The main current time parameter can be used to
customise heat input for each welding job. It is possible to parameterise current increase and
decrease, pulses and current pauses.
Main current time has the following parameters:
l Current increase time (up slope time) (SAZ)
l Main current (nominal current value)
l Main current time (SZ)
l Pause time (PZ)
l Number of pulses (IMP)
l Current decrease time (down slope time) (DS)

The welding time (SWZ) is the welding program time which must not be 0. It is calculated
using the general formula
(pulses x main current time) + ((pulses - 1) x pause
Welding time =
time)
If the number of pulses = 1, the welding time is completely defined through the main current
time specification. A specified pause time is not edited.
The main current time is a current-conducting time whose breadth is defined by the time and
whose adjustment range is limited by nominal current values.
The pause time is current-free and is defined only by its time. A pause time of 0 is permissible.
The following prerequisites must be met so that current is conducted during the welding
time:
l The main current time has a value of > 0
l The number of pulses is >= 1
l The nominal current value is > 0
l The <With current> inputs are active
If a value of > 1 is input for the pulses, the main current time is followed by a pause time and a
further main current time. The number of pulses defines the number of main current times.
Pulse mode enables heat distribution in the workpiece and helps to avoid impermissible punc-
tiform overheating with the highest possible current amplitude.
Current increase time

xx
Fig. 11-17: Current increase time

The <Current increase time> parameter is used at the start of main current time to set a con-
tinuous nominal current amplitude value change in the input current increase time from the
initial value to the nominal current value. The current increase time is part of the welding
time.
The increase in current always starts with the value that the pre-heating current ends with, if
it was parameterised, see Pre-heating, p. 93.
The increase in current will otherwise begin at 0.

6 Pre-heating current
7 Main current
a Squeeze time
b Pre-heating time
d Main current time
e Current increase time
h Recooling time
i Post-heating time
k Hold time
The slope of current increase is calculated as follows:
Main current pre-heating current
Slope =
If current increase time is longer than (pulses x main current time), the nominal current value
is not reached. During pause times, the nominal current amplitude value change is halted.
The initial current increase value is either
l the minimum permissible nominal value or
l the nominal pre-heating current value if the pre-heating time is > 0.
This results in the following behaviour:
l Initial value < nominal current value = increase in amplitude
l Initial value > nominal current value = reduction in amplitude
l Initial value = nominal current value = no nominal amplitude value change
Main current
xx
Fig. 11-18: Main current
The parameter specifies the scale divisions (Skt) which are set during the <Main current
time>.
Depending on the input under > REGULATION TYPE, it can also be specified in kA or SKT, see
Regulation type, p. 86.
The main current is greater than the post-heating current or hold time.

Main current 1 .. [Max Skt] xxx or xxx 0.01 ... [Max. current] [kA]
Main current time

xx
Fig. 11-19: Main current time
Parameterisable 0.5 ..[Max. main current time] per

The parameter determines the length of time for which <Main current>flows during the wel-
ding process.
Main current time consists of the parameterisable times in which current flows through the
workpiece, provided that the welding process is started with both inputs set to <With cur-
rent>.
If the welding process is started without current when setting up the module, the main cur-
rent time will still expire.
Pause time
PARAMETER MENU > PULSES >
xx
Fig. 11-20: Pause time

The parameter enables current pauses to be inserted during the <Main current time>. Pause
time is not a current-conducting time. During <Pause time>, heat compensation takes place.
<Pause time> is only taken into account in welding processes with one or more pulses, see
Pulses, p. 98. <Main current time> ends once the <Number of pulses> has been processed.
Logically, a distinction can be made between two pause times:
–xthe pause (PZ) between the pulses
–xthe pause (RKZ) between the last pulse and the post-heating time, see Recooling time, p.
101.
In the operating unit, these various pauses are assigned to the corresponding time para-
meters.

Pulses
xx
Fig. 11-21: Pulses

The parameter enables the <Main current time> to be broken down into individual pulses
with intermediate pauses. During the pause time, heat compensation takes place at the wel-
ding spot between the pulses.
See Pause time, p. 97.
The minimum setting is 1. If more than one pulse is programmed, the main current time is
repeated according to the set value after a possible pause time (PZ).
Main current time is over when the set number of impulses has been carried out to com-
pletion.
Fig. 11-22: Main current with pulses
7 Main current
a Squeeze time
b Pre-heating time
d Main current time
g Pause time
k Hold time
l Number of pulses
Current decrease time

xx
Fig. 11-23: Current decrease time

At the end of welding time, the <Current decrease time> parameter is used to set a con-
tinuous nominal current amplitude value change in the input current decrease time from the
nominal current value to the end value. The current decrease time is part of welding time.
The parameter thus determines the duration of the current decrease. The temperature of the
component decreases during this period of time.
The initial value is the <Main current>; the final value is 1 Skt or the value of the <Post-heating
current>, if it was parameterised.
Fig. 11-24: Current decrease time in the welding process
6/8 Pre-heating current/post-heating current

7 Main current
a Squeeze time
b Pre-heating time
d Main current time
f Current decrease time
h Recooling time
i Post-heating time
k Hold time
The slope of current decrease is calculated as follows:
Post-heating main current
Slope =
Current decrease time
If current decrease time is longer than main current time, the end value will not be reached.
If the current decrease time is longer than (pulses x main current time), the end value is not
achieved. During pause times, the nominal current amplitude value change is halted.
The end value of the current decrease is either
l the minimum permissible nominal value or
l the nominal post-heating current value if the post-heating time is > 0.
This results in the following behaviour:
–xNominal current value > end value = reduction of the amplitude
–xNominal current value < end value = increase in amplitude
–xNominal current value = end value = no nominal amplitude value change
If the <Current increase> and <Current decrease> functions are used in a welding time and
xxxxxxxxxx(current increase time + current decrease time) > (pulses x main current time)
the following behaviour arises:
–xAn attempt is made to achieve the nominal current value in the current increase time

–xIf the nominal current value is achieved, an attempt is made to achieve the end value in the
current decrease time
–xThe end value of the current decrease time is not achieved.
This means that the current increase takes precedence over the current decrease.
Note
The initial value of the current increase or the final value of the current decrease are not
dependent on the heat compensation time or the recooling time.
They are only dependent on the nominal pre-heating current value or the nominal post-hea-
ting current value (if used).
The <Pause time> is not part of the <Current decrease time>.

The current decrease occurs when the <Main current> is greater than the <Post-heating cur-
rent>.
11.7.5 Post-heating
In order to execute the welding job with the best possible quality, it may be necessary to not
continuously input heat into the material. The parameters for post-heating can be used to fur-
ther adjust heat input to the welding job; post-heating can thus be used to temper the mate-
rial.
The following parameters are available:
l Recooling time
l Post-heating time
l Post-heating current
Post-heating consists of exactly one rectangle, whose width is described by the post-heating
time and whose height is described by the amplitude of the nominal post-heating current
value.
If a post-heating time of > 0 is selected, a recooling time is performed if a value of > 0 has been
specified for the recooling time and this has been preceded by a current conducting time (of
the same current program).
The initial value of <Post-heating current> is the final value of the amplitude for the current
decrease, if this was parameterised.
See Current decrease time, p. 98.
If a post-heating time of 0 is set, no post-heating is carried out. In this case, the nominal post-
heating current value has no effect on the welding time.
The nominal current value setting can be specified in Skt for Skt mode or kA with current regu-
lation.
Post-heating

Recooling time
xx
Fig. 11-25: Recooling time

The parameter determines the period of time between the end of the <Main current time>
and the start of the <Post-heating time>. No current flows during this period of time. At the
welding spot, cooling takes place through the electrodes which are still applied.
Post-heating current
xx
Fig. 11-26: Post-heating current
The parameter determines the value of the current which heats the component during the
<Post-heating time>.
The initial value of the <Post-heating current> is the final value of the amplitude for current
decrease see Current decrease time, p. 98, if it was parameterised.
The nominal value specification for the amplitude is defined from 1...999 Skt.
Post-heating 1 .. [Max Skt] xxx or xxx 0.01 ... [Max current] [kA]
The nominal current value setting can be specified in Skt for Skt mode or kA for KSR mode,
see Regulation type, p. 86.
Post-heating time
xx
Fig. 11-27: Post-heating time

Certain welding jobs require post-heating of the material, e.g. to avoid stress cracks.
The parameter determines the length of time for which the component is heated by the
<Post-heating current> after the main current.

11.7.6 Hold time

xx
Fig. 11-28: Hold time
Parameterisable [Min. squeeze time] ..99 per

The hold time (NHZ), also called the post-pressing time, starts after the last time in which cur-
rent flows (main current or post-heating current). During the hold time, the electrodes
remain pressed together to allow the welding spot to recool so that the spot solidifies and is
then mechanically resilient.
The parameter determines the length of time for which the electrodes apply pressure on the
component after welding. No current flows during this period of time.
The following also applies to hold time:
As short as possible and as long as necessary. If the hold time is too long, the material may
harden due to more intensive cooling; if it is too short, the risk is run that the welding spots
cannot withstand the forces and tear apart.
The welding tool remains stable in this position.
The start interlock is withdrawn at the end of the hold time.
Successful welding and faulty welding in the hold time

During the hold time, the calculations for all monitoring are completed. If the hold time to
too short for the calculations, the hold time is extended.
The following information is then available at the end of this time:
l Successful welding/faulty welding
l Process behaviour as per configuration
l Error
The stepping contact signal can be updated by configuration:
l At the end of the minimum hold time or
l At the end of hold time
If welding is successful, the system is opened at the end of hold time and the stepping con-
tact output, the welding process is complete. At the same time, start interlock is released.
Depending on the set error class, the stepping contact is not output in the case of faulty wel-
ding, the hold time is extended, the welding unit remains closed. The corresponding mes-
sages are output.
By acknowledging the message, the hold time is ended, the system is opened and the step-
ping contact is output. The welding process is complete. This ensures that workpieces with
faulty welding do not go unnoticed for further processing. The behaviour of the module after
outputting the corresponding messages can be configured based on the error classes.
The welding tool remains stable in this position.

11.7.7 Open time

xx
Fig. 11-29: Open time
Parameterisable [Min. open time] ..99 per

The open time (OHZ) is used exclusively in series spot mode. It begins at the end of hold time.
See Series spot , p. 88.
Open time enables material transport or tool positioning. The <Solenoid valve> signal is shut
off for this purpose so that the welding unit can open. The welding unit can be moved to the
next welding spot in the short opening phase. When the open time ends the next welding pro-
cess begins with the squeeze time. The welding unit closes again.
This parameter determines the period of time between the end of the <Hold time> and the
start of squeeze time for the next welding process.
In series spot mode, the start interlock is cancelled at the end of the hold time. When the
open time ends, the start interlock is activated at the start of the next cycle. If <Immediate
start interlock> is configured, start interlock is set immediately.
Note
Cancelling the triggering start signal leads to the immediate end of open time and thus the
end of the serial spot process.


12 Device functions
12 Device functions
The configurable device functions are described in the following.
12.1 Constant current regulation (KSR)

The function is used to keep the welding current constant. The function monitors the welding
current based on the specified nominal current values and tolerances. The function is para-
meterised using the operating unit.
The amplitude of the current is dependent on various factors, ranging from fluctuations in
the utilities' mains supply to varying workpiece characteristics. The IQ devices' constant cur-
rent regulation is able to compensate such disturbing influences.
Regulation attempts to maintain a constant secondary current by changing the pulse width.
To do this, the welding control system evaluates the actual current value in each half cycle
and, in the next half cycle with the same polarity, corrects the ignition angle until the nominal
current value is achieved again. When constant current regulation is switched on, the values
for the current (I) are set via the operating unit directly in "kA".
Proper operation with constant current regulation is only possible as of a <Main current
time> of 2 per .
Messages
Messages are output if the interference variables can no longer be regulated because the
available output voltage setting range is not sufficient for this.
i=0
The message <i = 0> means that no measured current value could be formed despite ignition
angle output. The reason for this may e.g. be an interrupted ignition line connection to the
power stage or the measuring coil is not placed around the secondary side. In this error pro-
file, the ignition angles are kept constant , with the result that welding is ended without regu-
lation.
The message <Lower limit value> indicates that the ignition angles have been reduced to 1
scale division but the measured current is still too high. The possible reason could be an incor-
rectly input nominal value.
If the message <Upper limit value> is output, the ignition angles have reached the maximum
value of 999. Possible reasons could e.g. be:
l An inadequately dimensioned system,
l An incorrect cos phi setting (with AC regulation),
l Nominal value specified in the welding program is too large.

12 Device functions
12.2 With current

Note
Current is only output if the <With current> function is switched to active internally and exter-
nally.
The function enables a welding process with or without welding current output. The function
is activated using the [With current] button, see Structure, p. 17. It can also be switched to
not <With current> through an external signal. If one of the two statuses is passive, the pro-
gram runs without current.
When the <With current> input is active, the welding process is carried out with current, or
without current when the input is inactive.
The LED display indicates the status:
l The LED lights up constantly: the control system is set to <With current>. The cycle is per-
formed with current.
l The LED flashes: the external <With current> input is passive.
l The LED is off. The control system's <With current> button is passive.
12.3 IQ monitoring function IQ monitoring function

This function enables the welding current to be monitored separately for each program.
Within a time window (measuring time), <IQ limit value> monitoring compares the effective
values of the measured secondary current with the present nominal current values. If the per-
missible "tolerance plus" or the permissible "tolerance minus" are overshot or undershot, a
module message is output. Measurement is carried out in each half cycle. The pre-heating
time, post-heating time, current increase time, current decrease time and the pause times
during operation with pulses are not taken into consideration in determining the measuring
time. The delay time can also be used to further limit the measuring time.
12.3.1 Parameterise IQ monitoring function

The following steps must be performed to define the IQ parameters:
1. PARAMETER MENU > IQ PARAMETERS >...
SEE IQ PARAMETERS, P. 107.
2. Define <MAZ> (delay) parameter (default 0).
See Delay, p. 108.
3. Define <MZ> (measuring time) parameter (default 2 s).
See Measuring time, p. 108
4. Enter the desired tolerance limit for the <Tolerance +> parameter.
See Tolerances, p. 108.
5. Enter the desired tolerance limit for the <Tolerance -> parameter.
See Tolerances, p. 108
6. Select the <Monitoring type> parameter as desired.

12 Device functions
Further steps are necessary depending on the regulation type used:

If the regulation type KSR is selected and the monitoring type <Iref kA> is set, the reference
values are taken from the nominal values for the welding program.
If SKT is selected for nominal value specification in the welding parameters, values must be
input in the <Reference current (SKT)> parameter.
Monitoring is active on completion of parameterisation. The current used for welding is now
compared with the set tolerance values. If a deviation is greater than the tolerance value, a
message is output via <FK> and <Limit value error contact>. The function must be set under
<FIQ> error class configuration.
A warning appears on the display.
12.3.2 IQ parameters
Delay 0 .. 99.0 per
Measuring time 0 .. 99.0 per
Tolerance + 1 .. 99%
Tolerance - 1 .. 99%
Monitoring OFF / Iref kA
Reference current 0 .. 50 kA0,
12.3.3 Current measurement

Current measurement is carried out exclusively during main current time.
No current measurement or regulation takes place during pre- and post-heating. Pause times
are not evaluated for the measurement.
The measured current value is determined as the mean value of the effective welding current
during the measuring time.
Measurement of the actual value starts on expiry of the measuring delay time and ends on
expiry of the measuring time.

12 Device functions
12.3.4 Measuring time

PARAMETER MENU > IQ PARAMETERS >
xx
Fig. 12-1: Measuring time
Measuring time begins at the end of the delay time. If the delay time = 0, the measuring time
begins at the start of main current time 2 and ends on expiry of main current time 2. If a pre-
and post-heating current are parameterised, measurement is also carried out during main
current time 2.
12.3.5 Delay
PARAMETER MENU > IQ PARAMETERS
xx
Fig. 12-2: Delay
The delay is a parameterised period of time which delays the start of the measuring time. The
delay enables the current curve increase, which is delayed due to the inductivity of the wel-
ding circuit, to be removed from the measurement.
No delay is required for the current decrease at the end of the main current time. It does not
occur in the measuring time, as this ends with the main current time.
12.3.6 Tolerances
xx
Fig. 12-3: Tolerance plus
xx
Fig. 12-4: Tolerance minus
Positive and negative tolerances can be specified for the selected monitoring method. The
tolerances are the deviations which are permitted in comparison with the nominal values. If
tolerances are overshot or undershot, a message is output. In series spot mode the welding
process is stopped. In single spot and seam welding, restarting is not permitted.

12 Device functions
12.4 Travel measurement

PARAMETER MENU >
xx
Fig. 12-5: Travel measurement
Travel measurement monitors the electrodes' travel. The electrodes' travel is determined
using travel sensors. The electrodes' travel provides information on the size of the com-
ponent before and after the welding process and the extent to which the electrodes have
sunk in during the welding process. Three profile indexing processes can additionally be imple-
mented on the basis of distance marks.
Fig. 12-6: Travel path
01 Travel
02 Time
03 Squeeze time
04 Main current time
05 Hold time
06 Actual component value
07 Sink-in travel/actual final dimension
Travel measurement offers the following monitoring and control functions:

l Component control, see Component control, p. 111.
l Sink-in travel monitoring, see Sink-in travel monitoring, p. 112.

12 Device functions
l Final dimension monitoring

l Profile indexing
Fig. 12-7: Component control and travel measurement functions
01 Component tolerance +
02 Actual component value
03 Component tolerance -
04 Sink-in tolerance +/-
05 Actual sink-in value
06 Actual final dimension value
07 Final dimension tolerance -/+
The graphic shows:

l The position of the electrodes with an inserted component prior to the start of the
main current time for determination of the actual component value.
l The position of the electrodes at the end of the <hold time> for determination of the
actual sink-in travel value or the actual final dimension value.
12.4.1 General information on travel measurement

The welding control system is equipped with two analogue travel measurement inputs for
connecting potentiometric travel sensors. In PROCESS CONFIGURATION > WELDING PARAMETERS,
both travel sensors can be deactivated or optionally assigned to electrode holder 1 or elec-
trode holder 2.
Both travel sensors can also be assigned to one electrode holder.
The maximum available measuring range is 300 mm. The measurement resolution is 0.01
mm. In the range from 30 mm to 300 mm, the measurement resolution is 0.1 mm. The travel
sensors which are used must be calibrated for travel measurement operation, see Calibrate
travel sensor 1, p. 65.

12 Device functions
12.4.2 Prerequisite
Travel measurements are performed with one or two travel sensors. The selection of a sui-
table travel sensor is also crucial to the quality of the measurement. Travel sensors with a
maximum length of 300 mm can be used. Shorter sensors offer a higher resolution. The requi-
red reference voltage of 10 V is provided by the welding control system. The measurement
resolution is 12 bits.
Sensor length Accuracy [mm/bit] Accuracy [µm/bit]

25 mm 0.006 mm/bit 6.1035 µm/bit
50 mm 0.012 mm/bit 12.207 µm/bit
75 mm 0.018 mm/bit 18.310 µm/bit
100 mm 0.024 mm/bit 24.414 µm/bit
120 mm 0.029 mm/bit 29.296 µm/bit
150 mm 0.036 mm/bit 36.621 µm/bit
300 mm 0.073 mm/bit 73.242 µm/bit
The travel sensors which are used must be calibrated for travel measurement mode, see Cali-
brate travel sensor 1, p. 65.
12.4.3 Component control

Component control is used to monitor the correct size of the component and correct pla-
cement at the start of the welding process.
Monitor electrode holder 1 component dimension
Monitor electrode holder 2 component dimension
To be able to use component control, the detection limit values must be programmed. The
values to be input refer to the absolute position of the welding tool.
PARAMETER MENU > TRAVEL MEASUREMENT > COMPONENT DIMENSION MONITORING >
xx
Fig. 12-8: Maximum component control
xx
Fig. 12-9: Minimum component control
Component control is carried out at the end of <Squeeze time>. The travel sensor determines
the distance covered by the electrode, the <Actual component value>. At the monitoring
time point, the component is checked for adherence to the specified limits.

12 Device functions
If the <Actual component value> lies in the tolerance range, the welding process is released.
The welding process is stopped in the case of measured values outside of the defined tole-
rances, and an error message with the determined values appears.
M ODULE MESSAGES >
xx
Fig. 12-10: Component control module message
In the event of an error, the electrode holder does not open and the module message must
be acknowledged, see Acknowledging module messages, p. 156.
12.4.4 Sink-in travel monitoring

This function is used to monitor the electrode's sink-in travel during the welding process.
Sink-in travel is specified by the <Nominal sink in travel value> stored in the program.
Electrode holder 1 sink-in travel monitoring
Electrode holder 2 sink-in travel monitoring
Sink-in travel monitoring is used to check whether the component has reached the specified
nominal sink-in travel value at the end of the welding process. The tolerance range for control
is specified by the <Nominal value> stored in the program.
PARAMETER MENU > TRAVEL MEASUREMENT > SINK-IN TRAVEL MONITORING >
xx
Fig. 12-11: Maximum sink-in travel monitoring
xx
Fig. 12-12: Minimum sink-in travel monitoring
The sink-in travel check is carried out 10 s before the end of the <Hold time>. The travel sen-
sor determines the electrode's travel during welding. At the monitoring time point, the sink-
in travel is checked for adherence to the specified limits.
If the <Actual sink-in travel value> lies within the tolerance range, the welding process is com-
pleted with FK.
In the case of measured values outside of the defined tolerances, the FiliusACS-B-Multi-IQ |
FiliusACS-C-Multi-IQ reveals different behaviour depending on the set IQ error class.

12 Device functions
Error class FIQ 2:

The welding cycle is ended with the output of the stepping contact (FK). An error message
with the determined values appears.
M ODULE MESSAGE >
xx
Fig. 12-13: Sink-in travel monitoring module message FIQ 2
l The <Operational> output becomes inactive.

l The <Limit value error> output becomes active.
l The module message must be acknowledged.
l The module is ready to proceed again.
The electrode holder opens at the same time. To continue welding, the module message
must be acknowledged, see Acknowledging module messages, p. 156.
Error class FIQ 3

The welding cycle is stopped with the electrode holder closed. An error message with
the determined values appears.
xx
Fig. 12-14: Sink-in travel monitoring module message FIQ 3

After acknowledging, the electrode holder is opened and the stepping contact (FK) is output.
12.4.5 Final dimension monitoring

Note
Final dimension monitoring determines absolute values and is only recommended if deter-
mination of the final component dimension after the welding process is important to the pro-
duction process.
Final dimension monitoring necessitates comparison of the zero point.

Final dimension monitoring is used to check whether the component has reached the spe-
cified final dimension at the end of the welding process. The tolerance range for final dimen-
sion monitoring is specified by the <Nominal value> stored in the program.

12 Device functions
Electrode holder 1 final dimension monitoring
Electrode holder 2 final dimension monitoring
The travel sensor determines the position of the electrode 10 ms before the end of the <Hold
time> (actual final dimension value). If the <Hold time> is less than 10 ms, measurement is car-
ried out at the start of the <Hold time>.
To be able to use final dimension monitoring, the detection limit values must be pro-
grammed. The values to be input refer to the absolute position of the welding tool.
PARAMETER MENU > TRAVEL MEASUREMENT > FINAL DIMENSION MONITORING >
xx
Fig. 12-15: Maximum final dimension monitoring
xx
Fig. 12-16: Minimum final dimension monitoring
In the case of measured values outside of the defined tolerances, the FiliusACS-B-Multi-IQ |
FiliusACS-C-Multi-IQ reveals different behaviour depending on the set IQ error class.
Error class FIQ 2:

M ODULE MESSAGE >
xx
Fig. 12-17: Final dimension control module message FIQ 2


12 Device functions
Error class FIQ 3:

The welding cycle is stopped with the electrode holder closed. An error message with the
determined values appears.
xx
Fig. 12-18: Final dimension control module message FIQ 3

12.4.6 Profile indexing

Note
Profile indexing determines absolute values. Tool heating and abrasion will result in shifts of
the distance marks. The system's zero point should therefore be corrected at regular inter-
vals.
The function enables indexing to the next current profile section when travel measurement
reaches a defined value. The indexing functions are available for:
l the pre-heating time
l the main current time
l and the post-heating time
and can be performed with both travel sensors.
To be able to use profile indexing, the times in the program must be set to > 0 during pre-hea-
ting or post-heating.
Indexing after the pre-heating time (VWZ)

Electrode holder 1 profile indexing after the pre-heating time (VWZ)
Electrode holder 2 profile indexing after the pre-heating time (VWZ)

Valid profile indexing within the pre-heating time is achieved if the nominal travel value is
achieved after the minimum pre-heating current time has elapsed and prior to the end of the
pre-heating current time.
PARAMETER MENU > TRAVEL MEASUREMENT > PROFILE INDEXING >
xx
Fig. 12-19: Indexing VWZ travel (accordingly for SZ and NWZ)

12 Device functions
xx
Fig. 12-20: Indexing VWZ time (accordingly for SZ and NWZ)
If the parameterised travel for indexing is not achieved after the specified pre-heating current
time has elapsed, one of the following module messages is output.
For overshooting the input pre-heating time
For undershooting the minimum pre-heating current time
In both cases, the FiliusACS-B-Multi-IQ | FiliusACS-C-Multi-IQ reveals different behaviour

depending on the set IQ error class.
Error class FIQ 2:

Error class FIQ 3

The welding cycle is stopped with the electrode holder closed. An error message with the
determined values appears.
Indexing for the main current time (SZ)

Electrode holder 1 profile indexing after the main current time (SZ)
Electrode holder 2 profile indexing after the main current time (SZ)
Profile indexing for the main current time is set in the same manner as for the pre-heating
time and is displayed with corresponding module messages when not achieved. See above:
indexing after the pre-heating time (VWZ)

12 Device functions
Indexing for the post-heating time (NWZ)

Electrode holder 1 profile indexing after the post-heating time (NWZ)
Electrode holder 2 profile indexing after the post-heating time (NWZ)
Profile indexing for the post-heating time is set in the same manner as for the pre-heating
time and is displayed with corresponding module messages when not achieved. See above:
indexing after the pre-heating time (VWZ).

12 Device functions

13 Pin assignment
13 Pin assignment
The welding control system must be supplied with 24 VDC voltage as per the wiring diagrams.
The signal inputs can be connected to switches or PLC outputs. The switches must be sup-
plied via connection 1 of plugs X7, X8.
On use of PLC outputs, the 0 V level of the PLC outputs must be connected to connections
X7/12 and X8/10.
The signal outputs can be connected to actuators or PLC inputs.
On use of PLC inputs or actuators, the 0 V level of plug X9/X10 must be connected to the 0 V
24 level of the actuators or PLC inputs.

13 Pin assignment
13.1 Pin assignment 1
Fig. 13-1: Pin assignment 1

13 Pin assignment
13.2 Pin assignment 2
Fig. 13-2: Pin assignment 2

13 Pin assignment
13.3 Position of the connections
Fig. 13-3: Rear view - position of the connections
1X2 MG-IN Measuring coil input

1X4 Rpot IN2 Travel mea-
surement 2
1X3 Rpot IN1 Travel mea-
surement 1
X2 HF – 10 kHz Without function
X3 LE – AC Thyristor output sta-
ges
X4 MF – 1 kHz Without function
X5 LS708 LE10 Without function
X6 LS502S/LS130 LE20/LE26 Without function
X7 Digital IN E1-E10 24 V inputs
X8 Digital IN E11-E18 24 V inputs
X19 PROP V1-V2 Proportional valve
outputs
X9 Digital OUT O1-O8 24 V outputs
X10 Analog IN A|1 – A|5 Without function
X11 10/100 MB LAN Without function
X12 EXT. CAN Connection to
Filius RCl
X13 INT. CAN Without function
X14 INT. CAN Without function
X22 UART Without function
ON 1|2 Dip-Schalter für Adressbelegung EXT.-CAN
Lithium Batterie Lithium battery
INT. CAN Without function

13 Pin assignment
13.4 Notes on the connections
13.4.1 24 V input connection wiring diagram

The signal inputs can be connected to the contacts or PLC outputs. The contacts are supplied
via connection 1 of plugs X7, X8.
On use of PLC outputs, the 0 V level of the PLC supply must be connected to connections
X7/12 and X8/10.
Note
No external voltage may be connected to connections X7/1 or X8/1.
X7 and X8 24 V input connection wiring diagram

Connection I/O Name Remark
X7.1 A 24 V
X7.2 E Emergency stop
X7.3 E Start 1
X7.4 E Start 2
X7.5 E Temperature
X7.6 E Pressure contact
X7.7 E Pre-stroke
X7.8 E With current
X7.9 E Error reset
X7.10 E Water flow OK
X7.11 E Nc
X7.12 E 0 Vext 0 VDC potential connection to the PLC

X8.1 A 24 V
X8.2 E Program selection bit 0 Binary 1
X8.8 E Current end
X8.9 E Delete spot counter
X8.10 E 0 Vext 0 VDC potential connection to the PLC
13.4.2 24 V output connection wiring diagram
Note
Outputs marked * are de-energised via the EMERGENCY STOP relay.

13 Pin assignment
X9 24 V output connection wiring diagram

X9.1* E 24 V 24 VDC supply
X9.2* A Solenoid valve pre-stroke
X9.3* A Solenoid valve 1
X9.4 A Solenoid valve 2
X9.5 A Max. spot number
X9.6 A Stepping contact
X9.7 A Operational
X9.8 A VZ/NBS
X9.9 A Limit value error
X9.10 A 0 Vext 0 VDC potential connection to the PLC
13.4.3 Connection wiring diagram for proportional valve outputs

A proportional valve can be connected to the welding control system. Note the polarity on
connection under all circumstances.
The proportional valve cable is shielded via the shielding connection of connector X19.
X19.1 E 24 VDC Supply voltage
X19.2 E 0 VDC Supply voltage
X19.3 A Nominal proportional valve Max. 10 mA
value 1 0-10 V
X19.4 A Nominal proportional valve
value 1
0V
X19.5 A Nominal proportional valve Max. 10 mA
value 2 0-10 V
X19.6 A Nominal proportional valve
value 2
0V
X19.7 A Shield
The connector shielding is internally connected to earth potential.
13.4.4 Connection wiring diagram for current sensor

The connection cable is shielded via the shielding connection of connector X2.
1X2.1 A Shield
1X2.2 E Measuring coil signal -
1X2.3 E Measuring coil signal +
The connector shielding is internally connected to earth potential.

13 Pin assignment
13.4.5 Connection wiring diagram for voltage supply and power stages
Note
Due to reasons of galvanic separation, the power supply for the welding control system
should always be positioned separately. The other power supplies can be situated together.
X3 power stage connection wiring diagram

X3.1 Nc
X3.2 Nc
X3.3 Nc
X3.4 Nc
X3.5 E GND-ZT1
X3.6 A ZT1
X3.7 E 27 V synchronous
X3.8 E 27 V synchronous
X3.9 E 0VE
X3.10 E +24 V E
X3.11 E 0 V supply
X3.12 E 24 V supply
13.4.6 External CAN bus connection

With CAN bus connection only. The connection is optional.
The external CAN bus interface must be designed with a shielded, twisted pair cable (e.g.:
LIYCY 2x2x0.25 mm2) and an additional overall shield. The large-dimension shields must be
provided at both ends (e.g. with shielded terminals).
The maximum cable length should not exceed 50 m.
The CAN bus cable must not run parallel to mains or welding current cables.

13 Pin assignment

14 Input/output signals
The signals for the welding process are described in this chapter.
At least the following input signals are required for the welding process:
l Emergency stop, see Emergency stop , p. 127.
l Thyristor/temperature, see Temperature, p. 128.
l Water flow OK, see Water flow OK, p. 128.
l With current, see With current, p. 128.
l Measuring coil
l Pressure contact, see Pressure contact, p. 128.
l Start, see Start 1 and 2, p. 127.
Note
For further information on the input and output signals:
see Pin assignment, p. 119.
The various [Start interlock], [Start VHZ] and stepping contact [FK] welding parameter con-
figurations lead to different diagrams for the temporal curve of the output signals.
[Start interlock], see Start interlock, p. 55.
[Start VHZ], see Start of squeeze time, p. 54.
[FK], see Stepping contact, p. 128.
14.1 Emergency stop

The <Emergency stop> signal is an input signal. If <Emergency stop> becomes active, all active
functions are aborted or no functions can be activated. A module message to this effect is dis-
played.
14.2 Start 1 and 2

The <START1> and <START2> signals are input signals. When <START1> or <START2> becomes
active, the welding process starts. Depending on the configuration of the start interlock, a
pulse or a continuous signal is required for this.
14.3 Operational message

The operational message signal is an output signal. This output signal indicates welding rea-
diness.

14.4 Stepping contact

The <Stepping contact> (FK) signal is an output signal. This output signal indicates the end of
a welding process. The function of the <Stepping contact> (FK) is dependent on its con-
figuration.
By default, the <FK> signal is output at the end of <Hold time>. If the <Start> signal is present
for longer than the welding cycle takes, the <FK> signal remains active until the <Start> signal
becomes inactive.
If no further <Start> signal is present, <FK> is output as a 100-ms pulse as standard.
The pulse duration can be changed in the > PROCESS CONFIGURATION menu.
After a module message, the <FK> signal is only output after being acknowledged. This can be
delayed, with <Hold time> being prolonged internally.
14.5 Pressure contact

The <Pressure contact> (DK) signal is an input signal. With the <DK> input signal, the system
indicates that the necessary electrode force has been built up. The welding current is sup-
plied.
14.6 Current end

The <Current end> signal is an input signal. If this signal becomes active during seam mode,
current output is ended immediately and the hold time introduced.
14.7 Temperature
The <Temperature> signal is an input signal. If <Temperature> becomes active, the module
message <Transformer temperature> is output.
14.8 Water flow OK

The <Water flow OK> signal is an input signal. If it becomes inactive, the module message
"Flow monitor" is displayed.
14.9 With current

The <WITH CURRENT> signal is an input signal. When it becomes active, current output is acti-
vated if the [With current] button is also activated.

14.10 Pre-stroke
The <Pre-stroke> signal is an input signal. If it becomes active, the <Pre-stroke solenoid valve>
output is activated. The output's behaviour is dependent on the pre-stroke function setting.
14.11 Program selection

The signals for program selection are input signals. When external program selection is con-
figured, the welding program to be executed is pre-selected. The valency of the signals must
be interpreted in binary form, with the one for program 1 being the lowest-value bit. Depen-
ding on expansion, max. 24 = 16 programs can thus be selected per start input. This results in
the 1-16 programs for <START1>, and the 17-32 programs for <START2>.
See Selecting a program, p. 85
14.12 Solenoid valve

The signals for <Solenoid valve 1> and <Solenoid valve 2> are output signals. At the start of
the welding process, they are used to activate the pneumatic valves assigned to the relevant
start inputs.
14.13 Deleting a spot counter

The delete <Spot counter> signal is an input signal. If it becomes active, all welding spot coun-
ters are reset to 0.
14.14 Error reset

The error reset signal is an input signal. When it is activated, the current module message is
acknowledged.
14.15 Max. spot number reached

The <Max. spot number reached> signal is an output signal. It becomes active when the maxi-
mum number of welding spots configured in the welding control system is reached, see Elec-
trode management, p. 50.

14.16 VZ = interlock addition/

NBS = mains load limitation control
The signal for interlock addition (VZ)/mains load limitation control (NBS) is an output signal.
l X9/8 = positive potential versus X9/10.
xxxxxxxThe switched load must refer to 0 VDC of the control stage.
This output is set up for interlock purposes or NBS queries and is only activated during the
main current time, and also during the pause time in pulse mode.
If <With current> is inactive, the VZ/NBS output is never set.
The function of the VZ/NBS contact is configurable, either as an interlock addition or in com-
bination with the pressure contact as mains load limitation control.
l Configured as VZ:
The VZ output is activated throughout the entire current-conducting time, and also
during the pause time in seam or pulse mode.
l Configured as NBS:
Activation of the VZ output starts during the last VHZ period. The signal can be used as
a welding request signal for mains load limitation control so that the <Pressure con-
tact> can be used for welding release through mains load limitation control.
With the NBS function, the VZ_NBS output is set in the last squeeze time period. Only then is
the pressure contact polled.
14.17 Limit value error

The limit value error signal is an output signal. It is activated when the welding current lies out-
side of specified limit values.
14.18 Pre-stroke solenoid valve

The pre-stroke solenoid valve signal is an output signal.
The output's behaviour is dependent on the pre-stroke function setting.
If the <Pre-stroke> function is configured to static or scanning, the <Pre-stroke> output is swit-
ched on and off via the <Pre-stroke ON/OFF> input.
If the <Pre-stroke> function is configured to continuous, the pre-stroke output is switched on
continuously.

15 Data back-up
15 Data back-up
This menu is only available with a USB stick inserted.
Back-up to USB stick
Restore from USB stick
Back-up log book
Back-up to USB stick

CONFIGURATION MENU > DATA BACK-UP >
xx
Fig. 15-1: Back-up to USB stick
After selecting this function, the following message is shown on the display for the duration
of system back-up:
l Back-up active
The back-up file is saved to the USB stick.
The name of the back-up file is automatically assigned by the system according to the fol-
lowing pattern:
YYYYMMDD-HHMMSS_<Welding control system>.fbk.
The abbreviations have the following meaning:
l YYYYMMDD: Year-Month-Day
l HHMMSS: Hour-Minute-Second
l <Welding control system>: the welding control system designation defined in the con-
figuration.
Restore from USB stick

xx
Fig. 15-2: Restore from USB stick
System restoration can be carried out from the USB stick in this case.
After selecting this function, a list of the back-up files stored on the USB stick is displayed.
After selecting a back-up file, the system is restored without prompt.

15 Data back-up
Back-up log book

xx
Fig. 15-3: Back-up log book
The log book can be backed-up to the USB stick here.

The log book is not accessible via the operating unit.

16 Maintenance
16 Maintenance
16.1 Maintenance
The welding control system has a 3 V lithium battery. The battery is used to operate the real
time clock when switched off. A spent battery only results in time data loss.
As a precaution, the battery should be exchanged every two years, as there is no display indi-
cating a spent battery.
Incorrectly inserted battery

There is a risk of explosion if the lithium battery is inserted incorrectly. Physical injuries and
damage to the device may occur.
l Use only CR2032 type lithium batteries.
l Insert the battery carefully as specified.
Exchange battery
Prerequisites
o The system is de-energised.
o Lithium battery type CR2032 is ready.

o Rear side of the welding control system and battery bracket are accessible.
Procedure
1. Unscrew cover plate.
2. Remove old battery from the bracket on the rear side.
3. Insert new battery into the bracket; must engage.
4. Screw on cover plate.
5. Switch on the welding control system.
6. Check the time and date, and reset if necessary.
7. Dispose of the old battery as per the regulations.
Result
l The battery has been exchanged.

16 Maintenance

17 Storage
17 Storage
Storage frost-free in a dry, dust-free room. Room temperature must not exceed 50°C.

17 Storage

18 Disposal
18 Disposal
The operator is responsible for proper disposal of the module and all relevant components.
Electronic scrap
Exchanged, defective electronic parts must be disposed of as electronic scrap if repair is not
possible.

18 Disposal

19 Technical data
19 Technical data
Welding control system
Designation Value
Operating voltage 24 VDC -15% +20%
Current consumption (with 24 V outputs) Max. 2 A
Current consumption (without 24 V out- Max. 500 mA
puts)
Switch-on behaviour 5 A for 20 ms (with 24 V outputs)
Synchronising voltage 27 V/50 Hz, 27 V/60 Hz -25% +10%
Temperature Min. 5°C, max. 50°C
Maximum humidity Max. 85%, non-condensing
Maximum air pressure 80 kPA to 105 kPA up to 1000 m above mean sea level
Protection class IP20
Weight 770 g
Welding control system cable connection Max. 3 m, 20-pin ribbon cable
to power stage
Vibration Max. 5 m/s2 (YIS 60068-2-6) 10 – 55 Hz
Inputs
Designation Value (at +20°C)
24 V start inputs
Input voltage 0-30 VDC, normal 24 VDC
Level for ON status > 18 V
Level for OFF status <3V
Input current Max. 20 mA, galvanically separated
Overvoltage protection +40 VDC, max. 5 min.
24 V emergency stop inputs
Further 24 V inputs

19 Technical data
Outputs
Designation Value (at +20 C)
Total of all 24 V outputs Max. 1.5 A
24 V outputs
Loadability 300 mA, galvanically separated
Status <ON> output voltage at 2300 mA Supply voltage up to 2.2 V
load
Status <OFF> output voltage 0…3 V
24 V solenoid valve outputs
Loadability 300 mA, galvanically separated
Status <ON> output voltage at 300 mA load Supply voltage up to 2.2 V
Status <OFF> output voltage 0…3 V
Ignition pulse outputs
Ignition pulse voltage +24 V / max. 300 mA
Ignition pulse L1 5 kHz 150 µs/50 µs, ±10%
Proportional valve output 0…10 V, accuracy ±0.15 V, ±3%
USB interface
Designation Value
File system FAT 32
Size Up to 4 GB
19.1 Basic settings on delivery

On delivery, the functionally-relevant welding parameters are set as follows:
Designation Value
Start VHZ Immediately
Start interlock After squeeze time
Program selection Internal
Stop electrode exchange Deactivated
Stepping contact After hold time
Stepping contact pulse duration 0 = duration
Mains load limitation (NBS) Deactivated
Pre-stroke output Static
Cos phi 0.93 (15)
Min. squeeze time 1 period
Max. welding time 99 period
Min. hold time 1 period
Min. open time 1 period
First delayed half cycle = EVH 725 Skt
First delayed half cycle = ENP 750 Skt
IG2 = max. current 20 kA
Mains compensation Deactivated

19 Technical data
Designation Value
Connection technology Terminals with tightening torque 14 Nm
(Protected against access with the back of the hand cor-
responding to IP10, a cover to prevent finger access cor-
responding to IP20 is optionally available).
19.2 Default settings
Programs
All program slots have the following settings on delivery:
Program configuration
l Order: PRG (program number)
l SKT mode without mains voltage compensation
l Single spot mode
Currents
l All currents to minimum
Times
l All times to minimum
Pulses
l Pause time: 0 per
l Pulses: 1

19 Technical data
19.3 Dimensions
All data in mm
The holes for installation should have a diameter of 5.5 mm.
Fig. 19-1: Front view of FiliusACS-Multi-IQ
Fig. 19-2: Installation cut out of FiliusACS-C-Multi-IQ

19 Technical data
Fig. 19-3: Front view of FiliusACS-B-Multi-IQ
Fig. 19-4: Installation cut out of FiliusACS-B-Multi-IQ

19 Technical data

20 Module messages
20 Module messages
If a module message is present, it is shown on the main display. The display then auto-
matically switches to the menu
PARAMETER MENU > M ODULE MESSAGES
XX
Fig. 20-1: Error display
Information on the module messages can be displayed by pressing the [jog wheel]. If several
messages are present, these can be displayed by turning the [jog wheel].
The following module messages are shown on the display:
20.1 Flow monitor

PARAMETER MENU > M ODULE MESSAGES >
xx
Fig. 20-2: Flow monitor
1 Flow monitor
Module FiliusACS-B-Multi-IQ | FiliusACS-C-Multi-IQ
Info This message is triggered by an external flow or water monitor (<Water flow OK>
input).
Cause 1. The coolant supply flow rate is insufficient.
2. The coolant supply has failed.
3. Missing 24 V for the flow or water monitor circuit in the power unit.
Remedy Re 1. Check coolant supply on the power unit.
Re 2. Check coolant supply on the power unit.
Re 3. Check the wiring and voltage supply.
Note
If the <Flow monitor> function is not used, the input must have a fixed 24 V
connection.

20 Module messages
20.2 Thyristor / transformer temperature

xx
Fig. 20-3: Thyristor / transformer temperature
2 Thyristor / transformer temperature

Info The message is triggered by an overheated thyristor / welding transformer (<Tem-
perature> input).
Cause 1. The coolant supply flow rate is insufficient.
2. The coolant supply has failed.
3. The welding transformer is overloaded.
4. Missing 24 V for the thyristor transformer temperature circuit.
Remedy Re 1. Check coolant supply in the power circuit and remedy malfunction.
Re 2. Check coolant supply in the power circuit and remedy malfunction.
Re 3. Adapt welding job to the welding transformers.
Re 4. Check the wiring and voltage supply and remedy the malfunction.
Note
If the <Thyristor/transformer temperature> function is not used, this input must have a fixed
24 V
connection.

20 Module messages
20.3 Controller error upper stop

xx
Fig. 20-4: Controller error upper stop
3 Controller error upper stop

Info Maximum control limit reached. This message is output if the current is set to 999
Skt in control mode (by controller).
Cause 1. Damage to the electrode.
2. If this message is output with increasing frequency, the secondary lines are
worn.
3. The parameterised nominal current is higher than the current that can
actually be output.
4. The welding transformer's output voltage is too low for the set welding cur-
rent.
Remedy Re 1. Check electrode and exchange if necessary. Reset spot counter on
exchange.
Re 2. Exchange cable.
Re 3. Check welding parameters and correct if necessary.
Re 4. Used secondary cable with significantly larger cross-section or welding trans-
former with higher output voltage.

20 Module messages
20.4 Electrode exchange

xx
Fig. 20-5: Electrode exchange - inverse representation of counter group at top left and counter status
at bottom left
4 Electrode exchange
Info Welding electrodes are spent.
Cause 1. The parameterised [Max. spots] have been reached or exceeded by the spot
counter.
Remedy Re 1. Exchange or process electrodes and then reset the spot counter.
20.5 Upper limit value

xx
Fig. 20-6: Upper limit value
5 Upper limit value

Info This message is triggered by the current monitoring system if the welding current
lies above the parameterised tolerance.
Cause 1. The welding process is carried out with an incorrect sheet pairing.
2. The welding process is carried out without material.
3. The welding process is carried out with incorrect material.
4. The tolerance range is incorrectly parameterised.
Remedy Re 1. Select correct sheet pairing.
Re 2. Ensure that material is always inserted.
Re 3. Ensure that the correct material is inserted.
Re 4. Adjust tolerance setting.

20 Module messages
20.6 Lower limit value

xx
Fig. 20-7: Lower limit value
6 Lower limit value

Info This message is triggered by the current monitoring system if the welding current
lies below the parameterised tolerance.
Cause 1. The electrodes are soiled.
2. The material is soiled.
3. The welding process is carried out with an incorrect sheet pairing.
4. The tolerance range is not defined appropriately.
Remedy Re 1. Exchange electrodes.
Re 2. Clean material, extend squeeze time, increase pressure.
Re 3. Select correct sheet pairing.
Re 4. Adjust tolerance settings.
20.7 Withdraw Start1

xx
Fig. 20-8: Withdraw Start1
7 Withdraw START1
Info <START1> currently has the incorrect signal status.
Cause 1. <START1> is active on switching on the welding control system or the syn-
chronising voltage.
2. <START1> is active on resetting the emergency stop.
3. <START1> is still active after acknowledging an error message.
Remedy Re 1. Withdraw <START1>.
Re 2. Withdraw <START1>.
Re 3. Withdraw <START1>, acknowledge any present messages.

20 Module messages
20.8 Withdraw Start2

xx
Fig. 20-9: Withdraw Start2
8 Withdraw START2
Info <START2> currently has the incorrect signal status.
Cause 1. <START2> is active on switching on the welding control system or the syn-
chronising voltage.
2. <START2> is active on resetting the emergency stop.
3. <START2> is still active after acknowledging an error message.
Remedy Re 1. Withdraw <START2>.
Re 2. Withdraw <START2>.
Re 3. Withdraw <START2>, acknowledge any present messages.
20.9 Synchronisation error

xx
Fig. 20-10: Synchronisation error
9 Synchronisation error
Info Synchronising voltage error. The synchronising voltage is generated in the power
unit and is vital to synchronise the welding control system with the power mains.
A welding process is not possible without synchronising voltage.
Cause 1. The power unit is shut off, e.g. due to a system emergency stop.
2. The fuse for the power unit is defective.
3. The fuse for the synchronising transformer is defective.
Remedy Re 1. Eliminate existing dangers, then switch on power unit.
Re 2. Check fuses and exchange if necessary.
Exchange power unit if necessary.
Exchange power unit if necessary.

20 Module messages
20.10 No current measurable

xx
Fig. 20-11: No current measurable
10 No current measurable
Info The welding control system cannot detect any current or receives invalid data.
Message: I = 0
Cause 1. No measuring coil connected.
2. Measurement lead interrupted.
3. Measurement lead receives interference signals.
Remedy Re 1. Connect measuring coil as per wiring diagram.
Re 2. Check measurement lead and repair if necessary.
Re 3. Check shielding and poss. transmission resistances to the earth potential.
20.11 Withdraw external current end

xx
Fig. 20-12: Withdraw ext. current end
11 Withdraw ext. current end

Info <CURRENT END> currently has the incorrect signal status.
Cause 1. <CURRENT END> is active on switching on the welding control system or the
synchronising voltage.
2. <CURRENT END> is active on resetting the emergency stop.
3. <CURRENT END> is still active after acknowledging an error message.
Remedy Re 1. Deactivate <CURRENT END>.
Re 2. Deactivate <CURRENT END>.
Re 3. Deactivate <CURRENT END>, acknowledge any present messages.

20 Module messages
20.12 Emergency stop

xx
Fig. 20-13: Emergency stop
12 Emergency stop
Info Emergency stop has been actuated.
Cause 1. Emergency stop has been triggered due to safety reasons.
2. Missing 24 V for the emergency stop circuit.
3. If the error is displayed despite a closed emergency circuit, the 24 V fuse
may be defective.
Remedy Re 1. After eliminating the danger, reset the emergency stop.
Re 2. Check the wiring and the voltage supply, eliminate the malfunction.
20.13 Mains voltage error

xx
Fig. 20-14: Mains voltage error
13 Mains voltage error

Info The internally set undervoltage threshold <VacMin> has been undershot with the
welding control system operational.
Cause 1. Severe mains voltage fluctuations.
2. The welding process overloads the supply mains and causes an excessive
voltage dip.
Remedy Re 1. Clarify the cause and eliminate.
Re 2. Adjust the mains supply to the welding job (adapt cable cross-sections if
necessary)
or
Adapt the welding job to the mains characteristics.

20 Module messages
20.14 Component error during travel measurement

The component error for travel measurement 2 must be handled exactly like the component
error for travel measurement 1.
xx
Fig. 20-15: Component error during travel measurement 1
14 Component error during travel measurement 1: deviation by

<n> mm with program <No.>
Info Component control is active.
Cause 1. The inserted component lies outside of the set tolerances.
2. No, or an incorrect, component has been inserted.
Remedy Re 1. Check the component's dimensions.
Re 2. Check whether the correct component has been inserted.
Note
The welding process is not started if the message is triggered. The message is automatically
acknowledged once start has been withdrawn.
20.15 Measuring coil comparison

xx
Fig. 20-16: Measuring coil comparison
15 Measuring coil comparison error

Info This message appears if no measurement has taken place yet and comparison is
not possible.
Cause 1. No welding process has been performed yet after switching the control sys-
tem on for the first time.
Remedy Re 1. Only use the comparison when an actual value has appeared on the status
display.

20 Module messages
20.16 Sink-in travel error during travel measurement

The sink-in travel error for travel measurement 2 must be handled exactly like the sink-in tra-
vel error for travel measurement 1.
xx
Fig. 20-17: Sink-in travel error during travel measurement 1
16 Sink-in travel error during travel measurement 1: deviation

by <n> mm with program <No.>
Info Sink-in travel monitoring is active.
Cause 1. The specified sink-in travel was not achieved in program <No.>.
2. The cause may be electrode wear. The sink-in travel may be correct in this
case, but the electrode wear, which is also measured, triggers the message.
Remedy Re 1. Remedial measures are dependent on your individual process.
Re 2. Check electrodes for wear and mill or exchange if necessary.
Then record new reference value.
20.17 Final dimension error during travel measurement

The final dimension error for travel measurement 2 must be handled exactly like the final
dimension error for travel measurement 1.
xx
Fig. 20-18: Final dimension error during travel measurement 1
17 Final dimension error during travel measurement 1: deviation

by <n> mm with program <No.>
Info Final dimension control is active.
Cause 1. The specified final dimension was not achieved in program <No.>.
2. The cause may be electrode wear. In this case, the final dimension may be
correct but the electrode wear, which is also measured, triggers the mes-
sage.
Remedy Re 1. Remedial measures are dependent on your individual process.
Re 2. Check the electrodes for wear and mill or exchange them if necessary.

20 Module messages
20.18 No pressure contact/NBS

xx
Fig. 20-19: No pressure contact (DK)/NBS
18 No pressure contact/NBS
Info Pressure contact is inactive.
Cause 1. The electrode pressure is too low.
2. The <DK> input is not enabled through mains load limitation (NBS).
Remedy Re 1. Wait until the pressure switch is active, or cancel welding by withdrawing
the start signal.
Re 2. Other welding machines are consuming the maximum mains power, so that
welding release must not take place. Incorrect values are assigned to the
mains load limitation control parameterisation.
The error is automatically acknowledged when the pressure contact is established.
If this does not occur, withdraw start with <Immediate start interlock> or <Start interlock
from main current time> with [Cancel].

20 Module messages
20.19 Acknowledging module messages

Prerequisites
o A module message is present.
o The module message is shown on the display.
Procedure
1. Select [Delete error] by turning [jog wheel].
2. Press [jog wheel] to confirm.
In the case of further module messages, repeat steps 1 and 2.
3. Externally via the <Error reset> input.
Result
l The module message has been acknowledged.
Note
If a system message appears again immediately after being acknowledged, the cause of the
system message must be eliminated under all circumstances!
The following messages do not have to be acknowledged, as they are automatically ack-
nowledged when the malfunction is eliminated:
l Emergency stop
l Thyristor/transformer temperature
l Flow monitor
l Pressure contact

21 Appendix
21 Appendix
21.1 Update service

For information on this, contact HWH service, specifying the serial number of your module,
tel.: +49 40 766 904-84.

21 Appendix
21.2 EU declaration of conformity

21 Appendix

21 Appendix
160 35174-05en | 2016-01 | FiliusACS-B-Multi-IQ | FiliusACS-C-Multi-IQ | Operating instructions

21 Appendix
21.3 Abbreviations
+ AC
Alternating current
+Imess / -Imess
Current sensor
B
+Isek / -Isek
BTB
Secondary current measurement
Ready for operation
+Isoll / -Isoll
Analogue secondary voltage measurement C
+TEMP1 / -TEMP1 CAN
Temperature measurement 1 Controller Area Network
+TEMP2 / -TEMP2 CPU

Temperature measurement 2 Central Processing Unit
+U_POT1
Supply for distance measuring poten- D
tiometer 1 DC
Direct current
+U_SENSE1
Sensor connection for potentiometer sup- DK
ply 1 Pressure contact
+Usek / -Usek DS
Secondary voltage measurement Current decrease time (down slope time)
0 E
0V_POT1 EGB
0 V of supply for distance measuring poten- Electrostatic sensitive components
tiometer 1
ENP
0V_SENSE1 First delayed half cycle after pause time
0 V sensor cable connection for poten-
tiometer supply 1 ESD
Electrostatic discharging
A
EVH
A First delayed half cycle
Ampere
ext.
ABZ External, from outside
Delay

21 Appendix
F IG3
Current limit for post-heating current
F
Force IGBT
Insulated Gate Bipolar Transistor
FAT
File Allocation Table IMP
Pulses
FE
Functional earth IQR
Integrated quality control
FEHLER-RES
Error reset input IRT
Isochronous Real Time
FI
Fault current protection
J
FK
JJJJ-MM-TT
Stepping contact
Year-Month-Day (date format)
G
K
GB
kA
Gigabyte
Kiloampere
GND-ZT1
KSR
Ignition transformer 1 ground
Constant current regulation
GW
Limit value L
LED
H Light-emitting diode
HBT
LSB
Manual control unit
Least Significant Bit
Hz
Hertz M
MG
I Measuring coil
I
MSB
Current
Most Significant Bit
IG1
MV
Current limit for pre-heating current
Solenoid valve
IG2
Current limit for main current

21 Appendix
N PZ
Pause time
n.c.
Not connected
R
n.i.O.
RCD
Faulty
Residual Current Protective Device
NBS
RKZ
Mains load limitation control
Recooling time
NHZ
RT
Hold time
Real Time
NOT
Emergency stop S
NWZ SAZ
Post-heating time Current increase time (up slope time)
SFR
O Initial milling
OHZ
SHLD
Open time
Shielding
P SKT
Scale division
PE
Protection earth SPS
Programmable logic controller
Per
Period STP
Shielded Twisted Pair
PKT
Spot SWZ
Welding time
PKTZ
Spot counter SZ
Current time (main current time)
PQS
Process and quality management system
T
PROG
t
Program
Time
PROP VENTIL
TEMP
Proportional valve
Temperature
PWH
TEMPKON
Spot repetition
Thermal contact

21 Appendix
U VWZ
Pre-heating time
U
Voltage VZ
Interlock addition
U_MESS1
Metering signal connection of distance mea-
suring potentiometer 1 Z
Zgrp
Uac
Counter group
ZME
UacA
Electrode holder measuring unit
Mains voltage actual value
ZT
UacMin
Ignition transformer
Permissible minimum value below which a mes-
sage is output
UacS
Mains voltage nominal value
USB
Universal Serial Bus
Usek
Secondary voltage measurement
USYNC
Synchronising voltage
UTP
Unshielded Twisted Pair
V
V
Voltage
VDE
VDE (Association for Electrical, Electronic & Infor-
mation Technologies)
VH
Pre-stroke
VHZ
Lead time
vVHZ
First squeeze time

21 Appendix
21.4 Table of figures

Fig. 3-1: Type plate 16
Fig. 3-2: Front view of FiliusACS-C-Multi-IQ 17
Fig. 3-3: Front view of FiliusACS-B-Multi-IQ 18
Fig. 3-4: Display 20
Fig. 7-1: Examples of interference suppression 34
Fig. 9-1: Status display 38
Fig. 9-2: Menu structure 41
Fig. 9-3: Text input display 43
Fig. 10-1: Program administration 47
Fig. 10-2: Copy program 48
Fig. 10-3: Select source and target programs 48
Fig. 10-4: Order name after copying 48
Fig. 10-5: Delete program 48
Fig. 10-6: Back-up program(s) 48
Fig. 10-7: Overwrite program 49
Fig. 10-8: Load program(s) 49
Fig. 10-9: Select program 49
Fig. 10-10: Abort program loading 49
Fig. 10-11: Counter group 50
Fig. 10-12: Setting the pre-warning value 51
Fig. 10-13: Setting electrode exchange 51
Fig. 10-14: Start interlock VHZ 54
Fig. 10-15: Start interlock 55
Fig. 10-16: Internal program selection 55
Fig. 10-17: External program selection 55
Fig. 10-18: Continued running on electrode exchange 56
Fig. 10-19: Stop electrode exchange 56
Fig. 10-20: FK after hold time 56
Fig. 10-21: FK at the start of the hold time 56
Fig. 10-22: FK pulse duration 57
Fig. 10-23: Selection of the travel sensor's electrode holder assignment 57
Fig. 10-24: Nominal value of proportional valve 1 for calibration 58
Fig. 10-25: Nominal value of proportional valve 2 for calibration 58

21 Appendix
Fig. 10-26: The proportional valve nominal value is specified in % 58

Fig. 10-27: The proportional valve nominal value is specified in [dN] 58
Fig. 10-28: Selection as VZ function 59
Fig. 10-29: Selection as NBS function 59
Fig. 10-30: Selection of the travel sensor's electrode holder assignment 60
Fig. 10-31: Cos phi 60
Fig. 10-32: Cos phi setting 61
Fig. 10-33: Selection of the unit of time in which the parameters are input. 62
Fig. 10-34: Limitation of time input in per 62
Fig. 10-35: Limitation of time input in s 62
Fig. 10-36: Time limitation "Tlim" display 63
Fig. 10-37: Selection of the error class for monitoring errors 63
Fig. 10-38: Selection of the error class for regulation errors 64
Fig. 10-39: Calibrate travel sensor 65
Fig. 10-40: Calibrate travel sensor 1, reference point 1 66
Fig. 10-41: Calibrate travel sensor 1, reference point 2 66
Fig. 10-42: Force calibration 67
Fig. 10-43: Support point 1, electrode holder 1 68
Fig. 10-44: Support point 2, electrode holder 1 68
Fig. 10-45: Force specification in daN 68
Fig. 10-46: Force specification in % 68
Fig. 10-47: Input confirmation 68
Fig. 10-48: Force specification in daN 68
Fig. 10-49: Force specification in % 68
Fig. 10-50: Input confirmation 69
Fig. 10-51: Calibration curve with example data 69
Fig. 10-52: Set date/time 72
Fig. 10-53: Select language 72
Fig. 10-54: Set keyboard lock 73
Fig. 10-55: Set contrast 73
Fig. 10-56: Module name 74
Fig. 10-57: Delete log book 74
Fig. 10-58: Update bootloader display 75
Fig. 10-59: Feature update display 76
Fig. 10-60: Graphics processor firmware update display 76

21 Appendix
Fig. 10-61: Welding control system firmware update display 77

Fig. 11-1: Principle of a welding system 80
Fig. 11-2: Typical welding process in resistance welding 81
Fig. 11-3: Phases in the welding process 83
Fig. 11-4: Program 84
Fig. 11-5: Selecting a program 84
Fig. 11-6: Edit program 85
Fig. 11-7: Order 86
Fig. 11-8: Current regulation 86
Fig. 11-9: Operating mode 87
Fig. 11-10: Proportional valve, percentage input 90
Fig. 11-11: Proportional valve, force specification 90
Fig. 11-12: First extended squeeze time = first vVHZ 91
Fig. 11-13: Squeeze time = VHZ 92
Fig. 11-14: Pre-heating current 93
Fig. 11-15: Pre-heating time 94
Fig. 11-16: Heat compensation time 94
Fig. 11-17: Current increase time 95
Fig. 11-18: Main current 96
Fig. 11-19: Main current time 97
Fig. 11-20: Pause time 97
Fig. 11-21: Pulses 98
Fig. 11-22: Main current with pulses 98
Fig. 11-23: Current decrease time 98
Fig. 11-24: Current decrease time in the welding process 99
Fig. 11-25: Recooling time 101
Fig. 11-26: Post-heating current 101
Fig. 11-27: Post-heating time 101
Fig. 11-28: Hold time 102
Fig. 11-29: Open time 103
Fig. 12-1: Measuring time 108
Fig. 12-2: Delay 108
Fig. 12-3: Tolerance plus 108
Fig. 12-4: Tolerance minus 108
Fig. 12-5: Travel measurement 109

21 Appendix
Fig. 12-6: Travel path 109

Fig. 12-7: Component control and travel measurement functions 110
Fig. 12-8: Maximum component control 111
Fig. 12-9: Minimum component control 111
Fig. 12-10: Component control module message 112
Fig. 12-11: Maximum sink-in travel monitoring 112
Fig. 12-12: Minimum sink-in travel monitoring 112
Fig. 12-13: Sink-in travel monitoring module message FIQ 2 113
Fig. 12-14: Sink-in travel monitoring module message FIQ 3 113
Fig. 12-15: Maximum final dimension monitoring 114
Fig. 12-16: Minimum final dimension monitoring 114
Fig. 12-17: Final dimension control module message FIQ 2 114
Fig. 12-18: Final dimension control module message FIQ 3 115
Fig. 12-19: Indexing VWZ travel (accordingly for SZ and NWZ) 115
Fig. 12-20: Indexing VWZ time (accordingly for SZ and NWZ) 116
Fig. 13-1: Pin assignment 1 120
Fig. 13-2: Pin assignment 2 121
Fig. 13-3: Rear view - position of the connections 122
Fig. 15-1: Back-up to USB stick 131
Fig. 15-2: Restore from USB stick 131
Fig. 15-3: Back-up log book 132
Fig. 19-1: Front view of FiliusACS-Multi-IQ 142
Fig. 19-2: Installation cut out of FiliusACS-C-Multi-IQ 142
Fig. 19-3: Front view of FiliusACS-B-Multi-IQ 143
Fig. 19-4: Installation cut out of FiliusACS-B-Multi-IQ 143
Fig. 20-1: Error display 145
Fig. 20-2: Flow monitor 145
Fig. 20-3: Thyristor / transformer temperature 146
Fig. 20-4: Controller error upper stop 147
Fig. 20-5: Electrode exchange - inverse representation of counter group at top left and
counter status at bottom left 148
Fig. 20-6: Upper limit value 148
Fig. 20-7: Lower limit value 149
Fig. 20-8: Withdraw Start1 149
Fig. 20-9: Withdraw Start2 150
Fig. 20-10: Synchronisation error 150

21 Appendix
Fig. 20-11: No current measurable 151

Fig. 20-12: Withdraw ext. current end 151
Fig. 20-13: Emergency stop 152
Fig. 20-14: Mains voltage error 152
Fig. 20-15: Component error during travel measurement 1 153
Fig. 20-16: Measuring coil comparison 153
Fig. 20-17: Sink-in travel error during travel measurement 1 154
Fig. 20-18: Final dimension error during travel measurement 1 154
Fig. 20-19: No pressure contact (DK)/NBS 155

21 Appendix
21.5 List of symbols

Regulation type
Operating mode
Proportional valve
Single spot
Series spot
Seam
Start interlock at start of current time
Immediate start interlock
Start squeeze time after pressure contact
Start squeeze time immediately
Main current xxx 0.01 ... [Max. current] [kA] or

1 .. [Max Skt] xxx or xxx 0.01 ... [Max current] [kA]
Post-heating 1 .. [Max Skt] xxx or xxx 0.01 ... [Max. current] [kA]
Copy program
Delete program
Back-up program(s)
Load program(s)
Counter group
Welding parameters
Comparison + service

21 Appendix
ProgSel Internal program selection
External program selection
Stop electrode exchange Off
On
Sequence (FK) At start of NHZ
After NHZ
FK pulse duration 0…10 per; 0.1 ms
Assign travel measurement system 1 Off
Assign travel measurement system Off
Proportional valve 1 basic value Off
Proportional valve basic value Off
Electrode holder 1 force input Off
On
Electrode holder 2 force input Off
On
Mains load limitation Off
On
Constant
Pre-stroke output
Static
Scanning
Cos phi 0.44…0.93 in 16 stages (00 .. 15)
Min. squeeze time 1...99 per; 1...7000 ms
Max. welding time 1...99 per; 1...7000 ms
Min. hold time 1...99 per; 1...7000 ms

21 Appendix
Min. open time 1...99 per; 1...7000 ms
First delayed HW 600…999 SKT
1st delayed half cycle after pause 600…999 SKT
Max. faulty welding 5
Max. SKT 1…999 SKT
Max. current 1.00…99.99 kA
FIQ Error class IQ 2.3
FRG 2.3
Controller error class

21 Appendix
21.6 Index
A Constant current regulation 105
Air pressure 139 Continuous current mode 89
Article number 16 Contrast 73

Controller 70
B
Cos phi 60
Back-up 131 Counter group 50
Basic settings 140 Current decrease time 98
Battery 133 Current end 128
Bootloader 75 Current increase time 95
Butt welding 79 Current measurement 107
Button Current measurement sensor 124
cancel 19 Current pauses 97
sub-menu 19 Current profile 84
with current 19
D
C
Data back-up 131
Calibration Date 72
force 67 DC voltage
CAN bus 74, 125 24 V 32
Commissioning 35 Declaration of conformity 158
Component control 92, 109, 111 Default settings 141
Configuration 72 Delay 108
Configuration menu 41-42, 72 Delay time 108
Connection 25 Delete program 48
24 V inputs 123 Delivery scope 27
24 V outputs 123 Device description 15
CAN bus 125 Device family 13
Current measurement sensor 124 Display elements 38
functional earth 32 Disposal 137
plug 33
E
position 122
Power stages 125 Earthing 32
proportional valve outputs 124 Electrode caps 51

21 Appendix
Electrode exchange 56 Inductive overhang 60

Electrode management 50 Information 74
Electrodes 50 Initialisation 38
pre-warning 51 Input signal 127
wear 50 Installation 31
Electronic scrap 137 minimum distance 31
Electrostatic charging 26 Installation cut out 142-143
Emergency stop 26 Insulation test 25
Error class 63-64 Interface 21
FIQ 2 final dimension 114 Interlock addition 59, 130
FIQ 2 sink-in travel 113 IQ limit value 106
FIQ 3 final dimension 115 IQ monitoring function 106
FIQ 3 sink-in travel 113 IQ parameters 107
Error reset 129 J
F Jog wheel 19
Faulty welding 102 K
Final dimension
Keyboard lock 73
monitoring 110, 113
Firmware 75
L
Firmware updates 75 Language 72

Flash butt welding 15, 79 Limit value error 130
Flow monitor 127-128 Log book 21, 132
Force 92 delete 74
build-up 83 M
Functional earth 32, 35
Main current 84, 96-97, 99
H Main current time 94-95, 97, 116
Hand electrode holders 88 Mains frequency 37
Heat compensation time 94 Mains frequency detection 37
Heating 15 Mains load limitation control 59, 130
High-voltage 25 function 54
Hold time 88, 102-103 Mains voltage 19
Humidity 139 comparison 71
Mains voltage compensation 71
I
Maintenance 133
Ignition time point 61
Maintenance work 24

21 Appendix
Max. spot 129 Output signal 127

Maximum spot 51 P
Measuring coil
Packaging 29
comparison 70
Parameter menu 42
Measuring time 108
structure 41
Menu
Parameters 47, 82, 91
configuration 42
settings 52
parameters 42
Pause time 97
selection 42
Personal protection 24
Menu structure 41
Pin assignment 119
Mode
PLC 84, 119
single spot 87
Plugs 33
Module 11
Post-heating 84, 100
Module messages 145
Post-heating current 101
acknowledging 156
Post-heating time 101, 117
Molten material 79
Post-pressing time, see Hold time 102
Monitoring
Power factor cos phi
tolerance 108
adjustment 60
N Power setting 60
Navigation 19 Power stages 125
Nominal final dimension value 56 Pre-clamping time, see Squeeze time 92
Nominal value 113 Pre-heating 84, 93
O Pre-heating current 93, 95

Pre-heating time 94, 115
Occupational safety 23
Pre-stroke 60, 129-130
Open time 103
Pre-stroke solenoid valve 60, 130
Operating conditions 21
Pressure
Operating elements 19
build-up 91
Operating mode 87
Pressure contact 92, 128
Operating modes 87
Pressure contact control 54
Operating status 39
Process configuration 50
Operation
Profile indexing 110, 115
series spot 88
Program 85, 141
Operator 23
back-up 48
Order 86
copy 48

21 Appendix
edit 85 Service 9, 65
load 49 Service work 24
Program administration 47 Shield
Program selection 129 CAN bus 125
external 55 Shielding 124
internal 55 connection cable 124
Projection welding 15, 79 proportional valve 124
Proportional valve 58, 67, 90, 124 Signal 127
force 90 Signal input 32, 119
percent 90 Signal outputs 119
Proportional valve value calibration 58 Single spot mode 87
Pulse mode 95 Sink-in travel
Pulses 97-98 monitoring 109, 112
R Sink-in travel monitoring 92

Software updat 21
Real time clock 133
Solenoid valve 32, 129
Recooling time 101
Solenoid valve voltage 32
Reference current 107
Specialist electrician 24
Regulation type 86, 107
Specialist electricians 23-24
RESET function 43
Spot counter 50, 129
Resistance welding
Spot mode 87
general 79
Spot welding 15, 79
Restore
Squeeze time 53-54, 92, 103
USB stick 131
first extended 91
Return transport 29
Standards 9
Room temperature 21
Start 1,2 85, 127
S Start interlock 54-55, 91
Safety regulations Start signal 87, 91
country-specific 23 Status display 38
Seam mode 89 Status LED 19
Self-test 37 Status message 20
Sensor Stepping contact 83, 102, 128
travel 111 Stepping contact function 56
Sequence program 84 Stepping contact pulse duration 57
Series spot mode 87-88, 91, 103 Storage 135

21 Appendix
Structure 17 With current 106, 128

Sub-menu 42 Z
Successful welding 102
Zero point 113
Supply voltage 32, 35
Synchronising voltage 32
T
Target group 9
Technical data 139
Temperature 128, 139
Text input 43
Time 72, 133
Time basis 62
Tolerances 108
Transformer temperature 128
Transport damage 27, 29
Travel measurement 109
Travel measurement offset 67
Travel sensor 57, 65, 110
Travel sensors 109, 111
Type plate 16
U
UNDO function 43
Update 75, 157
Upset welding 15
USB connection 21
USB stick 21, 27, 35, 37, 131
V
Value input 42
W
Welded connection 79
Welding parameters, see Parameters 52
Welding process 79, 82
first 35
Welding readiness 127

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Welding Control System

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2 35174-05en | 2016-01 | FiliusACS-B-Multi-IQ | FiliusACS-C-Multi-IQ | Operating instructions

2 Description of the device family 13

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11 Parameterising the welding process 79

12 Device functions 105

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13 Pin assignment 119

14 Input/output signals 127

15 Data back-up 131

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20 Module messages 145

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1.1 About this documentation

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1.2 Typographical conventions

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Hazardous electrical voltage

Warning regarding magnetic fields

Emphasised text sections

Designation of Harms & Wende products

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2 Description of the device family

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3.1 Proper use

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Improper use, unauthorised conversion and spare part purchasing

Fig. 3-1: Type plate

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Fig. 3-2: Front view of FiliusACS-C-Multi-IQ

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Fig. 3-3: Front view of FiliusACS-B-Multi-IQ

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3.4 Operating elements

3.5 Status LEDs

Green LED lights: mains voltage is present.

Red LED lights: welding current is flowing.

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LED off: <With current> is inactive.

Fig. 3-4: Display

xx1 Time, see Time, p. 38.

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3.7 USB connection

3.8 Operating conditions

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4.1 Basic notes

National safety regulations

Person with electrical engineering training

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Dangers resulting from disregarding safety instructions

Operation in residential areas

4.2 Personal protection

Danger due to contact with electrical parts

l De-energise the system for service activities.

4.3 Safety instructions for service and maintenance work.

l De-energise the system for service activities.