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H&H P280 Manual

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P280 CONTROLLER
H&H RESISTANCE WELDERS
28701 S. Hwy 125
Afton, OK 74331
USA
Toll Free: 800-835-2965
Tel: (918)-257-5150
Fax: (918)-257-4550
www.hhwelders.com
hhwelders@wavelinx.net
OUR HANDSHAKE IS AS STRONG AS OUR BOND
1

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  • Page 1 P280 CONTROLLER H&H RESISTANCE WELDERS 28701 S. Hwy 125 Afton, OK 74331 Toll Free: 800-835-2965 Tel: (918)-257-5150 Fax: (918)-257-4550 www.hhwelders.com hhwelders@wavelinx.net OUR HANDSHAKE IS AS STRONG AS OUR BOND...
  • Page 2 NOTICE FOR: CUSTOMER, MAINTENANCE & MACHINE OPERATORS T I P C L E A R A N C E N O T T O...

  • Page 3: Machine Safety

    MACHINE SAFETY: It is the user’s responsibility to provide proper safety devices and equipment to safeguard the operator from harm for any particular use, operation of set up, and adequately safeguard the machine or machines, to conform to all Federal, State, and Local Government Safety Standards and All Industrial Safety Standards.

  • Page 4: Safety Precautions

    When welder machine is unattended, and/or during week-ends….POWER IS TO BE TURNED OFF! H&H Resistance Welders Incorporated Warranty The Model P280 Welding Controller has a limited warranty of five (5) years from date of installation and/or shipment, of parts, FOB: Afton, Oklahoma. [The (5) year warranty was incorporated 5/15/07] During that period, upon prepaid return to the distributor or factory, equipment proving to be defective will be repaired (or at our option, replaced), without charge for material.
  • Page 5 Some of the special circuitry and software which has been designed into the P280 has to do with power line monitoring. The software constantly monitors the incoming voltage level to allow itself time to respond to variations which could cause problems.

  • Page 6: Installation

    The P280 was designed with a PSIO board, which can be mounted piggy-back on the rear of the controller or mounted externally, using the ribbon cable. (The revised versions have deleted the ribbon cable). A small transformer is mounted on the PSIO board to allow only 120 volts AC to be present on the terminal strip, not 240 or 480 volts AC.
  • Page 7 S T R U C T U R E The P280 is constructed around a Micro Controller chip and the rest of the electronic components are only to support the chip. The physical boards and their components are referred to as HARDWARE and the program that operates the controller and resides in the chip is called the SOFTWARE.

  • Page 8: Operation

    O P E R A T I O N: The P280 is industry’s most user friendly welding controller to be found, because that is exactly how it was designed. Tactile touch means you can feel the key depression by means of a mechanical “thump” sensation.

  • Page 9: L I N E V O L T A G E M O N I T O R

    L I N E V O L T A G E M O N I T O R Circuitry will monitor the line voltage continuously. Operation of the P280 will be inhibited if the line voltage drops below 90 vac for a period exceeding 30 cycles of 60 hz, and an audible alarm will sound.
  • Page 10 P R O G R A M L O C K O U T Provided in the chassis of the P280 is a key-operated switch. In the program position, the operator can program the control. In the lockout position, access to be program is denied.
  • Page 11 This switch must be made and maintained before FS1 and FS2. If this does not happen, the P280 will not sequence. If FSA is made at POWER ON, P280 will lock up, displaying “88”, as with FS1 and FS2. If FS inputs are cleared, the P280 will function.
  • Page 12 13. Off Time LED – The number of cycles of time after release of weld pressure until sequence is complete. (0-99) S T A T U S I N D I C A T O R: (Front Panel) 1. Repeat LED – When illuminated, the weld sequence will keep repeating as long footswitch stages 1 and 2 are depressed.

  • Page 13: B A S I C S E Q U E N C E

    Machine turned OFF. 1. TURN ON THE POWER - The P280 will remain dark for about 1-2 seconds, the line frequency (60) will be displayed for 1 second, and then the display will either be “00” or “88”. The “00” indicates the first weld schedule.

  • Page 14: Troubleshooting

    T R O U B L E S H O O T I N G 1. CHECK CPU & PSIO BOARDS VISUALLY a. Check CPU board to insure all integrated circuits are seated properly. Check for broken leads on individual components. Insure ribbon cable is seated properly. (Newer version does not have a ribbon cable.) b.
  • Page 15 2. CLOCK Test Point Function Value JP2-4 Line Sync 5 V 60 Hz, 50% Duty Cycle square wave JP3-8 Line Sync 5V 60 Hz pulse normally Active on JP2-4 rising edge U5-38 Microprocessor 4MHz +/- 440 Hz Clock 3. SYNC Test Point Function Value...
  • Page 16 CAUTION The SCR Contactors can be damaged if you attempt to fire this welder without sufficient electrode force. The use of squeeze time in quantities sufficient to allow the air cylinder to actuate the electrodes and sufficient air pressure to establish the appropriate tip force is required to insure against damage caused by an open firing.
  • Page 17 O P E R A T I O N A L D E S C R I P T I O N INTRODUCTION Resistance welding is a process where metals are joined by clamping the material between two electrodes and then passing enough current through the material to heat and fuse it. Electrodes are used to both clamp and to pass the current through the work.
  • Page 18 machine is equipped with an in-line cylinder that moves an electrode up and down through a ram. This type of welder has the advantage that the electrodes are always in line providing fewer misalignment problems as the electrodes wear. HEAT PATTERN An ideal welding condition is obtained when all of the resistance is concentrated at only one point;...
  • Page 19 Up to a point, current and time can affect the weld in the same way. However, with the given amount of current, after a period of time elapses, the heat affected zone increases to a ping where all of the heat is being radiated, and no additional heat is being applied to the nugget.
  • Page 20 THROAT DEPTH Clearance distance from center line of electrodes to frame of machine. WELD STAND BY Machine in ready to weld condition; power on, sequence reset, pneumatic and electrical controls adjusted for weld, and electrodes open but brought down to weld stroke opening. WELD STROKE Stroke that opens electrodes for minimum clearance, typically just enough to allow work to be moved to next weld location.
  • Page 21 Pressure to the two chambers of the weld cylinder is controlled through the regulators with associated gauges. If a Variable Pressure Option is supplied, the welder will be equipped with two pressure regulators. One regulator is used to set the main and the other the bucking electrode force levels. To assure that the electrode force levels are at an acceptable level before the sequence is initiated, a control type contact gauge is supplied.

  • Page 22: Maintenance

    P R E V E N T A T I V E M A I N T E N A N C E S C H E D U L E SINGLE PHASE Monthly: Check connections at Make sure all connections are tight. Electrical input lines.
  • Page 23 Schedule Operation Description Daily Lubricate electrode Add lube through grease fittings at head. (Only at electrode head assy. Grease only with Seam Welders.) Chemplex 825 Weekly Lubricate Conductor Add lube through grease fittings at each Bars. (Only a welders pivot point. Grease only with Chemplex 825 w/conductor bars.) Weekly Lubricate linkage assy.
  • Page 24 Q U A L I T Y C O N T R O L In any types of welding operation, whether it is pots and pans or airplanes, the manufacturer is interested in obtaining a quality of weld consistent with his product. The machine, after all, is a machine.
  • Page 25 DEFECTS Any good manufacturing process requires a good inspection and control system to judge the quality and consistency of results and to take appropriate action when quality falls below a pre-set standard. Spot welding is a good production tool which will yield consistency of result in the same order of magnitude as results for latches, screw machines or punch presses.
  • Page 26 Too much machine pressure. The result of expulsion. Visual examination of measurement with the micrometer depth gauge is sufficient to detect excessive indentation. Zero indentation is extremely difficult to achieve since some of the indentation is caused by shrinkage of the weld nugget. Indentation can be minimized by decreasing the welding time, welding pressure, (but only if this pressure is very excessive).
  • Page 27 Sectioning and etching will disclose the presence of mis-shaped welds in a plane normal to that of the sheet. To eliminate mis-shaped nuggets, use only electrodes that have been machine cut. Do not dress electrodes with a file. Be sure the electrodes are properly aligned, and be sure that too small a radius is not used. LOW STRENGTH IN A SPOT WELD CAN BE CAUSED BY: Too small a weld for the sheet thickness.
  • Page 28 THE NEED FOR TESTS The actual test employed depends upon the importance of the structure being welded. As pointed out at the beginning of this discussion, quality welds may only be obtained from a machine having the necessary functions, the machine must be kept in good working order and the same problem must be presented to the machine on each weld (same material, contour &...

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