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Summary of Contents for GF Welding Weld334m
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USER’S MANUAL Weld334m Ed.5 – December 2004 Doc.39000326...
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No part of this manual may be reproduced or distributed in any form or by any means or stored in a database or retrieval system without the prior written permission of GF WELDING S.p.A. All rights reserved to GF WELDING S.p.A.
1.2.4 Power supply ............................6 1.2.5 Phase synchronising for welding......................7 1.2.6 Programming unit ..........................7 1.2.7 Connecting the Weld334m with the WMS central network ..............7 CHARACTERISTICS AND GENERAL DESCRIPTION OF THE WELD334M ........9 ..........................9 ENERAL DESCRIPTION ........................10 LOCK DIAGRAM OF ........................11 ARDWARE CONFIGURATION ............................12...
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Weld334m - User’s manual F360-IOB CARD – BASE I/O........................37 ........................37 ESCRIPTION OF FUNCTIONS P20 24V - I/O ............................ 37 P22 - HSA – C ....................... 37 IRCUIT BREAKER TRIP P21 . D ....................... 38 ESCRIPTION OF SIGNALS F356-IOE I/O EXPANSION CARD ....................... 41 10.1...
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Weld334m - User’s manual 9 – Diagram of diagnostic pressure control ........................80 Interbus-S –general architecture of I/O communications................81 Ethernet Tcp/Ip – Example of network architecture ..................... 82 InterBus-S- Example of network architecture....................... 83 WHITE PAGE..............................84 APPENDIX C - W ..................85...
Weld334m - User’s manual 1. Safety To insure correct installation and operation of the WELD334m welding control device, it is necessary to carefully read this chapter. Each operation on the machine is to be carried out only by qualified personnel with good understanding of the information contained in this manual;...
Weld334m - User’s manual 1.1 Hazards associated with the use of resistance welding machines Because of the presence of electric current and live parts in the machine, mounting, maintenance work and replacement of genuine parts is only to be entrusted to Qualified Personnel (electricians or authorised personnel).
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Weld334m - User’s manual High magnetic fields, generating very close to the welding gun and the secondary • cable, represent a serious hazard to people and property (e.g.: watches, cables for electric data transmission, magnetic devices, medical equipment and pace-makers).
EMC requirements with the surrounding ambient. It is recommended to scrupulously observe the conditions of use (meaning by this that the Weld334m cabinet is to be closed and all its earth leads must be connected).
Weld334m - User’s manual Here below are a few measures which are to be taken in order to avoid harm and damage to operators and equipment: 1. Earth the welding transformer secondary. 2. Install a differential on the welding transformer primary set to the minimum value of current (30mA).
20-25 internal resistor (these can be ordered from GF WELDING S.p.A.) The Weld334m permits using up to 6 sensors in series (one at a time is active when • welding). The quantity of sensors connected is to be set on the welding device (see Programming manual, Setup chapter).
Weld334m before installing the connector. This will discharge the static charge. Make sure no foreign bodies, such as metal chips or slags, fall inside the connector. Any damage to the HCM 4300 HHT graphic programming unit and to the Weld334m, resulting from tampering or deliberate disregard, will void the guarantee.
The Weld334m can be field programmed via the HHT4300 graphic unit or, through the centralising network, via a remote computer equipped with the WMS software and the adequate communication card.
Weld334m - User’s manual Block diagram of 334m The 334m can be divided into two separate functional blocks. The first block is the basic part of the system and consists of the main cards, which must always be installed, two internal fixed cards (power feeder and BUS) and three removable ones (CPU, I/OB and ADC).
Weld334m - User’s manual Hardware configuration Every function has been housed on a dedicated card; in addition to this, 24Vdc discrete inputs and outputs are divided into Base and Expansion types. The first position on the BUS, near connectors P1 and JP1, is to be compulsorily dedicated to the card CPU.
Pulse Ctrl. : 24Vdc with 10 ohm 2W resistance in series for current limitation Protections: Short circuit Overcurrent Overvoltage (disturbances and peaks) Programming port: local: Serial type for GF WELDING HHT4300 unit Laptop PC (with WMS GF WELDING software) On line: Serial, GF WELDING centralising system (see optional)
Weld334m - User’s manual 2.4.1 Utilisation characteristics The construction complies with the EC requirements, CE marking Operating 0° +60°C, humidity without temperature: condensation Storage temperature: +80°, humidity without condensation Weight: 2,5Kg maximum (depending on the configurations) 2.4.2 Dimensions, overall dimensions and fastening positions.
The Laptop connects to the P1 connector of the control device and communicates through an RS485 Full duplex serial port, with WMS rel. 2.61 and upgrades. Cable for connection between Weld334m and PC laptop: F2118; Order code: 32102110; With converter RS485 / RS232;...
Weld334m - User’s manual 3. Power supply and 24V for I/O Control device power supply The power supply section resides on the PS 8way, 5.08mm pitch connector for disconnectable terminals which are located on the front. Also housed on this connector is the input for the external synchronism.
Weld334m - User’s manual 3.1.2 Connections for main power supply. Diagrams for control device power supply are illustrated below. Ac input taken from the power line of the welding transformer. • 380Vac line Power Power transformer supply 14,4-32,4Vac Pulse Firing device...
To make use of 24V supply of I/O, certain rules are to be observed. These rules depend on the type of application used on the machine. The Weld334m is supplied by GF WELDING in a standard configuration; 24V = make jumpers between pin 5 and pin 6 (see figure below).
Weld334m - User’s manual 24V I/O can be managed in the following ways: Direct: 24VI supply with pins 5 - 6 of PS being free (see paragraph ◊ 3.2.2 figure a J1 connector: jumpers of I/O and ADC cards to be made in position 1-2.
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Weld334m - User’s manual Figure c: Use of +24VE (external) with earth on the Weld334m side Weld334m Power supply SYNC. +24VE Externa powe feeder 7 0V 8 0V Faston If earthing for 24VE supply has been performed on the welding control device side, then the external power feeder is not to be earthed.
Weld334m - User’s manual General protective devices on power supply General schematic of protective devices. Protection A: Voltage/current limit circuit placed on the power feeder primary 24VI 24VI/VE Input stage Protection : Internal power Self-reset feeder state type solid fuse On the basis of the type of connection in use, the protections operate in the following way: Protection A: General overvoltage and overcurrent protective circuit .
Weld334m - User’s manual Power feeder type F370-PSM Temperature* (°C) 20° 40° 50° 60° Current (A) 2.03 1.58 * Characteristics refer to the operating temperature of the component itself. Setting the external synchronism For the firing pulse to the SCRs to be synchronised with the mains of the SCRs, the two jumpers for the line synchronism must be set on the card.
Weld334m - User’s manual F351-BUS Interconnection card Code:33035100 4. F351-BUS Interconnection card BUS interconnection card for signals and power supply. J2 connector takes 24V supply for the I/O power supply. J1 connector takes 5V supply for the cards and +V for programming unit HHT.
Weld334m - User’s manual F384-CPU Microprocessor card Code:33038400 5. F384-CPU Microprocessor card This is the system calculation centre and it is fitted with a MCU Motorola 68332 card (20MHz clock). Data and program RAM resides on flash eprom (1MB). Permanent data is stored in a buffer battery.
Weld334m - User’s manual F353-ADC Analogue Card Code :33035300 6. F353-ADC Analogue Card This card includes 3 analogue inputs for acquiring signals from connectors P2 - P3 - P4 and the internal arrangement for housing the SEV module (optional extra) with output on the P2 for the electrode pressure adjustment (proportional solenoid valve).
Weld334m - User’s manual F353-ADC Analogue Card 6.2 P2 . Description of the signals for the Solenoid valve and the TFE The two green LED indicators are for the proportional solenoid valve and their function is the following: ENSERV : = illuminated when the relevant output on P2 is active STSERV : = illuminated when the signal is present on the input.
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Weld334m - User’s manual F353-ADC Analogue Card P2 . Functional description of signals Signal Function Shield ISERV o VSERV servovalve signal screening ENSERV Output. Active at 24V. Proportional solenoid valve enable. Before commencing the adjustment operation, the solenoid valve waits for this signal from the control device.
These adjustments are dependent on the settings entered in the Setup menu and in the welding program (see Programming Manual). On the basis of these settings, the Weld334m pilots the analogue voltage output over a range from 0 to 10V or the analogue current output over a range from 4 to 20 mA.
Weld334m - User’s manual F364-SEV and F385-SEV Proportional Servovalve Modules Mounting position of the F385-SVV Module F353-ADC F364-SEV Module Fixing of the module is ensured by the tight fit of the two connectors J1-J3 Make sure that the module is properly fitted into the card.
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Weld334m - User’s manual F364-SEV and F385-SEV Proportional Servovalve Modules WHITE PAGE...
Weld334m - User’s manual F359-MCP Memory Card and Printer Code:33035900 8. F359-MCP Memory Card and Printer The F359-MCP card supports a PCMCIA type memory card (Ram Card) and the parallel port for connection to a printer. F359-MDP MEMORY CARD Standard connector for the PCMCIA card.
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Weld334m - User’s manual F359-MCP Memory Card and Printer WHITE PAGE...
Weld334m - User’s manual F360-IOB I/O Basic card Code:33036000 9. F360-IOB Card – Base I/O This card is used for the basic connections toward the plant and houses a 2-position selector switch and the linear connectors P20, P21, P22. 9.1 Description of functions...
10mA In the case of a Weld334m IMF integrated inverter, the function becomes: Welding/starting time with current 10mA ** In the case of a Weld334m IMF integrated inverter, the function becomes: Inverter Ready P21 – Functional description of signals Signal Function +24TRASF.
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Weld334m - User’s manual F360-IOB I/O Basic card P21 – Functional description of signals Signal Function FINE SEQ. Output active at 24V. At the end of frequency cycles (electrode opening), the control device activates this output and terminates the sequence.
Weld334m - User’s manual F356-IOE I/O Expansion Card Code:33035600 10. F356-IOE I/O Expansion Card This card houses two terminal type connectors - a 18-way connector (P24) and a 16-way connector (P23) – for the connection to the field. They support 18 off 14V inputs (20/30V - 10mA) and 16 off 24V - 0.3A inputs, four of which (dedicated to the welding solenoid...
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Weld334m - User’s manual F356-IOE I/O Expansion Card P23 . Functional description of output signals Signal Function ALLSTB Same as ALLSTA but for channel B. RICHRAV Request for Dressing. Active at +24V. This output is activated as a function of the programming of the stepper concerned.
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Weld334m - User’s manual F356-IOE I/O Expansion Card P23 . Functional description of output signals Signal Function STATUS Welding current enable. Active at 24V. It indicates the condition for Weld Yes; when this function is enabled, this output is high. (see also WeldYes) EVSA Piloting output of the channel A welding solenoid valve.
Weld334m - User’s manual F356-IOE I/O Expansion Card 10.2 P24 . Description of input signals 18-way, 3.5mm pitch linear connector for disconnectable terminals Signal Description STARTA Start channel A STARTB Start channel B CEVASA Additional opening A control CEVASB Additional opening B control...
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Weld334m - User’s manual F356-IOE I/O Expansion Card P24 . Functional description of input signals Signal Function SALDASI Weld Yes. Active at +24V. It enables the welding current. Also the following functions are to be active: Weld Yes in the Setup stage* and the selector located on the front of IOB card.
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Weld334m - User’s manual F356-IOE I/O Expansion Card P24 . Functional description of input signals Signal Function CODEP Parity Code. Active at +24V. It is used only on robot operated lines. It is used for the logic check of CODE0..5 inputs and is dependent on the setting done in the Setup menu.
Weld334m - User’s manual F356-IOE I/O Expansion Card 10.2.1 List of program selection codes The list below shows the binary codes of the 64 welding programs Binary code Si gnal s Par i t y ! " " " "...
Weld334m - User’s manual F376-OPC Field-Bus InterBus-S Card Code:33037600 11. F376-OPC Field-Bus InterBus-S Card (Profile F-IBS/03) 11.1 Characteristics The F376-OPC card enables the welding I/O functions towards the field to be managed, as an alternative to the IOE field cards. This data communication occurs by optical fiber transmission through a serial bus, compatible with the InterBus-S protocol.
Weld334m - User’s manual F376-OPC Field-Bus InterBus-S Card 11.3 InterBus-S interface power supply There is a P25 connector on the front panel to supply the InterBus-S interface. Connector type: 2 way, 5.08 pitch, disconnectable terminals. Power supply input characteristics: Acceptable Input voltage: 24Vdc -15%+10% •...
Weld334m - User’s manual F376-OPC Field-Bus InterBus-S Card Identification code (ID Code) The welding control devices are considered by the InterBus-S net as digital devices belonging to the Profile-conforming digital devices with I/O addresses (PROFILE DIO). This functional category corresponds to the decimal identification code (ID code) 47 (2f hexadecimal).
Weld334m - User’s manual F386 Ethernet 100Base-T and CANbus module Code:33038600 12. F386 Ethernet 100Base-T and CANbus communication module Serial and CANbus communication card for Ethernet 10/100Base-T IEEE802.3 nets. This module enables the welding control to be connected to a serial network of the Ethernet type for communication towards the WMS centralizer.
Weld334m - User’s manual F386 Ethernet 100Base-T and CANbus module 12.2.3 P10 Ethernet 100Base-T connector RJ45 8-pole female shielded type MDI configuration Signal Function Positive data transmission Negative data transmission Positive data reception Not used Not used P10 connector Negative data reception...
Weld334m - User’s manual F383-COM RS422 Serial communication card Code:33038300 13. F383-COM RS422 Serial communication card RS422 serial interface for the communication with a remote device. The communication protocol depends on the functional goal that has to be achieved. Features:...
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Weld334m - User’s manual F383-COM RS422 Serial communication card Card layout...
14.1 General description A specific data communication Profile has been integrated into the firmware of the modular control Weld334m, which is automatically activated in the versions with Interbus-S type serial Fieldbus communication module. This Profile was developed for applications in the field of resistance welding.
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Weld334m - User’s manual InterBus-S Profil F-IBS/03 Control Word 1 – Functional description Signal Function Bit = 1. Start Command. Start weld program The number of the welding program is acquired and the related cycle is started. RAVOK Bit = 1. Electrode dressing completed.
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Weld334m - User’s manual InterBus-S Profil F-IBS/03 Control Word 2 Control Word 2 defines the commands relating to management of the supplementary functions of the steppers, and of accessory functions. Description Reset stepper gun 1 Reset stepper gun 2 Reset stepper gun 3...
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In each welding control, the necessary part of the database is saved through the WMS centralisation program. Signals sent by the Weld334m on the welding status, (diagnostics, program called up, electrode pressure, etc.) are integrated with a Spot Index value and the name of the welding spot.
Weld334m - User’s manual InterBus-S Profil F-IBS/03 14.1.2 Status Words Status Words indicate to the remote interface device the status of the welding sequence, and the status of the control and functionality of accessories in general. Status Word 1 Status Word 1 defines the standard welding outputs Description FINE SEQ.
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Weld334m - User’s manual InterBus-S Profil F-IBS/03 mode or constant current). STATUS Bit = 1. Execute “welding cycle with current” enabled. The welding cycle will be executed with current, that is to say under command of the power group. Danger Alarm Bit = 1.
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Weld334m - User’s manual InterBus-S Profil F-IBS/03 Status Word 3 Status Word 3 defines two Bytes included between bits 0-7 and bits 8-15 to communicate the technological parameters necessary to manage an electric gun, such as electrode closing force (WELD FORCE) and the thickness of the part to be welded (ELEMENT THICKNESS).
Weld334m - User’s manual InterBus-S Profil F-IBS/03 14.2 Robot directives update Use of Status and Control Word 2 within robot communication. Within the FASE control device (only 334m) the 2 Interbus Word is for the communication extended between the device and the robot for the information exchange concerning the already reset counter, after activating the reset counter with the number of the program.
Weld334m - User’s manual APPENDIX A - Maintenance Maintenance operations Replacing the cards is a very simple task which poses no problems. The wiring connections with the welding machine cannot be exchanged between one another and the connector ID code is also recalled on the front panel.
Weld334m - User’s manual Replacing the CPU card The CPU card has its own (compulsory) position on the P1 of the bus and is connected to the display module via a 10-way flat cable. The P7 3-way connector does not take 24V I/O supply from the bus, it takes the privileged power supply to power the programming unit from the RS485 port (P1).
Weld334m - User’s manual Replacing the welding control device Times indicated refer to a manual welding station Saving the configuration and programs of the control device to Minute be replaced on a Ram-Card Dismantling the control device to be replaced from the welding...
Weld334m - User’s manual Replacing the battery 3.6V CR2477N type lithium battery. The battery is housed on the F384 CPU card in an adequate seat which allows the battery to be replaced easily with no need for special operations. When replacing the battery, data stored on the RAM are not lost. A Supercap type capacitor powers RAMs during the replacement.
Weld334m - User’s manual APPENDIX B – Diagrams and network configurations Operating diagrams This section illustrates a few operating diagrams of the control device which allow analysing timing and synchronisms referred to the Start and Emergency conditions in manual or automated environments.
Weld334m - User’s manual 2 – START recognition with use in manual environment = 20mS Start Program code Program parity Call recognition: ∆T Min.40mS - Max.60mS since Start Start and Program Code must stay stable.
Weld334m - User’s manual 3 – EMERGENCY STOP condition : general diagram NOTE: The Emergency stop signal is active at 0V not considered :still hold Pgm 1 PGM 2 Now Start START* PROGRAM * PGM1 PGM2 CODE FINISHING WELD HOT TIME...
Weld334m - User’s manual 4 – EMERGENCY STOP condition during or outside the welding pulse NOTE: The Emergency stop signal is active at 0V PRE SQUEEZE SQUEEZE WELD HOLD CYCLE CURRENT Closed NO FK CASE 1 SPOT DONE Open EMERGENCY...
Weld334m - User’s manual 5 – EMERGENCY STOP excluded with START still active NOTE: The Emergency stop signal is active at 0V START Closed EMERGENCY Open (if spot done) since START = ON; same as standard condition 6 – START disabled condition during the welding pulse...
Weld334m - User’s manual 7 – Proportional Servovalve operating diagram Servovalve parameters description: OFFSET : 0 - 100 % ( active only after a reset; until a start cycle ) Stored in Setup function EV1 : 0 - 100 % Nominal value during welding cycle Stored in each program EV2 : 0 - 100 % Pressure variation value.
Weld334m - User’s manual 8 – ENABLE function (Interbus-s) 24V_Power Signal 0-10V/4-20mA servovalve activ ENABLE 24V servovalve inactive Pressure PA Inpunt Interbus Fase ENABLE( Bit 2) Servovalve Control Signal behaviour: ENABLE 24V: This function allows the valve control when voltage power supply interrupts (Fail save);...
Weld334m - User’s manual 9 – Diagram of diagnostic pressure control Mode of operation relates to the status of the programming parameter PROC / WAIT (see programming Manual, paragraph Electrode Force Diagnostic Mode) Process in PROC mode The control executes the sequence respecting the set timings. The diagnostic function signals any pressure errors.
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