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GF Welding Weld334m - User Manual

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

Table of Contents

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Summary

Safety

Hazards Associated with Resistance Welding Machines

Details hazards related to electric current and live parts, emphasizing qualified personnel for maintenance.

Observations on Connections

Focuses on earthing and insulation requirements for safe and reliable electrical connections.

Current Sensor

Explains the function, positioning, and wiring requirements of the current sensor for accurate measurement.

Power Supply

Details power supply requirements, including AC and DC inputs, and recommendations for transformers.

Phase Synchronising for Welding

Explains the importance of phase synchronization for correct welding operation and methods to achieve it.

Programming Unit

Provides instructions on handling the programming unit to prevent damage and maintain warranty.

Connecting to WMS Central Network

Guides on connecting the device to a central network for management and control.

Characteristics and General Description of Weld334 m

General Description

Describes the Weld334m as a control device for resistance welding machines, managing operations and diagnostics.

Block Diagram of 334 m

Illustrates the functional division of the Weld334m into basic and additional card packs.

Hardware Configuration

Details the modular card system and lists available cards for configuring the device.

Characteristics

Presents detailed technical specifications for power supply, I/O, programming ports, and optional extras.

Utilisation Characteristics

Specifies operating and storage temperature ranges, and the device's weight.

Dimensions and Fastening Positions

Provides physical dimensions and mounting details for the device.

HHT4300 Programming Unit

Describes the HHT4300 unit, its features, dimensions, and connection details.

Connection through Laptop

Explains how to connect a laptop for control device communication and software upgrades.

Power Supply and 24 V for I;O

Control Device Power Supply

Details the power supply section, connector, and input types (AC/DC).

PS: Description of Signals

Lists and describes the signals for the 8-way PS connector, including power and synchronism inputs.

Connections for Main Power Supply

Illustrates connection diagrams for AC and DC power supplies to the control device.

Power Consumption

Provides a table showing power consumption based on power supply type and configuration.

Use of 24 V - I;O

Explains rules for utilizing the 24V supply for I/O signals, including jumper settings.

Selecting 24 V - Internal or External

Details how to select between internal and external 24V supply for I/O distribution and jumper settings.

24 V Connections for Discrete I;O

Illustrates direct and indirect methods for managing 24V I/O using jumper settings and diagrams.

General Protective Devices on Power Supply

Setting the External Synchronism

F351-BUS Interconnection Card

F384-CPU Microprocessor Card

F353-ADC Analogue Card

P3 & P4: Description of Analogue Inputs

Details the analogue inputs on connectors P3 (TV) and P4 (TA) for various signals.

P2: Description of Signals for Solenoid Valve and TFE

Describes signals on connector P2 for solenoid valves and TFE, including functional descriptions.

F364-SEV and F385-SEV: Proportional Servovalve Modules

Servovalve Adjust:

Explains how to adjust servovalves for different operating conditions and parameter settings.

Voltage Outlet Characteristics

Specifies the characteristics of the voltage output for servovalve control.

Current Outlet Characteristics

Specifies the characteristics of the current output for servovalve control.

Connection of F364;F385-SEV Module on F353-ADC Card

Guides on connecting the servovalve module to the F353-ADC card using specific connectors.

F359-MCP Memory Card and Printer

F360-IOB Card - Base I;O

Description of Functions

Explains the functions of the Weld YES/NO selector switch and the 24Vdc I/O connector.

P20 24 Vdc - I;O

Describes the 24Vdc output for external devices and its protection, including status LED.

P22 - HSA - Circuit Breaker Trip

Details the HSA circuit breaker trip relay contacts for machine main switch tripping.

P21. Description of Signals

Lists and describes the 24V discrete digital inputs and outputs on connector P21.

F356-IOE I;O Expansion Card

P23. Description of Output Signals

Lists and describes the output signals on connector P23 for various functions like alarms and valve control.

P24. Description of Input Signals

Lists and describes the input signals on connector P24 for start, program selection, and diagnostics.

F376-OPC Field-Bus InterBus-S Card (Profile F-IBS;03)

Characteristics

Explains the card's function as an alternative to IOE cards, using optical fiber for data communication.

Optical Connectors InterBus-S

Specifies the type of optical connectors used and provides warnings for their use.

InterBus-S Interface Power Supply

Details the power supply connector and characteristics for the InterBus-S interface.

Description of Status LEDs

Explains the status LEDs indicating I/O functions and InterBus-S communication status.

Error Conditions with Control Device Shut Down

Describes error conditions and identification codes when the control device is shut down.

Optical Power Regulation

Explains the automatic optical power regulation and warnings about bridge configuration.

F386 Ethernet 100 Base-T and CANbus Communication Module

Technical Features

Lists technical specifications for the Ethernet and CANbus sections of the module.

Front Panel

Describes the front panel components, including CANbus connector and status LEDs.

P10 Ethernet 100 Base-T Connector

Details the Ethernet connector, its pinning, and status LEDs.

Ethernet Connection Cable

Provides information on Ethernet cable features and connection types (MDI/MDI-X).

F383-COM RS422 Serial Communication Card

P15 - Connection Port

Describes the P15 connection port, its signals, and recommended connection components.

InterBus-S Profil F-IBS;03

General Description

Explains the profile's role in data exchange, defining Control and Status Words for peripherals.

14.1.1 Control Words

Defines Control Words as commands for welding sequences sent to the control device.

Control Word 2

Defines Control Word 2 for managing supplementary functions of steppers and accessories.

Control Word 3

Defines Control Word 3 for selecting the Spot Index, used for welding spots in a database.

14.1.2 Status Words

Explains Status Words indicating welding sequence status and accessory functionality.

Status Word 3

Defines Status Word 3 for communicating technological parameters like weld force and element thickness.

Robot Directives Update

Explains how robot directives are updated via Control Word 2 for gun selection and reset confirmation.

APPENDIX A - Maintenance

Maintenance Operations

General guidelines for maintenance, emphasizing safety and correct procedures.

Replacing the Modular Cards

Step-by-step guide for replacing modular cards, including safety precautions and checks.

Replacing the CPU Card

Detailed instructions for replacing the CPU card, including jumper verification and connections.

Replacing the Power Feeder

Step-by-step guide for replacing the power feeder card, including fuse checks and jumper settings.

Replacing the Welding Control Device

Outlines the time and steps involved in replacing the entire welding control device.

Modifying a Welding Program

Explains how qualified personnel should modify welding programs and the time involved.

Replacing the Battery

Instructions for replacing the lithium battery on the F384 CPU card, ensuring data retention.

APPENDIX B - Diagrams and Network Configurations

Operating Diagrams

Provides diagrams analyzing timing and synchronisms for Start and Emergency conditions.

2 - START Recognition with Use in Manual Environment

Illustrates START recognition timing in a manual environment, with conditions for stability.

3 - EMERGENCY STOP Condition: General Diagram

Shows a general diagram of the EMERGENCY STOP condition, indicating signal behavior.

4 - EMERGENCY STOP Condition During or Outside Welding Pulse

Details emergency stop behavior during or outside a welding pulse, covering different cases.

5 - EMERGENCY STOP Excluded with START Still Active

Illustrates the behavior of EMERGENCY STOP when START is still active.

6 - START Disabled Condition During Welding Pulse

Shows a diagram where START is disabled during the welding pulse.

7 - Proportional Servovalve Operating Diagram

Explains servovalve operation, parameters, and how program code changes affect output.

8 - ENABLE Function (Interbus-s)

Describes the ENABLE function for valve control during power supply interruptions or via Interbus input.

9 - Diagram of Diagnostic Pressure Control

Illustrates diagnostic pressure control modes (PROC and WAIT) and signals for pressure errors.

Interbus-S - General Architecture of I;O Communications

Ethernet TCP;IP - Example of Network Architecture

InterBus-S- Example of Network Architecture

APPENDIX C - Weld334 m Application Diagram

GF Welding Weld334m Specifications

General IconGeneral
BrandGF Welding
ModelWeld334m
CategoryControl Unit
LanguageEnglish