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CHOWEL WELCOM 600P User Manual

Resistance welding controller
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OM-W600P-0410(E)
RESISTANCE WELDING CONTROLLER
WELCOM 600P
USER MANUAL
CHOWEL CORPORATION

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  • Page 1 OM-W600P-0410(E) RESISTANCE WELDING CONTROLLER WELCOM 600P USER MANUAL CHOWEL CORPORATION...
  • Page 2 Please, read carefully this manual for safe and efficient use of the welding controller The information in this manual is the possession of the chowel, it is subject to change without notice. And this manual can be changed also without the notice.
  • Page 3 WELCOM 600P IMPORTANT Read first this manual before operate this welding controller. In some case, failure to follow the instructions manual can lead to control or machine damage. In other cases failure to follow instructions can lead to injury, or death of personnel.
  • Page 4 WELCOM 600P 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. In other cases failure to follow these instruction can lea to injury, or death of personnel.
  • Page 5 WELCOM 600P CAUTION Turn electrical power 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. Turn stop cock OFF before some piping work.

  • Page 6: Table Of Contents

    WELCOM 600P CONTENTS Chapter 1. Installation of welder §1. Cooling water handling ....................9 §2. Connection of power source and welding transformer ..........10 §3. External I/O signal ..................... 11 §4. Pilot input of binary method ..................16 Chapter 2. Programming §1.
  • Page 7 §1. Monitor content ......................65 Reference . WELCOM 600P FAULT CODE TABLE ..............67 2. WELCOM 600P DATA SHEET .................. 68 3. ELECTRICAL CONNECTION DIAGRAM OF WELCOM 600P ....... 69 4. OUTSIDE VIEW OF WELDCOM 600P ..............70 CHOWEL CORPORATION - 6 -...
  • Page 8 WELCOM 600P ● Attention, check point before operation and in operation This control device is careful treatment because it is containing a backup battery internally to maintain program data and monitor data at a power OFF. 1. Please avoid the place which to need the store of the long term is as follows.
  • Page 9 WELCOM 600P 4. Check point in operation 4-1. After it confirm the existence over the safety of the equipment and check, must turn a power switch 4-2. It must provide suitable to a proper form power source to a welding power source.

  • Page 10: Chapter 1. Installation Of Welder

    WELCOM 600P Chapter 1. Installation of welder It expresses the sequence of the time to install the resistance welder control device in a task spot. It does not confirm properly and to prevent the accident not to become the operation, apply necessarily this sequence.

  • Page 11: Connection Of Power Source And Welding Transformer

    WELCOM 600P §2．Connection of power source and welding transformer As it do a cable connection within the body at electric wire terminal, do in the sequence such as there. 2-1. The earth of the body Earth a control device body certainly to prevent electric leakage accident.

  • Page 12: External I/O Signal

    WELCOM 600P §3. External I/O signal As it marked function and action of outside connection terminal signal, Connect the wiring sothat you are suitable to an utility purpose. 3-1. External input signal All the inputs are designed for contact input.
  • Page 13 WELCOM 600P  WELD ON/OFF INPUT When this input signal is ON, the operation mode is WELD, and when off, TEST MODE. In the test mode, if the pilot signal is set at ON, the sequence will be in the self-holding status.
  • Page 14 WELCOM 600P  TRANSFORMER THERMO INPUT When this signal is turned OFF, when the sequence is active, it is judged that the weld transformer is overheated, and the fault is put out and the Timer unit comes to stop. Connect this signal to the thermostat signal from the weld transformer.
  • Page 15 WELCOM 600P  RETRACT VALVE OUTPUT２ This is voltage output AC100V or DC24V for RETRACT VALVE no.2. Connect this signal to the solenoid valve. When not used, keep this signal open.  WELD COMPLETE OUTPUT This is a no-voltage A contact output which is turned ON when the sequence is completed and OFF when all the PILOT INPUTS are turned off.
  • Page 16 WELCOM 600P  ALARM OUTPUT This is a no-voltage A contact output signal which is turned ON when some alarm is detected. This output signal does not affect the weld sequence operation. Use this signal as an alarm signal to alarm the operators on the maintenance time.

  • Page 17: Pilot Input Of Binary Method

    WELCOM 600P §4. PILOT INPUT of binary method The PILOT INPUT signals are binary to enable many weld conditions enable to be selected. For the combination of the PILOT INPUT signals and the schedule no., refer to the following table.

  • Page 18: Chapter 2. Programming

    WELCOM 600P Chapter 2. Programming Program the operation of the welding Timer unit, the weld condition and the constant of the welder to be used. Specify the program schedule common to all schedule with X0, and the SCHEDULE NO. and VALVE/STEP NO.
  • Page 19 WELCOM 600P §1．Common program This is a program common to all schedules and specified with X0. Program the data common to all schedules. 1-1． Control constant program Program the function and constant common the all the schedule.  A-00 LOW CURRENT LIMIT Set the weld current drop detect level at 100% for the detection as specified.
  • Page 20 WELCOM 600P 1-3. Operation mode program Set the operation modes common to all the schedule no. with 0(OFF), 1(ON).  A-30 SPEPPER RESET METHOD Set the reset method for the step counter and weld counter to control the stepper. For resetting the complete schedule only, set them at 0, and for resetting all schedule, set them at ...
  • Page 21 WELCOM 600P §2．Program for each schedule number Program the conditions for each schedule no. Specify the schedule no. with sch１through sch31. There is no need to program the schedule no. that is not used. 2-1. Weld sequence program Program the weld sequence and the weld condition.
  • Page 22 WELCOM 600P  C-13 ＃２DOWN SLOPE TIME Set the down slope time after the #2 weld.  C-14 HOLD TIME Set the time for which the weld gun holds the squeeze after the weld ends.  C-15 WELD COMPLETE DELAY TIME Set the time until when the WELD COMPLETE signal is put out after the weld gun release begins.
  • Page 23 WELCOM 600P 2-3. Operation mode program Program the operation mode with 0(OFF), 1(ON).  C-30 CURRENT CONTROL METHOD Set this at 0 for the VOLTAGE COMPENSATE control mode, and 1 for the constant current control mode.  C-31 REPEAT FUNCTION When this is set at 0, the weld sequence is performed only once after the PILOT input is made.
  • Page 24 WELCOM 600P §3．Stepper program for each valve number Program the stepper condition for each valve/stepper no. Specify the valve no. with X1 through X31. There is no need to program the valve no. which is not used.  N-00 STEP 0 CURRENT RATE 50 ~ 100% Set the weld current rate of step 0 when the stepper is in operation.
  • Page 25 WELCOM 600P  N-18 STEP 9 CURRENT RATE 50 ~ 100% Set the weld current rate of step 9 when the stepper is in operation.  N-19 STEP 9 WELD COUNTS 1 ~ 9999 TIMES Set the weld count of the step 9 when the stepper is in operation.

  • Page 26: Chapter 3. Indicator And Monitor Data

    WELCOM 600P Chapter 3. Indicator and Monitor data Because this can use abundant monitor information about panel LED indicaotr and data indicator for VFD, use in a failure repair and integrity, the officer of a weld quality, the analysis. §1．Panel indicator of I/O signal I/O signal and front panel indicator content of action situation is marked as shown in the below, use for an check purpose of the action and an ON／OFF of each signal.
  • Page 27 WELCOM 600P 1-2． Panel indicator of output signal This is marked the ON/OFF situation of an outside output signal normally at the monitor.  VALVE１ When the VALVE OUTPUT 1 is ON, this indicator is ON.  RETRACT１ When the RETRACT OUTPUT 1 is ON, this indicator is ON.
  • Page 28 WELCOM 600P 1-3． Panel indicator of the sequence signal When this is at a time of the sequence control, this indicates the situation of signal normally.  SQUEEZE TIME When the PILOT signal is active, this is ON at the PRESSURE TIME.

  • Page 29: Monitor Of Internal Data

    WELCOM 600P §2．Monitor of internal data According to the TEACHING BOX (TB600) mark, this is indicates monitor data. 2-1．Common monitor item The followings are the monitor items common to all the start systems, holding the latest weld result.  B-00 SCHEDULE NO．...
  • Page 30 WELCOM 600P  B-14 ＃2 CONDUCTING ANGLE This item indicates average value of the thyristor conduction angle in the #2 WELD TIME.  B-15 ＃２WELD CURRENT This item indicates average value of the weld current in the #2 WELD TIME in the constant current control mode.

  • Page 31: Chapter 4. Fault Detection

    WELCOM 600P Chapter 4. Fault detection Fault is checked for at the time of power on, incative status, start and sequence end and alarm the detection according to its cause. §1. Fault detection items The followings are the typical times, details and remedies of fault for each fault code. Use them for troubleshooting.
  • Page 32 WELCOM 600P  E12 LOW VOLTAGE IN WELD This fault is checked for when the power is turned on, and alarmed immediately, if any. This fault indicates that the power has been shut OFF during the welding or the drastic voltage drop was caused.
  • Page 33 WELCOM 600P This fault indicates that the secondary cable is short circuited or almost short circuited. Replace the secondary cable.  (E42) VALVE CABLE BREAK This is checked when the pressure starts and the GUN opens, the former alarmed immediately, the latter alarmed after sequence ends.

  • Page 34: Fault History

    WELCOM 600P §2．Fault history The faults caused are recorded according to the schedule and the fault code for use in maintenacne. 2-1．Common fault history The schedule no. that detected faults as common fault history record them up to 10 in the order of detection.

  • Page 35: Stepper Control Function

    WELCOM 600P Chpater 5. Special functions and usage The following functions are provided to maintain the high weld quality and easy maintenance. Use them according to your line situation and control system. §1．Stepper control function As the weld operation is repeated at a constant current, the electrode tips wear and their squeezeareas become larger, and consequently the current density of the weld parts becomes lower and the weld quality is degraded.
  • Page 36 WELCOM 600P ｄ．If the NUMBER OF STEPS should be less then 10, any number of steps can be used by setting the STEP WELD COUNTS on the way at 0 to skip it. ｅ．After completing the stepper operation, the weld control is continued in accordance with the setting of the 9 step.

  • Page 37: Secondary Cable Break Predict Function

    WELCOM 600P §2．Secondary cable break predict function In welding in the constant current control mode, if the secondary cable is almost disconnected, it can not be found. If the disconnection is detected by excessive drop in the current, replace the secondary immediately.
  • Page 38 WELCOM 600P §3．Secondary cable short circuit test function If short circuit is caused, to the inside of the kickless cable, the weld current will be diverted on the way, increasing reactive power and degrading the weld quality. However, this can not be found from the outside.

  • Page 39: External Input Pilot

    WELCOM 600P §4．External input pilot The usage of the RERACT PILOT, FOOT SWITCH, PALM SWITCH is content. This is not operated to the action to want to connect wrong at a wire connection. The shown in the following diagram, this is to mark the PILOT INPUT MEHTOD of a control device.
  • Page 40 WELCOM 600P 3-2． The case to connect RETRACT ①:ON, EXT.PILOT ②:ON, FOOT/PALM ③:OFF(PALM) This use PALM SWITCH, operates like [Figure 5-4]. ③:OFF implies here the situation to be connected th the CN3.16. When action of PALM SWITCH is achieved the A SWITCH with the 1 SWITCH A1 and A1 is ON at the same time, Operate with the figure.
  • Page 41 WELCOM 600P 3-6． The case to connect RETRACT ①:OFF, EXT.PILOT ②:ON, FOOT/PALM ③:OFF(PALM) The PILOT to the input at PILOT 1,2,4,8 does the welding by the PALM SWITCH A1+A. 3-7． The case to connect RETRACT ①:OFF, EXT.PILOT ②:OFF, FOOT/PALM ③:ON(FOOT) or OFF(PALM) The schedule according to the input of PILOT 1,2,4,8 does the welding.

  • Page 42: Chapter 6. Operation Sequence

    WELCOM 600P Chapter 6. Operation sequence In the following papes, examples of the operation sequences of various external signals are shown.Check to be sure that, when they are used together with the PLC, there is no unreasonable usage. The PILOT input signal initiate the weld sequence after removing the chattering caused by the contact bounds of the initiation switch or the delay and correcting the time irregularity of each pilot signal in the binary pilot mode.
  • Page 43 WELCOM 600P 1-2．PULSATION control sequence Pilot input Valve output Weld current Weld Complete Output US1 WT1 DS1 US2 WT2 DS2 US2 WT2 DS2 US2 WT2 DS2 Number of Pulsation : 4 In REPEAT mode Initial Squeeze Time US２ Up Slope Time 2 Squeeze Time WT２...
  • Page 44 WELCOM 600P 1-3．REPEATER control sequence Pilot input Valve output Weld current Weld Complete Output US1 WT1 DS1 US2 WT2 DS2 US1 WT1 DS1 US2 WT2 DS2 Approx. 6cycle Initial Squeeze Time US２ Up Slope Time 2 Squeeze Time WT２ #2 Weld Time Pressure Stable Time DS２...
  • Page 45 WELCOM 600P 1-4．Pulse start mode sequence The followings are the weld sequence applicable to the case where the PULSE PILOT is set at ON and the pulse signal is used for initiation. When the sequence is used in the binary pilot mode, take into consideration using the program step of the weld PLC that all the pilot signals can be fixed in a short time.
  • Page 46 WELCOM 600P 1-5．Sequence at a pressure pilot When sequence is not operated, valve output is operated according to ON/OFF of pilot input. Pilot input Valve output CHOWEL CORPORATION - 45 -...
  • Page 47 WELCOM 600P 1-6．Sequence when interlock signal operate Pilot input Valve output Interlock input Interlock output Weld current Weld Complete output US1 WT1 DS1 US2 WT2 DS2 Number of pulsations repeat Weld waiting period Initial Squeeze Time US２ Up Slope Time 2 Squeeze Time WT２...

  • Page 48: Fault, Warning Output Sequence

    WELCOM 600P §2．Fault, warning output sequence 2-1．Sequence when detection is made at the initiation Pilot input Valve output Weld complete output Fault output Fault reset input CHOWEL CORPORATION - 47 -...
  • Page 49 WELCOM 600P 2-2．Sequence when detection is made after the weld Pilot input Valve output Weld current If weld complete is Weld ON in case of fault Complete output Fault output Fault reset input US1 WT1 DS1 US2 WT2 DS2 Initial Squeeze Time US２...

  • Page 50: Fault Reset By Pilot Sequence

    WELCOM 600P §3．Fault reset by pilot sequence This sequence shows the operation when the Fault reset by pilot is set at ON and the error reset is not made after the fault is detected but the reset start is made by the pilot input.

  • Page 51: Reweld At Fault Sequence

    WELCOM 600P §4．Reweld at fault sequence This sequence shows the operation when the Reweld at fault is set at ON and the NO CURRENT are detected as an fault. In case of other faults than the fault caused by the NO CURRENT, the EXTREMELY LOW CURRENT and the LOW CURRENT, reweld is not made.

  • Page 52: Chapter 7. Data Input And Monitoring

    WELCOM 600P Chapter 7. DATA input and monitoring It is content to the window indicator condition and the usage method about DATA input of each functions and the welding condition of control device. ① INPUT SIGNAL INDICATOR LED: This indicate the connection condition of a external input signal.

  • Page 53: The Normal Window

    WELCOM 600P §1．The normal window After welding control device is power on, the display of VFD represent like Figure 1-1. Cursor Tno.00 Sch01 Prog ? C-00 0 Cycle C-01 30 Cycle v Init. Squeeze Time [Figure 1-1] ① When the NETWORK use, this is the number to distinguish the control device.

  • Page 54: The Fault Window

    WELCOM 600P §2．The fault window The case which the fault happens with the figure 2-1, it indicates the fault number and content with the code of the fault to happen. (Figure 2-1 is the example of the case which the thyristor overheating among the welding happens to a PILOT number 2.)
  • Page 55 WELCOM 600P ( 5 = History Data Reset ) : It measures the voltage of power source. Only, when input power source is 220V, Read 1/2 of the indicating value. ( 6 = Line Voltage Check ) : It returns the initial window. (Use the key when you pushed wrong.) The each key: it returns the normal window.
  • Page 56 WELCOM 600P ① is indicated to the schedule NO. before the schedule COPY MODE enters and cursors, 02 at the ② ③ anything does not indicated at the 3) Input a schedule NO. to wanted the COPY. This is not need to input when it is identical.
  • Page 57 WELCOM 600P Example 2 When it try to copy a schedule number 3 datas at a schedule number 4 2) the key number 3) the key number 5) the key number 8) After schedule COPY, the function windows return. [ Function ] Schedule Duplicate ０= Data Initialize...
  • Page 58 WELCOM 600P Example 3 When it try to copy a schedule number 1 datas at a schedule number 2 ~ 4 2) the key number 3) the key number or the case which the schedule is 01, it pushed the key number 4) 6) the key number 9) After schedule COPY, the function window returns.
  • Page 59 WELCOM 600P 3-4．Each Reset It is executed to as follows if it invert to an each kind RESET MODE. 2) the key number Reset Function ０= Stepper Reset １= Counter Reset - Select a Number [Figure 3-6] The reset function is 1.
  • Page 60 WELCOM 600P 3-5．Timer NO. Confirm/Change To change the mode to the timer no. confirm/change modes, use the following key strokes. 2) If it is executed to key number , the display of VFD is indicated to Figure 3-9. Timer Equipment...
  • Page 61 WELCOM 600P 3-7．The welding history DATA initialization It do as follows if it initialize a welding history DATA which have been saved at the Timer. 2) If it is executed to key , display of VFD is indicated to Figure 3-11.

  • Page 62: Chapter 8. Troubleshooting

    WELCOM 600P Chapter 8. Troubleshooting Not to operate board way to want for the welding control device, examine the reason closely at the time which the trouble of the obscurity happens to be the desire according to this sequence. §1．External I/O checking I/O indication in normal operation The following table shows examples of the indicator of the welding controller and the external I/O signal.
  • Page 63 WELCOM 600P I/O indication in abnormal operation If the indication is not what expected identify, the cause and provide remedy as follows. b. The Power LED is not ON The power is not supplied to the power terminal 01 and 02...
  • Page 64 WELCOM 600P  Notes Because the checking of I/O signal is predicted to a pressure scrapped of termainal, it do not a wiring check to the eye, use the TESTER and tools necessarily and measure resistance and voltage. The power source is isolated necessarily to prevent the danger, an input signal gives the signal and deals in the terminal of the device to take.
  • Page 65 WELCOM 600P §2．Program check The followings are the possible causes and remedies for the troubles such that the sequence to initiation or the weld current is not as specified. 2-1 The NO CURRENT FAULT is detected a. Check whether the initial squeeze time is sufficient or not.
  • Page 66 WELCOM 600P c. Check the setting of the SPECIFIED CURRENT or the COMPENSATE CURRENT. Make sure that the applicable current setting items are not the same between the SPECIFIED CURRENT and the COMPENSATE CURRENT. 2-4 The LOW CURRENT FAULT is detected a.

  • Page 67: Chapter 9. Exceptation

    WELCOM 600P Chapter 9. Exceptation §1. Monitor Content After connection end, it indicates about explanation of a control situation monitor content which is possible and the meaning of the vocabulary. 1-1 The power source among welding, current wave and angle...
  • Page 68 WELCOM 600P 1-3 TR. Margin TR.Margin indicates the reserve of ability to increase a welding current, it is careful of the part such as there. a. The dimension of TR.Margin is percentage, this value calculate and are the price to rescue from firing angle and power factor of TR.

  • Page 69: Welcom 600P Fault Code Table

    WELCOM 600P WELCOM 600P FAULT CODE TABLE DETECTION ITEMS FAULT CODE JUDGEMENT FIRMWARE FAILURE FAULT EXTERNAL RAM FAILURE FAULT NO PRESSURE CONTROLLER FAULT PIO VOLTAGE FAILURE FAULT LOW LINE VOLTAGE ALARM ILLEGAL POWER FREQUENCY FAULT LOW VOLTAGE IN WELD SELECTABLE...
  • Page 70 WELCOM 600P PROGRAM DATASHEET OF WELCOM 600P CHOWEL CORPORATION - 69 -...

  • Page 71: Electrical Connection Diagram Of Welcom 600P

    WELCOM 600P ELECTRICAL CONNECTION DIAGRAM OF WELCOM 600P CHOWEL CORPORATION - 70 -...

  • Page 72: Outside View Of Weldcom 600P

    WELCOM 600P OUTSIDE VIEW OF WELCOM 600P CHOWEL CORPORATION - 71 -...

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