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CHOWEL WELCOM-250Y Maintenance Manual

Resistance welding controller
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MM-W250Y,Z-041117(E)
MAINTENANCE MANUAL
FOR
RESISTANCE WELDING CONTROLLER
(MODEL : WELCOM-250Y, WELCOM-250Z)
CHOWEL CORPORATION

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Summary of Contents for CHOWEL WELCOM-250Y

  • Page 1 MM-W250Y,Z-041117(E) MAINTENANCE MANUAL RESISTANCE WELDING CONTROLLER (MODEL : WELCOM-250Y, WELCOM-250Z) CHOWEL CORPORATION...
  • Page 2 WARNING To guard against injury, the following basic safety precautions should be observed in the instruction manual of the resistance welding controller CHOWEL CORPORATION. Model : WELCOM-250Y, WELCOM-250Z 598, SUNGGOK-DONG, DANWON-GU, ANSAN-CITY, KYUNGGI-DO, REPUBLIC OF KOREA ⓒ Copyright CHOWEL CORPORATION...
  • Page 3 CHOWEL has developed this document for its licensees and customers. The information contained herein is the property of CHOWEL and may not be copied, used, or disclosed to others without prior written approval from CHOWEL and may not be copied, used, or disclosed to others without prior written approval from CHOWEL.
  • Page 4 WELCOM-250Y, Z MAINTENANCE MANUAL READ FIRST To use this welding controller in safety, the operator should follow industry standards and safety senses whenever working on, or near the weld machine. In some case, failure to follow the warning instruction can lead to control or machine damage.
  • Page 5 WELCOM-250Y, Z MAINTENANCE MANUAL CAUTION 1. Turn electrical power OFF before changing the tap switch at the weld transformer. In the case failure to follow the instruction like a welding at changing the tap switch can lead to injury to personnel.

  • Page 6: Table Of Contents

    WELCOM-250Y, Z MAINTENANCE MANUAL CONTENTS 1. Specification of WELCOM-250Y,Z ······································· 7 2. Fault detection ······························································· 11 3. Circuit diagrams ····························································· 15 4. TB30 ·········································································· 31 5. RB10 ············································································ 34 CHOWEL - 6 -...

  • Page 7: Specification Of Welcom-250Y,Z

    WELCOM-250Y, Z MAINTENANCE MANUAL 1. Specification of WELCOM-250Y,Z 1-1 Voltage and Frequency . Welding power supply : Single phase AC440±15% 50/60Hz Automatic selection . Control power supply : Unnecessary due to be fed from a voltage dropped welding power supply.
  • Page 8 WELCOM-250Y, Z MAINTENANCE MANUAL . Time range Initial squeeze time : 0 - 99 CYC Squeeze time : 1 - 99 CYC Up-slope time : 0 - 30 CYC #1 weld time : 0 - 99 CYC Down slope time...
  • Page 9 WELCOM-250Y, Z MAINTENANCE MANUAL 1-11 Counter . Total weld counter : 1 / 1 to 99,999,999 . Each schedule counter : 14 / 1 to 99,999,999 1-12 Fault detection . Controller failure : Fault output . Internal power failure : Fault output .
  • Page 10 WELCOM-250Y, Z MAINTENANCE MANUAL Schedule no. : 1 to 14 Fault code : 0 to 99 Total weld count value : 0 to 99,999,999 Target control current, #1,#2 weld : 2.0KA to 25.5KA Average Firing angle, #1,#2 weld : 20 to 150 degree...

  • Page 11: Fault Detection

    WELCOM-250Y, Z MAINTENANCE MANUAL 2. Fault detection Fault is checked for at the time of power on, inactive status, start and sequence end and alarm the detection according to its cause. 2-1 Fault detection items The followings are the typical times, details and remedies of fault for each fault code.
  • Page 12 WELCOM-250Y, Z MAINTENANCE MANUAL . E11 ILLEGAL POWER FREQUENCY This fault is checked for when the power is turned on, and alarmed immediately, if any. This fault indicates that the weld line frequency could not be identified when the power is turn on.
  • Page 13 WELCOM-250Y, Z MAINTENANCE MANUAL . E31 SCR SHORT This fault is checked for always while welding is not active, and alarmed immediately, if any. This fault indicates that the thyristor came to be short circuited. Replaced the thyristor and check whether the weld current is above the rated current or not.
  • Page 14 WELCOM-250Y, Z MAINTENANCE MANUAL . E62 HIGH CURRENT This fault is checked for when the weld current control ends, and alarmed when the sequence ends. This fault indicates that the weld current is above the high current limit level. Check whether the weld current and the over current detect set level have been set properly or not.

  • Page 15: Circuit Diagrams

    WELCOM-250Y, Z MAINTENANCE MANUAL 3. Circuit diagrams 3-1 Layout diagram for WELCOM-250Y CHOWEL - 15 -...
  • Page 16 WELCOM-250Y, Z MAINTENANCE MANUAL 3-2 Layout diagram for WELCOM-250Z CHOWEL - 16 -...
  • Page 17 WELCOM-250Y, Z MAINTENANCE MANUAL 3-3 Timer unit and I/O display CHOWEL - 17 -...
  • Page 18 WELCOM-250Y, Z MAINTENANCE MANUAL 3-4 Electrical connection for WELCOM-250Y CHOWEL - 18 -...
  • Page 19 WELCOM-250Y, Z MAINTENANCE MANUAL 3-5 Electrical connection for WELCOM-250Z CHOWEL - 19 -...
  • Page 20 WELCOM-250Y, Z MAINTENANCE MANUAL 3-6 Connection diagram for WELCOM-250Y timer unit CHOWEL - 20 -...
  • Page 21 WELCOM-250Y, Z MAINTENANCE MANUAL 3-7 Connection diagram for WELCOM-250Z timer unit CHOWEL - 21 -...
  • Page 22 WELCOM-250Y, Z MAINTENANCE MANUAL 3-8 Connection diagram for I/O connector (WELCOM-250Y) CHOWEL - 22 -...
  • Page 23 WELCOM-250Y, Z MAINTENANCE MANUAL 3-9 Harness diagram for WELCOM-250Y CHOWEL - 23 -...
  • Page 24 WELCOM-250Y, Z MAINTENANCE MANUAL 3-10 Harness diagram for WELCOM-250Z CHOWEL - 24 -...
  • Page 25 WELCOM-250Y, Z MAINTENANCE MANUAL 3-11 Electrical connection for step down T/R and SCR CHOWEL - 25 -...
  • Page 26 WELCOM-250Y, Z MAINTENANCE MANUAL 3-12 Circuit diagram for WELCOM-250Y, Z(1/4) CHOWEL - 26 -...
  • Page 27 WELCOM-250Y, Z MAINTENANCE MANUAL 3-13 Circuit diagram for WELCOM-250Y, Z(2/4) CHOWEL - 27 -...
  • Page 28 WELCOM-250Y, Z MAINTENANCE MANUAL 3-14 Circuit diagram for WELCOM-250Y, Z(3/4) CHOWEL - 28 -...
  • Page 29 WELCOM-250Y, Z MAINTENANCE MANUAL 3-15 Circuit diagram for WELCOM-250Y, Z(4/4) CHOWEL - 29 -...
  • Page 30 WELCOM-250Y, Z MAINTENANCE MANUAL 3-16 Circuit diagram for firing PCB CHOWEL - 30 -...

  • Page 31: Tb30

    WELCOM-250Y, Z MAINTENANCE MANUAL 4. TB30(Teaching Box) 1) Data display method : Spread sheet method 2) Function select method : Select from function menu 3) Display : 20 characters x 4 lines LCD (with EL backlight) 4) Capacity of backup memory...
  • Page 32 WELCOM-250Y, Z MAINTENANCE MANUAL 11) Circuit diagram for TB30(1/2) CHOWEL - 32 -...
  • Page 33 WELCOM-250Y, Z MAINTENANCE MANUAL 12) Circuit diagram for TB30(2/2) CHOWEL - 33 -...

  • Page 34: Rb10

    WELCOM-250Y, Z MAINTENANCE MANUAL 5. RB10(Reset Box) 1) Display : 4 characters 7 segment LED 2) Interface : Timer communication interface (Base on RS-422 standard) 3) Power supply : supplied from communication line 4) Display contents - Start schedule no.
  • Page 35 WELCOM-250Y, Z MAINTENANCE MANUAL 8) Circuit diagram for RB10(1/2) CHOWEL - 35 -...
  • Page 36 WELCOM-250Y, Z MAINTENANCE MANUAL 9) Circuit diagram for RB10(2/2) CHOWEL - 36 -...

This manual is also suitable for:

Welcom-250z