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Weld334m

Programming Manual
Release 2.0

Edition 4 June 2004

Code 39000425

Programming Manual

GF WELDING S.p.A.
Strada del Portone, 18/24 10137 TORINO (Italia)
Tel.:

011-3033.278 (Italy Sales dept.)


011-3033.270-279 (Foreign Sales dept.)

Tel.:

011-3033.277 (Italy Service)


011-3033.274 (Foreign Service)

Fax:
e-mail:
web:

II

011-3092046
mail@gf-welding.it
www.gf-welding.it

GF WELDING

Programming Manual

Warranty
All conditions of warranty as described in this section are general and
complete the specific purchasing conditions. In any case they refer to the
local jurisdiction and to eventual particular conditions, agreed with the
purchaser, included in the contract of purchase.
In particular the period of warranty is one year after delivery, if not agreed
in the purchasing contract differently.
Furthermore Company GF WELDING S.p.A. guarantees the Weld 334m to
be free of any defects caused by manufacturing. In case an error should
occur during warranty period, which is caused by manufacturing, the maker
will carry out all necessary repairs or exchange defect parts. The maker
insists on the right to decide, whether to exchange or repair the defect
parts. The user has to pay for shipment costs.
Company GF WELDING S.p.A. will not take any responsibility for damages
or resultant damages of the customer caused by shipment delays,
manufacturing defects or breakdown of the control.
Company GF WELDING S.p.A. does not guarantee the software or
hardware of the welding control to be free of errors or to be competitive
with each standard or in particular to comply with the special
manufacturing demands of the user.
In particular Company GF WELDING S.p.A. does not take responsibility for
the correctness of the weld- and current-increment programs, which were
created for the production demands of the user.
The warranty terminates with breakdowns caused by wrong connectings,
improper use or faulty operation. This refers to damages caused by
electrostatic discharge, which occurs during connection or disconnection of
energized devices, tampering and/or executed reparations from staff nonauthorised from GF WELDING.
Keyboards, cables, trackballs, connectors or other consumable parts are not
covered by this warranty.

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GF WELDING

Programming Manual

INDEX
1

GENERAL NOTES CONCERNING PROGRAMMING ............................. 1-1

1.1
1.2

Programming................................................................................... 1-1
Manual Keyboard HCM 4300 HHT..................................................... 1-1

1.2.1
1.2.2

1.3

Keys ............................................................................................... 1-2


Display ............................................................................................ 1-3

Menu structure ................................................................................ 1-5

CONFIGURATION <F5-ETC F3 CONFIG> ........................................ 2-1

2.1

Parameter of the Configuration menu.............................................. 2-1

2.1.1
2.1.1.1
2.1.1.2
2.1.1.3
2.1.1.4
2.1.2
2.1.2.1
2.1.2.2
2.1.2.3

Configuration parameters................................................................... 2-1


Release Software ........................................................................... 2-1
Software Release keyboard (HHT) .................................................... 2-2
Language ..................................................................................... 2-2
Date and time ............................................................................... 2-2
Addresses for connection to the Ethernet TCP/IP network ....................... 2-3
IP Address .................................................................................... 2-3
SubNet Mask................................................................................. 2-3
TCP Port ....................................................................................... 2-3

BASE SETTINGS <F5-ETC F4 SETUP> ............................................ 3-1

3.1

SETUP Menu -CONFIGURATION WELD 334m ................................... 3-1

3.1.1
Parameter of SETUP - WELD334M CONFIGURATION............................... 3-2
3.1.1.1
WMS-NET network address: ............................................................ 3-2
3.1.1.2
Device name:................................................................................ 3-2
3.1.1.3
Working mode:.............................................................................. 3-2
3.1.1.4
Preset Analog output:..................................................................... 3-2
3.1.1.5
Weld alarm threshold A: ................................................................. 3-3
3.1.1.6
Weld alarm threshold B: ................................................................. 3-3
3.1.1.7
Current transducer: ....................................................................... 3-3
3.1.1.8
N. current transducers: .................................................................. 3-3
3.1.1.9
Start code parity............................................................................ 3-4
3.1.1.10
Module address parity: .................................................................. 3-4
3.1.1.11
Execution in repeat: ...................................................................... 3-4
3.1.1.12
Execution with current:.................................................................. 3-4
3.1.1.13
Station type:................................................................................ 3-5
3.1.1.14
PRESSURE-OK Input mode:............................................................ 3-5
3.1.1.15
SVV Ang-Out 4-20mA check ........................................................... 3-5
3.1.1.16
End of sequence output minimum time (FINESEQ)............................. 3-5

3.2

Menu SETUP - GUN PARAMETERS 0 ................................................ 3-6

3.2.1
3.2.1.1
3.2.1.2
3.2.1.3
3.2.1.4
3.2.1.5
3.2.1.6

3.3

Alarms Configuration in REPORT menu. ...............................................3-10


Machine Shutdown Enable of Diagnostic Alarms .................................3-10

Menu SETUP - CABLE WEAR ........................................................... 3-11

3.4.1
3.4.1.1
3.4.1.2
3.4.1.3
3.4.1.4

3.5

3-6
3-6
3-7
3-7
3-7
3-7
3-7

SETUP Menu - ALARMS CONFIGURATION ........................................ 3-8

3.3.1
3.3.2

3.4

Parameter on page SETUPGUN PARAMETERS 0....................................


Max. Electrode force [kN]: ..............................................................
Coil sensitivity [mV/kA]: .................................................................
Sensitivity TF [V/kN] ......................................................................
Measured Parameter I min [kA]: ......................................................
Measured Parameter I max[kA]: ......................................................
Measured Parameter CosPhi: ...........................................................

SETUP CABLE WEAR ......................................................................3-12


Enable ........................................................................................3-12
Prewarning ..................................................................................3-12
Stop ...........................................................................................3-12
Counter.......................................................................................3-12

Menu SETUP TIP DRESSER WEAR ............................................... 3-13

3.5.1
3.5.1.1
3.5.1.2
3.5.1.3
3.5.1.4

Comment to the SETUP TIP DRESSER WEAR .....................................3-13


Enable ........................................................................................3-14
Prewarning:
[%] ......................................................................3-14
Stop: ..........................................................................................3-14
Counter.......................................................................................3-14

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Programming Manual

MENU PROG (WELD PROGRAMS) <F2 PROG> ................................ 4-1

4
4.1
4.2
4.3
4.4

F2 COPY ................................................. 4-2


Copy welding programs
Clear welding program F3 CLEAR.................................................... 4-3
Selection Single spot - Repeated spot F5 SS/RPT ............................ 4-4
Menu EDIT F1 EDIT.......................................................................... 4-5

4.4.1
4.4.2
4.4.3
4.4.4
4.4.5
4.4.6
4.4.7
4.4.7.1
4.4.7.2
4.4.7.3
4.4.7.4
4.4.7.5
4.4.7.6
4.4.7.7
4.4.7.8
4.4.7.9
4.4.7.10
4.4.7.11
4.4.7.12
4.4.7.13
4.4.7.14
4.4.7.15
4.4.7.16
4.4.7.17
4.4.7.18
4.4.7.19
4.4.7.20
4.4.7.21
4.4.7.22
4.4.7.23
4.4.7.24
4.4.7.25
4.4.7.26
4.4.7.27
4.4.7.28
4.4.7.29
4.4.7.30
4.4.7.31
4.4.7.32
4.4.7.33
4.4.7.34
4.4.7.35
4.4.7.36

STEPPER MENU <F3 STEPPER> ...................................................... 5-1

5
5.1
5.2
5.3
5.4
5.5
5.6

Copy steppers F2 COPY.................................................................... 5-3


Clear Stepper F3 CLEAR ................................................................... 5-3
Reset spot counter F1 RESET .......................................................... 5-4
Modify stepper counter content F2 PRESET.................................. 5-6
Relevant I/O Signals for steppers: .................................................. 5-7
EDIT (Creation and modification of stepper) F1 EDIT ................... 5-9

5.6.1
5.6.2
5.6.3
5.6.3.1
5.6.3.2
5.6.3.3
5.6.3.4

VI

Welding control circuit ....................................................................... 4-5


Welding mode .................................................................................. 4-5
I/O Signals of the control during weld sequence .................................... 4-7
Example: Edit Weld program .............................................................. 4-7
Function keys of menu EDIT WELD PROGRAM ....................................... 4-9
Table of parameters for different welding modes...................................4-10
Parameters of menu EDIT WELD PROGRAMS .......................................4-11
Program number ..........................................................................4-11
Program name [ : ] ......................................................................4-11
Mode of welding [ : ] ....................................................................4-11
Enable program [ : ] .....................................................................4-11
Pulse type [ PLS: ] ........................................................................4-12
Number of pulses [ : ] ...................................................................4-13
Stepper/Electrode parameter [ Stp_: ].............................................4-13
Presqueeze [ 1.Sqz: ]...................................................................4-14
Squeeze [ 2.Sqz: ].......................................................................4-14
Hold time [ Hold: ] .......................................................................4-14
Open [ Open: ]............................................................................4-14
Equivalent energy value [ VEE_ ]: ..................................................4-17
Squeeze variation cycles [ CPV_: ] .................................................4-17
Squeeze variation mode [ MPV_: ] .................................................4-18
Electrode force 1. [ P1: ]...............................................................4-22
Electrode force 2. [ P2: ]...............................................................4-22
CosPhi nominal [ CosPhi: ] ............................................................4-22
Maximum Current tolerance [ %I.max:]..........................................4-23
Minimum current tolerance [ %I. min: ] ..........................................4-23
Tolerance range (min-max-lim) of welding current:...........................4-24
Limit current tolerance [ %I. lim: ].................................................4-25
Electrode force tolerance [%T. Prs:] ...............................................4-25
Electrode Force Diagnostic Mode [%T. Prs:].....................................4-26
Spot repetition [Rtr:]....................................................................4-26
Firing angle limitation [Ang:] .........................................................4-27
Sheet thickness [Th.1, Th.2, Th.3] .................................................4-28
Up-slope [ Up_S:]........................................................................4-28
Down-slope cycles [ Dw_S: ] .........................................................4-29
Cool time [ Wait: ] .......................................................................4-31
Weld time [Weld] :......................................................................4-31
Delayed firing of first half-cycle [ 1^Ang: ] ......................................4-32
Welding current [ Pwr %: ] ...........................................................4-32
Diagnostics current [ I.Dgs.:] ........................................................4-32
Blanking cycles [Blank: ]..............................................................4-32
Welding current programmed in kA [ I.Prg.: ] ..................................4-33
Measured welding current [ I: kA ] .................................................4-33

Dressing 1 ....................................................................................... 5-9


Dressing 2 ......................................................................................5-10
Parameter for Dressing 1 ..................................................................5-11
Stepper number [ S: ] ...................................................................5-11
Stepper name [ : ]........................................................................5-11
Dressing mode [ : ].......................................................................5-11
Stepper data format [ : ] ...............................................................5-12

GF WELDING

Programming Manual

5.6.3.5
5.6.3.6
5.6.3.7
5.6.3.8
5.6.3.9
5.6.3.10
5.6.4
5.6.4.1
5.6.4.2
5.6.5
5.6.6
5.6.7
5.6.7.1
5.6.7.2

Prewarning__:..............................................................................5-12
Stop_______: ..............................................................................5-12
Dressing_:...................................................................................5-12
Offset_______: ............................................................................5-12
Pt. x Pieces _______:....................................................................5-13
P.x Emergency : ..........................................................................5-13
Parameter for Dressing 2 ..................................................................5-13
Pt.x Dressing_ : ...........................................................................5-14
Pt.x Emergency: ...........................................................................5-14
Stepper: Current - and pressure increment curve .................................5-15
Increment with Graphic method .........................................................5-16
Increment with Tabular method .........................................................5-18
Tabular stepper Menu....................................................................5-19
Programming the Tabular increment ................................................5-19

TRACE MENU <F4 TRACE> ............................................................. 6-1

6
6.1

Parameter of page SPOT TRACE

F1 PROG .................................... 6-1

6.1.1
Parameter SPOT TRACE ..................................................................... 6-2
6.1.1.1
Program number [ P: ] ................................................................... 6-2
6.1.1.2
Program name [ : ]........................................................................ 6-2
6.1.1.3
Welding mode [ : ]......................................................................... 6-2
6.1.1.4
Welding time [ Cycles: ] ................................................................ 6-2
6.1.1.5
Nominal welding current [ I Prg.: ] .................................................. 6-2
6.1.1.6
Setpoint current [ I Nom: ] ............................................................. 6-3
6.1.1.7
Measured welding current [ I. Mis:
kA ]...................................... 6-3
6.1.1.8
Stepper number [ Stp : ] ................................................................ 6-3
6.1.1.9
Stepper counter [ Cnt : ] ................................................................ 6-3
6.1.1.10
Current increment in (%) [ INC% : ] .............................................. 6-3
6.1.1.11
Setpoint Electrode force 1 [ Prs1: ]................................................. 6-3
6.1.1.12
Setpoint Electrode force 2 [ Prs2: ].................................................. 6-4
6.1.1.13
CosPhi [ CosPhi: ] ....................................................................... 6-4

I/O TRACE F2 I/O .......................................................................... 6-5

6.2
6.2.1

6.3

Index of I/O abbreviations ................................................................. 6-6

Special functions F3 TEST .............................................................. 6-8

ALARMS MENU <F1 ALARMS> ........................................................ 7-1

7
7.1

Error categories............................................................................... 7-3

7.1.1
7.1.2
7.1.3
7.1.4

7.2

Index: abbreviations of reset procedures:.............................................


Process diagnostics (Error code from 01 to 50)......................................
Normal or hardware errors (error code 51 to 100) .................................
Fatal error (Error code 101 and higher) ...............................................

7-3
7-4
7-5
7-6

I/O Signals, which are caused by errors.......................................... 7-7

MENU REPORT <F5-ETC F2-REPORT>............................................. 8-1

8
8.1
8.2
8.3

Define Reports................................................................................. 8-2


Modify reports F5 MODIF ................................................................ 8-2
F1 VIEW ............................................................... 8-3
View reports

CARD MENU (BACKUP OF DATA)

9.1
9.2

<F5-ETC F1-CARD> .................... 9.1

Load firmware to the control ........................................................... 9.1


Store/load of Programs ................................................................... 9.3

APPENDIX ...............................................................................................1
Appendix A
Operating
Operation
Operating
Operating
Operating
Operating
Operating

Operating diagrams.................................................................. 1

diagram
diagram
diagram
diagram
diagram
diagram
diagram

Appendix B

1
3
4
5
6
7
8

- Single cycle sequence ........................................................... 2


Type of weld ....................................................................... 4
- Dressing 1 stepper mode (part 1 of 2) ..................................... 5
- Dressing 1 stepper mode (part 2 of 2) ..................................... 6
- Dressing 2 stepper mode ....................................................... 7
Seam mode ........................................................................ 8
Cycle mode ..................................................................... 9

DIAGNOSTICS ALARMS............................................................ 1

Description of alarms............................................................................................ 1

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Programming Manual

PREFACE
This manual contains theoretical and technical details about the usage and
operation of the welding control Weld334m.
Mainly this is a programming instruction, which is useful for persons, who
are setting up the parameters of the control. Knowledge of electrotechnical
basics as well as experience about resistance welding are mandatory to use
and program the welding control.
Concerning safety, danger of resistance welding devices, safety rules, startup of the control and technical features please refer to the Hardware
Manual. The spot weld is the result of complex electrical, thermic,
metallurgic and mechanic processes, which are performed within a short
amount of time.
To use the welding control knowledge about technical correlations between
all effective parameters of resistance welding is necessary.
These parameters have to be specified by the operator or other factors
need to be considered, which refer to environmental issues or preceding
process steps. The operator, however specifies effective parameters of the
control - 5 out of more than 100. However, the 2 most important
parameters define the necessary thermal energy for successful welding. In
some cases inadequate conditions of preceding process steps like bad fitting
parts or insufficient design of devices can be compensated by efficient
combination of the control parameters.
The operator has to find the working point within the process window in
order to provide quality and safety of welding. The control carries out the
programmed parameters only. The errors issued by the control indicate
deviations from fixed settings. In any case the spot may not be of bad
quality.
Please notice, that state of the art controls like Weld334m, which offer
constant current control, stepper, error diagnostics, statistical functions and
more, will not guarantee perfect weldings in any case. The control repeats
the process with highest amount of precision, as it was programmed by the
operator. In case errors are issued by diagnostics of the control,
countermeasures must be done instantly. In most cases of abnormality the
current could not reach full amount because the secondary circuit does not
permit more or parts are far apart.
The actual welding quality results from the programming of the operator
and not from the control only.
This manual shall enable the user, to learn about how to program the
control and to look as a reference in order to perform the task quickly and
securely. This programming instructions will not be a substitute for training
on resistance welding.
All details mentioned in this manual are not guaranteed and can be changed
without notice. Company GF WELDING does not have any obligations on
this item.
The soft- and hardware as described in this manual is part of a Licensing
agreement and all information must be kept confidential.
It is prohibited to pass the documentation of soft- and hardware to a third
party. The purchaser is allowed to make one copy of the software as a
backup.
Parts of this manual including copies or other notes may not be duplicated
or distributed by electronic or mechanic means without written permission
of Company GF WELDING S.p.A.
Copyright by GF WELDING S.p.A.

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Programming Manual

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GF WELDING

Programming Manual
General Notes

1 General notes concerning Programming

1.1 Programming
There are three different ways how to program the welding control WELD334m:
1

Usage of the hand held keyboard HCM 4300 HHT (Hand Held Terminal), which is
connected to the control unit.

Usage of the Personal Computer or Laptop with WMS Software (Welding


Management System), which is connected to the control unit with a cable supplied
by GF WELDING S.p.A.

Via Main computer with WMS Software, which offers control function and central
programming of each welding control, which are connected to the main computer
via bus system.

For Usage of WMS (delivered separately by GF WELDING) a computer with following


features is necessary:

Processor Pentium

Microsoft Windows 3.1, 3.11, 95, 98, NT4, 2000

10 MB HDD

1.2 Manual Keyboard HCM 4300 HHT


The manual keyboard HCM 4300 HHT is an external device for programming
locally.
The HHT is connected to the Weld334m by a 9-pin Sub D connector. The
matching plug is located at the upper left corner on the frontside (marked
with the HHT Symbol).
The HHT may be plugged or disconnected during operation of the control.
Attention:
The WELD320 Welding control is using the same connector type as the
previous Weld 334m for the manual keyboard. These two manual keyboards
however are not compatible and may only be used together with the same
welding control version. HHT as well as the control unit can be damaged
hardly.

The HHT has a liquid crystal display with 240x64 pixels. A text consisting of
8 lines with 40 signs each can be displayed.
Around the display there is an input area with 13 keys allocated.

GF WELDING

1-1

Programming Manual
General Notes

1.2.1

Keys
All kind of standard functions and related keys are described in the
following.
Arrow keys:

Are there any data displayed on the screen, the 4 arrow keys will move the
cursor into the 4 directions.
Soft keys: F1 F2 F3 F4 F5
These keys activate the functions above, which are displayed in the lower
bar.
Keys: + (plus)

- (minus)

These keys change the content or values of the fields, where the cursor is
located. In case of a numeric field, the number will be increased (+) or
decreased (-). In case of a character field, the predefined words will alter.

Remark:

The definition of field will be explained in the following.

To 'edit' means to setup or change data, which are displayed in


a field.

ESC key:
With the Escape or Abort-key running operations will be stopped and the
program will return to the previous menu.
Pressing ESC several times is useful to return to the main menu.
ENT key:
This key confirms the entry of data or values.
When the function 'SAVE' is displayed in the lower bar, the ENT key will
perform the same function as the key. In order to confirm changes the
save function must be activated by pushing the related key. The displayed
star (*) in the upper bar will disappear, when changes are saved.

HCM 4300 HHT


ESC

SETUP - Cable wear


Enable
ON
Prewarning
000001
Stop
0000100
Counter
100
RESET-A RESET-B SET-A
F1

Upper bar

1-2

F2

OFF
000001
0000100

100
SET-B
ETC

F3

Data area

GF WELDING

F4

F5

ENT

Lower bar

Programming Manual
General Notes

1.2.2

Display
The display is divided into three different areas:

Upper bar: contains the title of the active page (menu)

Data area: contains all fields, which can be edited

Lower bar: contains the related functions of the keys F1F5

Upper display bar:


Contains the title of the active page (Mask).
The star (*) at the right end of the upper bar shows, that some change of
one field is not save yet.
REMARK:

In case the star (*) does not disappear after saving some entry,
any faulty data entry is indicated. For example: the first sign of
an numeric field must be a number, the entry must be corrected.

The cursor jumps to the faulty or missing data field and indicates
where to correct the entry.

Data area
In the data area all operating parameters of the control, which can be
edited, are displayed. Furthermore statistical or dynamic information in the
fixed or changing fields can be read. However they can not be edited.
On some pages the data area may have more than 6 lines. Use the arrow
keys to take a look at the remaining lines.
In the data area there are three different kinds of fields displayed:

Fixed fields, which can not be edited (contain descriptions)

Changing fields, which can not be edited (contain measured or calculated


values)

Fields, which can be edited (contain all programmable parameters)

In order to distinguish fields, which can be edited, from fields, which can
not be edited, just move the cursor using the arrow keys. The cursor will
appear on fields only, which can be edited.
There are three different kind of fields, which can be edited:

with predefined character values

Fields with numeric values

Fields with character values, which can be edited (signs or numbers)

Fields with predefined character values


After selecting a field by using the arrow keys, press + or - key to toggle
between the predefined values.
Example: in the SETUP menu the module code parity can have one of three
settings:
OFF
EVEN
ODD

GF WELDING

1-3

Programming Manual
General Notes
Fields with numeric values
After selecting a field (use the arrow keys ), change the value
by using + or - key and the number will increase or decrease.
In case a printer is installed in parallel to the control, the active menu can
be printout. In the printouts of the menus additionally the upper and lower
limits are shown at the left side of the related fields.
Example: In the SETUP menu the number of current sensors can be
entered, which can be in the range between 1 and 6. On the
printout you can see on the left side of the field [1-6].
Fields with character values
After selecting the field (use the arrow keys ), which shall be
edited, the + and - key can be used in order to find following signs:
ABCDEFGHIJKLMNOPQRSTUVWXYZ0*+-/012345689

The first digit of a character field must be a sign.


The maximum length of a character field is indicated by the final position of
the cursor, where it can be moved.
Example: In the setup menu the field, which shows the Module name, the
name is preset with 'Weld 334m'. This is the default setting of
the maker.
Lower bar
The lower bar shows all the functions which are related to the soft keys
F1F5.

EXAMPLE:

In case the F2 key is defined with the COPY function, the copy procedure
of a program will be initiated by pushing F2.

1-4

In case the F1 key is defined with Page+ (next page), the data area does
not show the whole content of the activated page. Use F1 key and the
remaining data in the next page will be shown.

In case the F5 key is defined with ETC , besides the 4 shown functions,
further functions exist. The further functions will be displayed by pushing
the F5 key.

GF WELDING

Programming Manual
General Notes

1.3 Menu structure


On the HHT 8 Submenus can be accessed from the main menu.

ALARMS: errorlog of the last 500 error messages

PROG: Setup and editing of welding programs

STEPPER: Current/Pressure curve, setup and editing of stepper programs

TRACE: Display of relevant information about each spot welds and status
of inputs and outputs in real time

CARD: Ensures storage of data. Displays functions for use of RAM card

REPORT: Summary of operation data and errorlog of the last 24 hours

CONFIG: Display and modification of date, time and language

SETUP: Base settings

During installation of the control, following 6 steps must be performed:


1. Configuration of the control (go into the menus CONFIG and SETUP)
2. Programming of the control (go into the menus PROG and STEPPER)
3. Checking of performed spot welds (go into the menu TRACE)
4. To check the errorlog go into the menu ALARMS
5. To check the number of error messages go into the menu REPORT
6. To make a backup of all control parameters go into the menu CARD
The description of the different menus follows the above mentioned
sequence

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1-5

Programming Manual
General Notes

1-6

GF WELDING

Programming instructions
Language/Date/Time

2 Configuration

<F5-ETC F3 CONFIG>

2.1 Parameter of the Configuration menu


In the Configuration menu the following is shown:

Software version of control

Software version of HHT

Further configuration setup can be done:

language

date and time

In case the control is connected to a centralized network management,


through the program "WMS", the time and date will automatically be
updated to those of the central PC.
Since the CONFIG menu is dynamic, if the welding control is configured with
the F381-ETH card, the NETWORK function is assigned to function key F1.
Following table shows the complete CONFIG menu:

Configuration

SoftwareRelease

Language

WELD334m

v.1.1

HCM

v2.00

4300 HHT

English

Date & Time


Mon 09/02/1998
09:54:17

NETWORK

MODIFY

All function keys, which are available in the Configuration menu:


F1 NETWORK:
This enables you to access the menu of the addresses
for connection to the Ethernet TCP/IP network.
The F5 key performs 2 different functions:
F5 MODIFY:
F5 SAVE:

2.1.1
2.1.1.1

modification of elements by selection of predefined values


and names
saves all entered changes (in case of correct data entry,
the star* in the upper bar of the submenu will disappear)

Configuration parameters
Release Software
Parameter:

Pixed text, which cannot be edited

Prog. Version:

Preset by the manufacturer

Description:

Model of welding control and firmware version installed


Example: WELD334m v1.1
The firmware can be changed by memory card (see
section 9)

GF WELDING

2-1

Programming instructions
Language/Date/Time
2.1.1.2

Software Release keyboard (HHT)


Parameter:

fixed text, which cannot be edited

Prog. Version:

Preset by the manufacturer

Description:

HHT Model and firmware version installed


Example: HCM 4300 HHT v2.00

2.1.1.3

Language
Parameter:

a preset language can be selected

Prog. Version:

Changeable, according to the family of chosen languages


(see Note).

Description:

This allows the language used by the welding control in the


various menus to be selected; the languages available are:
Italian, English, German, French, Spanish, Portuguese,
Dutch, Polish.

Remark: From release 1.10, the number of languages available is limited to


3-4; the languages are chosen during production of the welding
control. In order to up-date the software to one of the languages
listed (and not present in the configuration) contact GF WELDING
After-Sales Dept.

2.1.1.4

Date and time


Parameter:

some number can be entered

Prog. Options:

Date (From 01/01/1980 till 31/12/2030)


Time (From 00:00:00 till 23:59:59)

Description: Allows to change date and time of the control unit


Format of date is: DD/MM/YYYY
Format of time is: hh:mm:ss
When pushing SAVE the clock starts at second zero

Example: In order to shift the clock by one hour please follow this
procedure:
1. Press the F5 key in the CONFIG menu (MODIFY). The function
of the F5 key will change to SAVE.
2. Press the arrow key 4 times and the cursor will be positioned
on time.
3. Press the + key once. The hour will be increased by one
hour.
4. Press the F5 key once. All changes will be saved. The star in
the upper bar will disappear. The function of the F5 key will
change to MODIFY.

2-2

GF WELDING

Programming instructions
Language/Date/Time

2.1.2

Addresses for connection to the Ethernet TCP/IP network

On accessing the NETWORK CONFIGURATION menu (F5)(F3) you can define the IP
address, the Subnetwork and the Port for connecting the welding control to the WMS
centralized network management with TCP/IP network.
NETWORK CONFIGURATION

IP Address

192.168.000.008

SubNet Mask

255.255.255.000

TCP Port

01200
SAVE

2.1.2.1

IP Address
An IP address consists of 4 numbers between 0 and 255 separated by fullstops. The address is free: however, if the centralized network is connected
to the company network, you must check that the IP addresses have not
already been used by other devices or PCs.

2.1.2.2

SubNet Mask
This number, together with the address, identifies the subnetwork in which
the welding control is situated. The protocol subnetwork is predefined
(Class C): normally all welding controls plus the WMS, that comprise a
system, must belong to the same subnetwork.

2.1.2.3

TCP Port
The HOSTPORT channel is predefined at 01200 (5 editable figures);
however, if you modify the number conflicts may occur. The HOSTPORT
value of the welding control must be the same as that set in the WMS
application software.

GF WELDING

2-3

Programming instructions
Language/Date/Time

WHITE PAGE

2-4

GF WELDING

Programming instructions
Setup

3 Base settings

<F5-ETC F4 SETUP>

The base settings of the welding control are done in the SETUP menu.
The SETUP menu consists of 4 pages (masks). Following choices are
possible:
1. SETUP - WELD 334m CONFIGURATION: Main parameters of the
configuration
2. SETUP GUN PARAMETERS 0 (0-16): Specific configurations of used
guns = stepper
3. SETUP - ALARMS CONFIGURATION: Selection of error messages, which
will block restarts and will be reported in the errorlog (REPORT)
4. SETUP - CABLE WEAR: Setup of spot counters to specify maintenance
intervals (for example: exchange of gun cables)
5. SETUP TIP DRESSER WEAR: parameters
maintenance for dressing electrodes

concerning

the

tool

3.1 SETUP Menu -CONFIGURATION WELD 334m


Following table shows the page SETUP - WELD334M CONFIGURATION. Each
value can be selected using the arrow keys on the HHT:
REMARK: All values in brackets show the range of each setup parameter
SETUP WELD334m CONFIGURATION

WMS-NET network address

(0 32)

: 00

Device name

(8 digits)

: FASE 334m

Working mode

(WELD320 WELD334m) : WELD334m

Preset analog output:

(0 100)

: 050

Weld alarm threshold A:

(1 20)

: 01

Weld alarm threshold B:

(1 20)

: 01

Current transducer

: ENABLED

N.current transducers

(1 6)

: 1

Start code parity ( OFF - EVEN - ODD)

: OFF

Module address parity ( OFF - EVEN - ODD)

: OFF

Execution in repeat

: OFF

Execution with current (OFF - ON)

: OFF

Station type (Automatic - manual)

: Manual

Pressure-OK Input mode (24V=OK - 0V=OK)

: 24V=OK

EOS Output minimum time ( 0 - 99)

: 00

GF WELDING

3-1

Programming instructions
Setup
Function keys of SETUP - WELD334M CONFIGURATION
F1 PAGE+:

Move to the next page in the SETUP menu

F4 PRINT:

Print the complete SETUP menu

F5 SAVE:

Saves all changes. In case all entries were ok, the star in
the upper bar will disappear.

Key

Scrolls the menu of the Configuration page in the Setup


menu

Key + -:

3.1.1
3.1.1.1

Changes the parameters

Parameter of SETUP - WELD334M CONFIGURATION


WMS-NET network address:
Parameter :
Range:

(00 32)

Description:

3.1.1.2

can not be edited

Displayed in network mode. Shows the address of the


control in the WMS-NET. This variable text is a read text
only (it may be modified via Hardware only).

Device name:
Parameter:
limits:

8 digits - the first must be a sign

Description:

3.1.1.3

some alphanumeric value can be entered

Name of the welding control (mnemonic).


recommended to use the name of the station.

It

is

Working mode:
Parameter:
Range:

(WELD320 WELD334m)

Description:

3.1.1.4

a preset value must be selected

Adapts the welding control to Normal operation


(Weld334m) or to the functions of the previous version
(WELD320).

Preset Analog output:


Parameter:
Range:

(0 100)

Description:

3-2

a numeric value need to be entered

Applicable only on controls with servo valve command.


This is the analog voltage in %, which is applied after
reset. The electrode force will be same as the specified
percentage of the maximum force, which is set after Reset
or at the first start after a no voltage status

GF WELDING

Programming instructions
Setup
3.1.1.5

Weld alarm threshold A:


Parameter:

a numeric value must be entered

Range:

(1 20)

Description: specifies the number of allowable faulty weld spots in indicated


by alarm Code E005 in sequence (occur after the lower
current limit has not been reached.)
See also section 4.4.7.20
Channel A only.
REMARK: The control manages 2 welding guns (channel A
= gun1 and channel B = gun2). Each gun is
controlled by valve EVSA and EVSB and start
button STARTA and STARTB.
3.1.1.6

Weld alarm threshold B:


Parameter:

a numeric value must be entered

Range:

(1 20)

Description:

specifies the number of allowable faulty weld spots


indicated by alarm Code E005 in sequence (Meas. cur.<
min threshold)
See section 4.4.7.20
Channel B only

3.1.1.7

Current transducer:
Parameter:

a preset value must be selected

Presettings:

(ENABLED - DISABLED)

Description:

Activation current transducer


If activated following can be monitored:

Display of welding current

Analysis of welding current

Constant current mode CCM.

Correction of firing angle

In case of disabled current transducer, all CC-configured


programs will be executed with Normal mode. No current
will be displayed.
In cc mode a program will not be executed if the current
transducer is switched off. The error message E077 invalid machine parameter will be issued.

3.1.1.8

N. current transducers:
Parameter:

some numeric value must be entered

Range:

(1 6)

Description:

The number of current transducers in series can be


specified. This is necessary for compensation of inaccurate
measurements coming from transducers, which are
operating in series. Additionally the measurement loop is
checked before welding.

GF WELDING

3-3

Programming instructions
Setup
3.1.1.9

Start code parity


Parameter:
Settings:

(OFF EVEN - ODD)

Description:

3.1.1.10

a preset expression need to be selected

The usage of the parity bit (control bit) can be specified. It


determines if the start and program selection signals occur
with/without parity. This parameter is mainly used for
robots or PLC.

Module address parity:


Parameter:

a preset expression need to be selected

Settings:

(OFF EVEN - ODD)

Description:

parity selection for participation in the WMS network.


The parity bit (control bit) refers to the machine code
specification. This parameter may only be used, if the
control is connected to the network.

3.1.1.11

Execution in repeat:
Parameter:

a preset expression need to be selected

Settings:

(OFF ON)

Description:

ON Repeat mode active. (if other Consents are present).


The welding is repeated as long as start is activated.
Following conditions must be fulfilled, in order to run welds
in repeat:

The parameter RP must be set in menu PROG. See


section 4.3

The external input REPEAT must be +24 V

The switch 'REPEAT' - if present - on the front side of


the control panel must be on.

OFF repeat mode is switched off without respect to the


input status or parameters. (the different Consents are
connected in series).
3.1.1.12

Execution with current:


Parameter:

a preset expression need to be selected

Settings:

(OFF ON)

Description:

ON - Operation with welding current (if other Consents are


present).
Following conditions must be fulfilled:

The external input SALDA SI must be on

The switch SALDA - if present - on the front side of the


control panel must be on.

OFF - Operation without welding current. The status of the


input 'WITH CURRENT' and the switch 'WELD' do not have
an effect (the different Consents are connected in series).

3-4

GF WELDING

Programming instructions
Setup
3.1.1.13

Station type:
Parameter:
Settings:

(MANUAL AUTOMATIC)

Description:

3.1.1.14

a preset expression need to be selected

This configuration affects the read mode of the Program


execution Start input signals (STARTA STARTB Refer to
the enclosed operation diagrams).

PRESSURE-OK Input mode:


Parameter:

a preset expression need to be selected

Settings:

(0V=ok

Description:

The switching performance is specified.

24V=ok)

0V=ok 0V on input STSERV indicates that the Electrodes


pressure has reached the value required.
24V=ok 24V on input STSERV indicates that the Electrodes
pressure has reached the value required.
3.1.1.15

SVV Ang-Out 4-20mA check


Parameter type: Editable field with preset value
Preset values:

(ENABLED DISABLED)

Description:

Enables/disables the analogue diagnostic output in 420mA current, used to control a proportional valve.
When enabled, if the control detects a discontinuity in the
servovalve command during execution of the welding cycle
(e.g. cable connection to servovalve disconnected or
discontinuous, servovalve failed) it will diagnose error
E098, of the blocking type.
This function is only available if servovalve command cards
that integrate the diagnostic circuit are used.

3.1.1.16

End of sequence output minimum time (FINESEQ)


Parameter:

a numeric value must be entered

Range:

(0 99)

Description:

If, a welding program being terminated, the Program


Execution Start signal (STARTA STARTB) is not active,
this parameter indicates the minimum activation time of
the End-of-Sequence output signal (FINESEQ). If the Start
signal goes to active status during this period, the End-ofSequence output signal will copy the same status as the
Start signal.

GF WELDING

3-5

Programming instructions
Setup

3.2 Menu SETUP - GUN PARAMETERS 0


Following table shows the page SETUP - GUN PARAMETER on the HHT.
NOTE: Values in brackets are the ranges of each parameter.
SETUP GUN PARAMETERS 0
Max Electrode force[kN]

(00.00 30.00)

Coil sensitivity [mV/kA]

30.00

(0050.0 2000.0) : 0150.0

Force sensitivity [V/kN]

PAGE +

00.0

I min [kA]

Estimated
Parameters

:
(0.0 150.0) :

0.0

I max [kA]

(0.0 150.0) :

0.0

CosPhi

GUN -

GUN +

(0.0 1.0) :
PRINT

0.00

SAVE

Available function keys on page SETUP - GUN PARAMETERS 0


F1 PAGE+:
F2 GUN-:

Back to previous gun (Stepper).

F3 GUN+:

Go to next gun (Stepper).

F4 PRINT:

Print the complete SETUP menu.

F5 SAVE:

3.2.1

Move one page forward

Save all changes (after successfully saving, the star at the


upper bar will disappear)

Parameter on page SETUPGUN PARAMETERS 0


Each of the 16 Stepper programs refers to one of the 16 guns or electrodes.
Gun 0 has no related stepper. Gun 1 relates to stepper1, gun2 to stepper2
etc. up to gun 16, which relates to stepper16.
On this page there are 2 base setting parameters. Furthermore 3
parameters are displayed, which are calculated by the control. The
calculation of the parameters is done during each weld.

3.2.1.1

Max. Electrode force [kN]:


Parameter:

a numeric value must be entered

Range:

(00.00 30.00)

Description:

Only working with proportional valve (00.00-30.00).


Enter the electrode force, which results from the maximum
control of the proportional valve (it is not equivalent to the
mains pressure)
Maximum control is given with the voltage of 10V or with
the current of 20mA applied at the control input of the
proportional valve.
(see section 4.4.7.15 and 4.4.7.16)

3-6

GF WELDING

Programming instructions
Setup
3.2.1.2

Coil sensitivity [mV/kA]:


Parameter:
Range:

(0050.0 2000.0) Unit mV/kA

Description:

3.2.1.3

a numeric value must be entered

This parameter is to be set with the conversion coefficient


indicated by the current transducer (TA) manufacturer.
Typically, current transducers feature 150 mV/kA
sensitivity, meaning that when 1 kA is let through, they
generate 150mV voltage.

Sensitivity TF [V/kN]
Parameter type: Editable field with numerical value
Limits:
Description:

3.2.1.4

(00.00 30.00)
Parameter to be set with the conversion coefficient
declared by the manufacturer of the force transducer (TF).
The force transducers must generate an analog signal in
voltage proportional to the force to be measured.

Measured Parameter

I min [kA]:

Parameter:
Range:

(0.0 150.0)

Description:

3.2.1.5

Variable text, not to be edited

Available minimum current of the machine, detected by


the control during welding.

Measured Parameter

I max[kA]:

Parameter:
Range:

(0.0 150.0)

Description:

3.2.1.6

Variable text, not to be edited

Indicates maximum current which can be set to the


welding control based on the current measured.

Measured Parameter

CosPhi:

Parameter:

Variable text, not to be edited.

Range:

(0.0 1.0)

Description:

Determines the power factor cos, which is measured by


the control by the control based on the current measured.
The closer cos approaches the value 1, the greater is the
machine yield.
In the vectorial representation for Voltage and Current,
angle indicates the shifting between Voltage and Current
caused by load impedance.

GF WELDING

3-7

Programming instructions
Setup
EXAMPLE:

Resistive load only, voltage and current with same phase, angle
= 0 cos = 1
Inductive with resistive load, current is 30 delayed to the voltage,
angle = 30 cos = 0,866
Inductive with resistive load, current is shifted by 45 later than
voltage, angle = 45 cos = =0,707
Inductive load only, current is 90 delayed to the voltage, angle
= 90 cos = 0

3.3 SETUP Menu - ALARMS CONFIGURATION


To give the possibility to manage the diagnostic in a customized way, in this
menu it is possible to set 16 alarms with error code between 0 and 50 (see
CAP 7).
The alarms set in that way will affect the following functions: Weld alarm
threshold (see points 3.1.1.5 and 3.1.1.6); Cables wear (see point 3.4),
Stepper (see chapter 5) and Report (see chapter 8)
Following table shows the page SETUP - ALARMS CONFIGURATION on the
HHT
SETUP - ALARMS CONFIGURATION
N01
N02

E002- Stepper warning channel B


E000-OK
E000-OK

N09

E000-OK

N10

E000-OK

N11

E000-OK

N12

E000-OK

N13

E000-OK

N14

E000-OK

N15

E000-OK

N16
A

N06

N08

E001- Stepper warning channel A

N07

E032 Null welding current

N05
>

E031 Meas.cur.< lim threshold

N04

E006 Meas.cur.> max threshold

N03
*

E005 Meas.cur.< min threshold

E000-OK
B

Column A:
Column B:

Order number

Column C:

3-8

Abort function of error active (with *)

Error code and error description

GF WELDING

Programming instructions
Setup
Notes on previous table:

The error messages E005, E006, E031, E032, E001 and E002 are used in
the menu REPORT (See section 8)

The error messages E031, E032, E001 and E002 are configured with
abort function.

The error message is selected by the cursor > on position N05, which
refers to code E001.

Code E000-OK means: no error message is programmed.

The error message, which is configured with abort function,


prevents any restart. The user has to reset the alarm.
All error messages, which are configured without abort function, are
logged in the alarm history or in menu REPORT.

On the page SETUP - ALARMS CONFIGURATION, following


function keys are available:
F1 PAGE+:

Moves to the next page of the SETUP menu

F2 SELECT:

Enables or disables the ABORT functions with respect to


the alarm indicated by the pointer >

F3 ALL:

Enables or disables the abort function of all 16 error


messages

F4 PRINT:

Prints actual page

F5 SAVE:

Saves all changes

Usage of keys:
CONFIGURATION)

(ESC +

ENT

SETUP ALARMS

ON the page SETUP - ALARMS CONFIGURATION the cursor > is moved in


the left column and the functions of certain keys differ as described in
section 1.2.1
Functions of each keys are given in Table below:
Key :

moves the cursor up in the left column

Key :

Error code Exxx will be increased or decreased

Keys + -:

moves the cursor up or down by 5 lines in the left column

ESC key:

The escape key stops running actions and returns to the


previous menu. Any changes are not saved.

ENT key:

The Ent or Return key can enable or disable the actual


selected alarm (position of cursor >).

GF WELDING

3-9

Programming instructions
Setup

3.3.1

Alarms Configuration in REPORT menu.


In the REPORT menu bargraphs show, how often certain errors occurred.
(see section 8.3).
On this page in the SETUP menu, it can be defined, which process diagnosis
messages (E001 - E050) are logged in the REPORT menu.
There are some error messages (E001 - E002 - E003 - E004 - E046 - E049
- E050), which will not increase the error log counter, even they are
existing in the SETUP - ALARMS CONFIGURATION menu.
These alarms do not have effect on the statistical analysis of the faults of
the faulty welds as they concern the electrodes or cables wear.
They are existing in the SETUP - ALARMS CONFIGURATION menu in order
to configure them with abort function.

SETUP - ALARMS CONFIGURATION

>

N01
N02
N03
N04
N05

PAGE+

E001-Stepper warning channel A


E002-Stepper warning channel B
E006Meas. Curr.> max. threshold
E031Meas. Curr.< lim. threshold
E032Nul welding current
SELECT

ALL

PRINT

SAVE

Example: to define the message E015-Tip force out of tolerance, in


the REPORT menu, following steps must be performed:
1. Select the first empty position with the cursor (E000-OK)
2. Push the key several times until the desired Error code and
Error description is displayed.
3. Press F5 SAVE

3.3.2

Machine Shutdown Enable of Diagnostic Alarms


There are some welding processes, where messages with abort function are
recommended in order find root cause before operation is continued. The
control is stopped until the reset signal is present on the RESAH input or by
pressing F1 key from ALARMS HISTORY menu.

SETUP ALARMS CONFIGURATION

*
>*

PAGE+

N01
N02
N03
N04
N05

E001-Stepper warning channel A


E002-Stepper warning channel c. B
E006Meas. Curr.> max. threshold
E031Meas. Curr.< lim. Threshold
E032Nul welding current
SELECT

ALL

PRINT

SAVE

Example: To configure as an abort alarm the error message E032Nul welding current, perform following steps
1. Move the cursor to the position, where the Error E015 is displayed.
2. Press F2 SELECT and the star (*) in the first column will appear.
3. Press F5 SAVE.

3-10

GF WELDING

Programming instructions
Setup

3.4 Menu SETUP - CABLE WEAR


Following table shows the page SETUP - CABLE WEAR on the HHT.
REMARK: the text in brackets is not shown on the HHT. It informs about the
upper and lower limits of the given fields.
PAGE CABLE WEAR menu
SETUP CABLE WEAR
Enable (ON OFF)

ON

OFF

Prewarning(1-999999)

000001

000001

Stop

0000100

(100 999999)

Counter (0 999999)

100
PRINT

PAGE+

0000100

100
SAVE

ETC

Other commands appearing on Cable Wear menu


RESET-A

RESET-B

SET-A

SET-B

ETC

Function key of the menu SETUP CABLE WEAR:


F1 RESET-A:

Reset of spot counter for welding channel A.


REMARK: no confirmation will follow or be requested.

F2 RESET-B:

Reset of spot counter for welding channel B.


REMARK: no confirmation will follow or be requested.

F3 SET-A:

Presetting of the spot counter for welding channel A. After


pressing F3 a window with the counter setting will appear.
Select the desired counter number using +,- and arrow
keys. Confirm change by pushing ENT and SAVE with F4.
Remark: the maximum value is given by the programmed
Stop value.

F4 SET-B:

Presetting of the spot counter for welding channel B. After


pressing F4 a window with the preset counter will appear.
Select the desired counter number using +,- and arrow
keys. Confirm change by pushing ENT and SAVE with F4.
Remark: the maximum value is given by the programmed
Stop value.

F5 ETC:

Shows further functions of the menu

F1 PAGE+:

go to next page of the SETUP menu

F3 PRINT:

Prints out the content of the actual page

F4 SAVE:

Saves all inputs and changes

GF WELDING

3-11

Programming instructions
Setup

3.4.1

SETUP CABLE WEAR


This function consists of 2 independent spot counters for channel A and B.
The spot counter of channel A counts all spots, which are initiated from
Start A. The spot counter of channel B counts all spots which are initiated
form Start B. There is no relation to steppers. However same as with
stepper functions it is possible to issue messages as soon as some
predefined counter is reached.
This function enables maintenance intervals defined by number of spots. It
only makes sense to use this function in case of repeatability of cable wear
and maintenance intervals. The estimation of counts per maintenance is
empirical.
This function is mainly used for devices with gun cables to indicate, when
the cable needs to be replaced. Further options are possible. The
application allows to define the maximum number of welds, which can be
performed by one cable. As soon as this count is reached a error message
E046 (channel A, gun1) or E047 (channel B, gun2) will be issued. In
addition a prewarning can be programmed, where the messages E003 (gun
A) or E004 (gun B) are issued. This messages indicate maintenance work
must be done soon.
Please note the biggest benefit you may get with host computer managed
by WMS.
All values must be found by experience. A welding machine equipped with
two guns (A and B) is capable to run 500.000 welds on gun A and 850.00
welds on gun B. The operator will set the prewarning thresholds with these
values whereas the alarm thresholds are increased by about 10%. This
gives some safety margin before the machine will be stopped. The number
of welds on gun A would be 550.000 and for gun B 935.000.
In opposite to the stepper no outputs will be generated.

3.4.1.1

Enable
Parameter:
Options:

(ON - OFF)

Description:

3.4.1.2

Preset values must be selected

Enables the count of welds for cable wear management of


channel A/B. When to Off position, the counter of executed
welds is not incremented

Prewarning
Parameter:
Range:

(1 - 9.999.999)

Description:

3.4.1.3

a numeric value must be entered

Number of welds necessary to generate a Cable Wear


Prealarm of channel A/B.

Stop
Parameter:
Range:

(100 - 10.000.000)

Description:

3.4.1.4

a numeric value must be entered

Number of spots before the maintenance must be carried


out

Counter
Parameter:
Range:

(0 10.000.000)

Description:

3-12

enter the actual number of spots

Shows the actual number of spots. The counters can be


modified manually using SET-A or SET-B.

GF WELDING

Programming instructions
Setup

3.5 Menu SETUP TIP DRESSER WEAR


The table below shows the SETUP TIP DRESSER WEAR page (displayed on
the hand-held keyboard)
NOTE: Text between brackets is not displayed on the hand-held keyboard.
It provides useful information on the limits of the value appearing in
the adjacent field.
SETUP TIP DRESSER WEAR
Enable(ON OFF)
%Prewarning
Stop (10099999999)

ON
000001
00001000

Counter (0 9999999)

PAGE+

RESET

PRESET

PRINT

SAVE

Function keys of the SETUP TIP DRESSER WEAR


F1 PAGE+:

Allows moving to the next SETUP page

F2 RESET:

Reset command of dressing counter


NOTE: No additional confirmation of operation is requested

F3 PRESET:

Manual setting of counter for executed dressings. By


pressing the F3 key, a window will appear in which the
Counter Preset may be set. This value shall have to be
validated by pressing the ENT key and then F5 SAVE key.
NOTE:

Maximum settable value


programmed STOP value

is

equal

F4 PRINT:

3.5.1

the

Executes the print of the current page

F5 SAVE:

to

Permits moving into other Setup menu pages

Comment to the SETUP TIP DRESSER WEAR


This page allows the user to manage the DRESSER wear function (wear
results from the operation of the machine over time). This means
determining a maximum number of operations the dresser is capable of
doing; a prealarm and an alarm threshold are programmed. This function,
similar to the one used to control the Cable Wear function, allows
programming, in a rational manner, the maintenance interventions on the
dresser. In the same way as Cable Wear, when set thresholds are reached,
the welding control warns the user on the necessity of performing
maintenance operations (this is done by displaying the E007 message and
then E045 message). If the alarm has been configured as an Abort function
(refer to Setup 3.3), the welding cycle is shutdown.
It should be noted that maximum flexibility in use of this function is
obtained by linking the welding control to the remote central unit for
Weld334m (WMS) welding controls. In fact this unit has been equipped with
enhanced functions for highlighting, in a quick and simple manner, the
status of cable wear and electrode wear counters. And this represents a
precious help for operators.

GF WELDING

3-13

Programming instructions
Setup
Unlike the electrode wear management, the TIP DRESSER WEAR function is
not dependent on programs, special clamps and it has no dedicated
outputs.
* Only if configured as an Abort alarm on the Setup- Alarm Configuration
3.5.1.1

Enable
Parameter:
Range:

(ON - OFF)

Description:

3.5.1.2

Preset values must be selected

Enables the count of dressing operations. When to the OFF


position, the counter is not increased.

Prewarning:

[%]

Parameter:
Range:

(1 - 100)

Description:

3.5.1.3

a numeric value must be entered

Number of welds required before the request for Dresser


Maintenance is displayed.
Once this threshold is reached, the welding control will
generate E007 message to indicate that the Stop value is
about to be attained.
This warning is only loaded to the Alarm History.

Stop:
Parameter:
Range:

(100 - 10.000.000)

Description:

3.5.1.4

a numeric value must be entered

Number of dressing operations required before the request


for Dresser To Be Reset is displayed. Once this threshold is
reached, the welding control will generate E045 message
to indicate that the Stop value has been attained.
This warning is only loaded to the Alarm History and
whether the alarm code has been configured as an Abort
Function in the Setup- Alarm Configuration menu, the
welding cycle will be shutdown.
It is necessary to reset the counter (to do this press F2RESET key) to reset the operating conditions.

Counter
Parameter:
Range:

(0 10.000.000)

Description:

3-14

a numeric value must be entered

Counter of dressing operations executed. Counter may be


forced out through the F3-Preset key and then validated
by pressing ENT key.

GF WELDING

Programming instructions
Weld programs

<F2 PROG>

4 Menu PROG (Weld programs)

All kind of parameters of the 255 possible weld programs can be accessed
in the menu PROG (WELD PROGRAMS).
The menu PROG shows a list of all existing programs with the main
parameters including date/time of the last modification.
The following table shows the directory.
(Only 10 out of 255 programs are shown).
Page menu WELD PROGRAMS
WELD PROGRAMS
P01

TEST111

Const. Cur

ON

S00

S.SP

P02

BODEN3

Normal

OFF

S00

S.SP

P03

PAVIM3

Const. Cur

ON

S00

S.SP

P04

SEITENT

Const. Cur

ON

S00

S.SP

P05

>

AAA

Const. Cur

ON

S01

RPT

COPY

.
CLEAR

PRINT

EDIT

SS/RPT

WELD PROGRAMS
P01

Const. Cur

ON

S00

RPT

Mon 09/02/1998 09:11:23

P02

TEST222

Const. Cur

OFF

S00

RPT

Tue 10/02/1998 10:11:32

P03

BODEN3

Normal

ON

S00

RPT

Mon 09/02/1998 11:11:04

P04

SEITENT

Monitor

ON

S00

RPT

Mon 09/02/1998 18:11:55

P05

AAA

Const. Cur

ON

S01

SS

Tue 10/02/1998 09:11:44

P06

BBB

Monitor

ON

S01

SS

Mon 09/02/1998 09:11:19

P07

>

TEST111

CCC

Corr.Cos

ON

S02

SS

Fri 06/02/1998 09:11:56

P08
P09
P10
A

COLUMN A:

The cursor > can be moved by using the arrow keys

COLUMN B:

Program number (P01 P255)

COLUMN C:

Program name (mnemonic)

COLUMN D:

Welding mode (see section 4.4.1)

COLUMN E:

Program activation (see section 4.4.7.4)

COLUMN F:

STEPPER which belongs to welding program (Autom.


Current/pressure increment see section 4.4.7.7). S00
means, no STEPPER program is assigned to the weld
program.

COLUMN G:

Key F5 selects the option repeat / single spot (RPT/SS) in


series with the other consents required (see section
3.1.1.11)

COLUMN H:

Date and time of create or modify the program

GF WELDING

4-1

Programming instructions
Weld programs
REMARK: Column H is displayed in alternative to columns D E F G when
using arrow keys
The content of the columns can be changed by selecting the programs using
the arrow keys and pushing F1 EDIT. Column G can be changed by using F5
SS/RPT only.
Key + proceeds to the 5 succeeding, whereas key - proceeds to the 5
previous programs.
Function keys in the menu WELD PROGRAMS:
F1 EDIT:

Selects the program next to the cursor > for editing (see
section 4.4)

F2 COPY:

a menu will be opened (see section 4.1) in order to copy a


program

F3 CLEAR:

a menu will be opened (see section 4.2) in order to delete


a program

F4 PRINT:

all parameters will be printed, which belong to the


program where the cursor is positioned

F5 SS/RPT:

Selection of operating mode (see section 4.3)


SS = Single spot
RPT = Repeated spot

4.1 Copy welding programs

F2 COPY

In this menu programs will be copied. This means to transfer data of one
program to another program.
Page menu COPY WELD PROGRAMS
COPY WELD PROGRAMS
P01

TEST111

Const. Cur

ON

S00

SS

P02

TEST222

Normal

OFF

S00

SS

P03

PAVIM3

Const. Cur

ON

S00

SS

P04

FIANCATA

Const. Cur

ON

S00

SS

P05

>

AAA

Const. Cur

ON

S01

RPT
COPY

SELECT

Example: Copy of parameters of program Nr.4 (P04) to program 8


(program 4 must contain data, program 8 may contain data but
must not be edited)
1. From menu WELD PROGRAMS, push F2 key COPY and the upper display
bar will show COPY WELD PROGRAMS. The F1 key selects and the F5 key
copies the program.
2. Move the cursor to the program (source),which shall be copied, by using
the arrows
3. In order to select the program, which shall be copied, push F1 SELECT
and the ENT key. The star * will appear next to line P04 in column A.
4.

4-2

Move the cursor to the program (target) using the arrows All
parameters of the source program will be transferred to the target
program.

GF WELDING

Programming instructions
Weld programs
5. Push F5 key COPY. All parameters of program 4 will be transferred to
program 8.
6. To go back to menu WELD PROGRAMS push ESC key.

F3 CLEAR

4.2 Clear welding program

To clear means to cancel all parameters of a program. It is not possible to


access a program, which was cleared.
Page menu CLEAR weld programs
CLEAR WELD PROGRAMS
TEST111

Cont.Cur

ON

S00

SS

TEST222

Normal

OFF

S00

SS

P03

BODEN3

Cont.Cur

ON

S00

SS

P04

SEITENT

Cont.Cur

ON

S00

SS

P05
SELECT

P01
P02

>

AAA

Cont.Cur

ON

S01

RPT

ALL

CLEAR

Example: Clear program Nr. 2.


1. Push F3 key CLEAR from menu WELD PROGRAMS.
In the upper display bar CLEAR WELD PRGRAMS will appear. F1 will
select a single program, F2 will select all programs and F5 takes care of
the function CLEAR.
2. Use the arrow keys and move the cursor to the program P01, which
shall be cleared.
3. In order to select the program, which shall be cleared, push the F1 key
SELECT or push the ENT key. The star * will appear in column A next to
P01. In case all programs of the control shall be deleted, push key F2
ALL. To undo this command key F2 ALL must be pushed again.
4. Press F5 CLEAR and the message CONFIRM? [ENT=YES / ESC = NO] will
appear.
5. Confirm with ENT key.
6. In order to go back to menu WELD PROGRAMS, push ESC key.

GF WELDING

4-3

Programming instructions
Weld programs

F5 SS/RPT

4.3 Selection Single spot - Repeated spot


SS (Single spot):

After start one weld operation will be executed. For


next weld, Start must be activated again. This
operation mode is used for automatic devices.

RPT (Repeated spot): Weld operations will be executed as long as Start


is closed. This operation is used for manual
devices.
Page menu weld programs SINGLE SPOT - RIPEAT
WELD PROGRAMS
TEST111

Const.Cur

ON

S00

SS

TEST222

Normal

OFF

S00

SS

P03

BODEN3

Const.Cur

ON

S00

SS

P04

SEITENT

Const.Cur

ON

S00

SS

P05
EDIT

P01
P02

>

AAA

Const.Cur

ON

S01

RPT

COPY

CLEAR

PRINT

SS/RPT

Example: Serial spot ( repeat mode )with program P01


1. Program P01 is preset with option SS (see column G)
2. Move cursor to program P01 using the arrow keys .
3. Push key F5 in menu WELD PROGRAMS. Option RPT (column
G) will be changed to S.SP.
Also refer to the diagrams with enabled and disabled functions in
section 4.4.7.11.

4-4

GF WELDING

Programming instructions
Weld programs

F1 EDIT

4.4 Menu EDIT

To set welding parameters is the most important task of the control.


All parameters of the welding programs (Current, cycles, electrode force
etc) can be edited.
The quality of weld is determined by the parameters, which were given by
the operator.
Please take notice the control offers additional functions. For this reason,
the parameters must adapt to the hardware, which is in use. All parameters
with free functions should be adapted to the welding, whereas all default
parameters, which are set by maker, should not be touched.

4.4.1

Welding control circuit


The welding control circuit has following structure:

Thyristor (SCR) on primary circuit of the welding transformer

Welding transformer

Current transducer (sensor) on secondary circuit of the welding


transformer

Electrodes, which are connected to the secondary circuit of the


transformer

The current of the primary circuit is controlled by the thyristor.


The current control is done by changing the firing angle of the thyristor
(phase angle control)

Input signal

HHT

Output signal

Control
WELD334m
Current
transducer

Line

4.4.2

Transformer
SCR

Electrodes

Welding mode
Six different welding modes can be selected within one program:
1. NORMAL
Normal welding. In the NORMAL mode, the user sets the percentage of
maximum current with which he wants to perform welding. There is no
verification of the actual welding current as no current transducer is
expected to be installed.

GF WELDING

4-5

Programming instructions
Weld programs
2. MONITOR
Same as Normal operation mode, however in addition it is possible to
monitor actual current. This makes process diagnosis easy (see section
4.4.7.20). A current transducer is mandatory.
3. CONSTANT CURRENT
Actual current in kA will be same as setpoint current. This is achieved by
the welding control, which sets the ignition angle of the thyristor.
Parasitic effects like change of impedance of the secondary circuit or
changes of voltage supply will be compensated and the welding current
will be kept constant. A current transducer is mandatory (see section
4.4.7.20).
4. SEAM NORMAL
Operation mode is for seam welding only. In this mode the active
parameters (see section 4.4.6) will be repeated until the start signal is
switched off. The welding program can be changed without
interrupting the Signal START. The Seam normal operation mode is
similar to Normal apart from the parameter downslope.
5. SEAM MONITOR
This operation mode is similar to Monitor apart from the parameter
slopedown.
6. SEAM CONSTANT CURRENT
This operation mode is similar to CONSTANT CURRENT apart from the
parameter slopedown.
7. HALF CYCLE:
This welding mode must be selected if the welding control is installed in
plant where the welding technology known as AL-S is applied.
For this type of application, the duration of welding is fixed and consists
of a single network half-wave.
The sequence of welding spots is produced by alternating the input of
the primary welding circuit with a positive half-wave and a negative halfwave, so as to avoid saturating the transformer. (See diagram in the
appendix for an example)
8. HALF CYCLE MONITOR: As for the HALF CYCLE mode, with the
possibility of monitoring the current and making any process diagnostics
required (see point 4.4.7.19). A current sensor is mandatory.

All operation modes mentioned above effect the menu EDIT WELD
PROGRAMS dynamically, where all displayed parameters will change in
dependency on the selected Welding Mode. See also Operating Diagram
3 of Appendix A page 4.

4-6

GF WELDING

Programming instructions
Weld programs

4.4.3

I/O Signals of the control during weld sequence


Following I/O signals effect the execution of the welding process:

CODE0 - CODE 5
Programcode
CODE P
Parity code Program.

WELD
334m

EVSA
Weld valve channel A
EVPA
Pressure variation ch.A
EVSB
Weld valve channel B

STARTA
Cycle start ch. A

EVPB
Pressure variation ch.B

STARTB
Cycle start ch. B

I/VSERV
control servo valve
l

CONSSALD
Weld enable

RICHSALD
Weld request

REPEAT
Repeat mode

FINESALD
End of weld

SALDA SI
With weld current

FINESEQ
End of sequence

SOLOPR
Force only
STSERV
Status servo.valve

4.4.4

Example: Edit Weld program


A new program shall be edited - in this example program 8 is used:
1. Press ESC in order to return to the main menu.
2. Press key F2 PROG
3. Press arrow key until cursor is placed in the line of program P08.
4. Press key F1 EDIT.
5. The default menu for program editing consists of two pages, which can
be shown using key F1 PAGE+. It looks as follows:

GF WELDING

4-7

Programming instructions
Weld programs

Program menu Normal mode: Page 1


P:08

Stp_: 00

:ON

: Normal
VEE_: 00

PLS: N

: 00

Up_S : 00

1^Ang: 000

1Sqz

_: 00

CPV_: 00

Weld

Pwr

2Sqz

_: 00

MPV_: 0

Dw_S : 00

Hold

: 00

P1: 00.00

Wait : 00

Open

_: 00

P2: 00.00

PAGE +

SAVE

PROG -

: 00

I:

%:000

KA

PROG +

Program menu Normal mode: Page 2

P:08 :

: Normal

:ON PLS: N

Up_S : 00
Weld : 00

: 00

1^Ang: 000
a

Pwr %: 000

Dw_S : 00
Wait: 00
CosPhi :

KA

0.80
SAVE

PAGE +

I:

PROG -

PROG +

First the mode of welding must be defined:


In this example the mode CONSTANT CURRENT shall be used. This is the
most common mode, which takes advantage of the whole capability of the
control.
To change the mode of welding proceed by following steps:
1. Push the arrow key twice and the cursor will be placed on the field,
where the preset value 'Const.Cur' can be selected.
2. Push key + twice and the operation mode will be switched from NORMAL
to Const.Cur
Following tables show how it looks, when a 'Const.Cur' program is edited
(use key F1 PAGE+)
Program menu Costant Current mode: Page 1
P:08

Stp_: 00
1Sqz: 00
2Sqz: 00
Hold : 00
Open: 00
PAGE +

4-8

: Const.Curr. : ON

:
VEE_: 00
CPV_: 00
MPV_: 0
P1: 00.00
P2: 00.00
SAVE

Up_S: 00
Weld: 00
Dw_S : 00
Wait_ : 00
PROG -

GF WELDING

I:

PROG +

PLS:N: 00
1Ang : 000
Blank: 000
I.Prg : 000.0
KA

Programming instructions
Weld programs

Program menu Costant Current mode: Page 2


P:08

: Const.Cur : ON

PLS:N:

00

Up_S : 00
Weld : 00
00

%I.max:

00

Rtr: 00

%I.lim:

00

Blank: 00

Dw_S : 00

%I.min:

1^Ang: 000

I.Prg: 000.0

Ang: 000
SAVE

PAGE +

Wait : 00

PROG -

I: KA

PROG +

Program menu Costant Current mode: Page 3


P:08

: Const.Cur : ON

PLS:N:

00

Th.1 :

00.00

Up_S

: 00

1^Ang: 000

Th.2 :

00.00

Weld

: 00

Blank: 00

Th.3 :

00.00

Dw_S

: 00

Wait

: 00

PAGE +

SAVE

PROG -

I.Prg: 000.0
I: KA

PROG +

The parameters can be edited by usage of the function keys.


All values must be within a certain range, otherwise the data can not be
saved.

4.4.5

Function keys of menu EDIT WELD PROGRAM


F1 PAGE+:

go to next page

F2 SAVE:

saves all allowable changes (the star * in the upper right


corner will disappear).

F3 PROG -:

go to previous program

F4 PROG +:

go to next program
REMARK: in case the special pulse mode is selected, the
function keys will modify:

F3 PULSE -:

parameters of previous pulse

F4 PULSE +:

parameters of next pulse are shown

F5 ETC:

go to next page with the functions F1 PAGE+ ; F2 SAVE ;


F3 PROG - ; F4 PROG + ; F5 ETC

Furthermore the right upper corner of the display shows the pulse number
(see section 4.4.6) which is actually selected.

GF WELDING

4-9

Programming instructions
Weld programs

4.4.6

Table of parameters for different welding modes


All kind of parameters of the weld program depend on the actual operation
mode (welding mode),which was selected in the opened program.
Following table shows the actual existing parameters of each operation
mode: (Y) exist (N) not exist.

Welding modes
Abbreviation
4-10

Monitor

Const.Cur.

Seam N.

Seam M.

Seam C.C.

Cycle N.

Cycle M.

Program Nr.
Program name
Welding mode
Enable programs
Pulse type
Number of pulses
Stepper/electrode parameter
Presqueeze time
squeeze time
Hold time
Open time
Equivalent energy value
Delay squeeze control
Squeeze variation mode
Electrode force 1.
Electrode force 2.
CosPhi nominal
maximum current tolerance
Minimum current tolerance
Limit current tolerance
Electrode force tolerance
Electrode force diagnostic mode
Repeating spots
Firing angle limitation
Sheet thickness
Upslope cycles
Downslope cycles
Cool time
Weld time
Delayed firing of first half-cycle
Welding current
Diagnostics current
Blanking cycles (Blank)
Welding current in kA
Measured welding current

Normal

Description

P:
:
:
:
PLS:
:
Stp_:
1. Sqz_:
2,. Sqz_:
Hold _:
Open_:
VEE_:
CPV_:
MPV_:
P1:
P2:
CosPhi:
%I.max:
%I. min:
%I. lim:
%T. Prs:
%T. Prs:
RTR:
Ang:
Th.
UpS:
DwS:
Wait_:
Weld:
1Ang:
Pwr %:
I.Dgs.:
Blank:
I.Prg.:
I: kA

yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
no
no
no
yes
yes
no
no
yes
yes
yes
yes
yes
yes
yes
no
no
no
no

yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
no
yes
yes
yes
yes
yes
yes
yes
yes
no
no
yes

yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
no
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
no
no
yes
yes
yes

yes
yes
yes
yes
no
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
no
no
no
yes
yes
no
no
yes
yes
no
yes
yes
yes
yes
no
no
no
no

yes
yes
yes
yes
no
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
no
no
yes
yes
no
yes
yes
yes
yes
yes
no
no
yes

yes
yes
yes
yes
no
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
no
yes
yes
yes
yes
yes
no
yes
yes
yes
no
yes
yes
yes
no
no
yes
yes
yes

yes
yes
yes
yes
no
1
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
no
no
no
yes
yes
no
no
yes
no
no
yes
no
no
yes
no
no
no
yes

yes
yes
yes
yes
no
1
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
no
no
yes
no
no
yes
no
no
yes
yes
no
no
yes

GF WELDING

Programming instructions
Weld programs

4.4.7

Parameters of menu EDIT WELD PROGRAMS


In respect of different welding modes there are 2 categories of parameters:
Hot parameters: These parameters will have an effect on the result. They
are located within the box on the right side of the menu
EDIT WELD PROGRAMS and they are shown on both pages
of the menu.
Cold parameters: All parameters for electrodes, diagnostics etc.
All process times are given in cycles. One cycle is 20ms
with a supply frequency of 50Hz and about 16.7ms with a
supply frequency of 60Hz.
The abbreviation or the symbol of each parameter is
shown in brackets.
The list below gives the description of all of the
parameters concerning the different welding modes.

4.4.7.1

Program number
Parameter:

a numeric value must be entered

Range:

(01 255)

Description:

Order number
In case the cursor is placed in some other field, next
program can be shown by pressing F3 PROG- or F4
PROG+. All parameters of the new selected program are
displayed.

4.4.7.2

Program name

[:]

Parameter:
Limits:

8 characters, first must be a sign

Description:

4.4.7.3

a character value must be given

Name of the welding program, mnemonic only. This


parameter is also shown in column C of table WELD
PROGRAMS (see section 4).

Mode of welding [ : ]
Parameter:
Presettings:

(Normal Monitor - Const.Cur Seam N. Seam M.


Seam C.C. Cycle N. Cycle M.)

Description:

4.4.7.4

a preset value must be selected

See Section 4.4.1. This parameter is also shown in column


D of table WELD PROGRAMS (see section 4).

Enable program [ : ]
Parameter:

a preset value must be selected

Presettings:

(ON OFF)

Description:

This function enables (ON) or disables (OFF) the welding


program. In case a disabled program will be selected,
error message E091 will be issued. This parameter is also
shown in column E of table WELD PROGRAMS.
(see section 4).

GF WELDING

4-11

Programming instructions
Weld programs
4.4.7.5

Pulse type [ PLS: ]


Parameter:

a preset value must be selected

Presettings:

(N S) Normals and Specials

Description:

One pulse means duration of current (welding time),


where the current is not interrupted [Weld:].
A welding program may consist of several pulses, which
are separated by intervals [Cool time WAIT], where no
current is flowing

In case of a single pulse, there is no difference between


pulse type normal and pulse type special. All pulses are
the same. The slope up time applies to the first pulse,
the slope down time applies to the last pulse only.

Pulse type special: each pulse can be setup individually.

In the most simple welding program all welds [Weld] are


unified within one single pulse.
For all three types of Seam welds the pulses are of special
type.
REMARK: The dotted lines in following diagram show exactly one period of
net frequency (this is 20ms in case of 50Hz).

Pulse type Normal


Following graph shows a welding program, which consists of 5 current
pulses type normal [PLS:N:05].

The current is identical for all pulses.

No slope-up or slope-down cycles are defined.

Weld cycles per pulse = 4 cycles [Weld:04]

The cool time between each pulse takes 2 cycles [WAIT:02].

I
[KA]

T [cycles)]

4-12

GF WELDING

Programming instructions
Weld programs

Pulse type special


Following graph shows a welding program, which consists of 3 pulses type
special [PLS:S:03].

The first pulse (warm-up pulse) takes 4 cycles [Weld:04] and the cool
time, which separates it from the succeeding pulse, takes 2 cycles
[WAIT:02].

The second pulse (actual weld) takes 7 cycles [Weld:07] and the cool
time, which separates it from the succeeding pulse, takes 3 cycles
[WAIT:03].

The third pulse (postwarming) takes 3 cycles [Weld:03] and the cool
time, which separates it from the succeeding pulse, takes 0 cycles
[Wait:00].

The current is identical for all pulses.

No slope-up or slope-down cycles are programmed.

I
[KA]

T [cycles)]

4.4.7.6

Number of pulses [ : ]
Parameter:

a numeric value must be specified

Range:

(1 20) for pulse type normal


(1 4) for pulse type special

Description:

Number of pulses, which are effective during welding


operation.
For pulse type special the number of pulses appears on the
right of the upper window with the hot parameters (see
section 4.4.6).

4.4.7.7

Stepper/Electrode parameter [ Stp_: ]


Parameter:

a numeric value must be specified

Range:

(0 16)

Description:

this parameter assigns one out of 16 stepper programs to


the welding program (see section 5). A number between 1
and 16 can be entered. Normally all welding programs,
which command the same gun, have to refer to the same
stepper program.
To disable the stepper function, the parameter has to be
set to 0.
This parameter is also shown in column F of table WELD
PROGRAMS (see section 4).

GF WELDING

4-13

Programming instructions
Weld programs
4.4.7.8

Presqueeze [ 1.Sqz: ]
Parameter:
Range:

(0 99)

Description:

4.4.7.9

a numeric value must be specified

This is the time for closing the gun. In case operation


mode RPT is active, the prolonged hold is valid for the first
spot weld only.

(Unit = Periods)

Squeeze [ 2.Sqz: ]
Parameter:
Range:

(0 99)

Description:

4.4.7.10

a numeric value must be specified

This is the time given for the gun, to build up the electrode
force after the welding program has started. This time
value must be found out by experience.

(Unit = periods)

Hold time [ Hold: ]


Parameter:
Range:

(0 99)

Description:

4.4.7.11

a numeric value must be specified

This is the time, where the electrode force remains after


welding. The spot weld shall cool down and reforge under
the influence of the electrodes. This time value must be
found out by experience.

(Unit = periods)

Open [ Open: ]
Parameter:
Range:

(0 99)

Description:

4-14

a numeric value must be specified

This is the time for the gun to open, move to the new
position and close again. It applies for serial welds only.
This time value must be found out by experience.

(Unit = periods)

GF WELDING

Programming instructions
Weld programs

Welding graph for single spot SS


Following graph shows the sequence for single spot:
See also operating diagram 1 of Appendix A page2
The welding program has following parameters:

1Sqz, time for welding guns to close is 3 cycles

2Sqz, time for welding gun to reach nominal squeeze is 2 cycles

one pulse takes 4 cycles and type is Normal [Weld:04]

Up-slope or down-slope cycles are not defined

Hold time is 4 cycles [Hold: 04]

Open time is 3 cycles [Open: 03]

The REPEAT option is not enabled (see section 3.1.1.11)

The input signal START remains until output signal FINESEQ (end of weld
cycle) on

STATUS = 1
STATUS = 0

START

1SQZ

2SQZ

WELD

HOLD

OPEN

Solenoid valve

End of sequence

T [cycles

GF WELDING

4-15

Programming instructions
Weld programs
Welding graph for repeated spot RPT
Following graph shows the sequence in repeat mode

The welding program has following parameters

1Sqz, time for closing welding guns is 3 cycles [1Sqz:03]

2Sqz, time for closed guns to reach nominal force is 2 cycles[2Sqz:2]

one pulse of welding type Normal takes 4 cycles [Weld:04]

No uplope or downslope cycles are defined

Hold time is 1 cycle [Hold: 01]

Open time is 3 cycles[Open: 03]

Operation mode RPT (see section 3.1.1.11)

The input signal START remains on till begin of second welding sequence

Output signal FINESEQ end of weld cycle will generated as longs as


specified in the menu SETUP- CONFIGURATION WELD334m (see section
3.1.1.14)

STATUS = 1

START
START

STATUS = 0

1SQZ

2SQZ

WELD

HOLD

OPEN

Prortional valve

End of weldsequence

T [cycles]

4-16

GF WELDING

Programming instructions
Weld programs
4.4.7.12

Equivalent energy value [ VEE_ ]:


Parameter:

a numeric value must be specified

Range:

(0 10)

Description:

0= no spot counting
10= each spot will be counted
If one gun is driven by several welding programs, all
programs will have the same stepper parameters. The
highest amount of electrode wear (electrode alarm)
however is caused by the program, which commands the
highest amount of energy (current as a function of time).
Usually it will be the program, which is used for welding of
the biggest sheet thickness combination. The equivalent
energy value parameter [VEE_:] makes it possible, to
assign electrode wear (electrode lifetime, stepper alarm)
due to energy for each welding program.
For the program with the highest amount of electric
energy consumption, means highest amount of electrode
wear, VEE_: is set to 10.
After execution of each weld the internal spot counter is
increased by 1. For programs which apply less energy for
welding, where VEE_: has a smaller value, the counter will
increase in proportion to this.
For instance another program which uses half of the
energy, the value for [VEE_:] will be set to 5. In order to
increase the counter by one, 2 spots have to be welded by
this program.
Parameter 0 means, stepper is disabled for this program.
Value 10 means, all spots will be counted 100%, 8 = 80%,
7 = 70% etc.

4.4.7.13

Squeeze variation cycles

[ CPV_: ]

Parameter:

a numeric value must be specified

Range:

(0 99)

Description:

The control manages 2 welding channels A and B. Only


servo control valve of channel A will be analysed in
following examples.

(Unit = cycles)

Force can be applied to the electrodes using three different


configurations of control valves:
A) Monostable solenoid valve for weld (EVSA) (valve for
opening and closing the welding gun)
B) Monostable solenoid valve (EVSA) and a monostable
pressure valve (EVPA). When EVPA together with EVSA
is actived, a higher amount of force is achieved as with
EVSA only.
C) Monostable solenoid valve (EVSA) and a proportional
solenoid valve for pressure control.

GF WELDING

4-17

Programming instructions
Weld programs

The proportional valve applies 3 different values to the


electrodes:

OFFSET (PRESET) OF ANALOG OUTPUT (see section


3.1.1.4)

ELEKTRODE FORCE 1 (see section 4.4.7.15)

ELEKTRODE FORCE 2 (see section 4.4.7.16)

Parameters [ CPV_: ] [ MPV_: ] [ P1: ] [ P2: ] must be set,


when configurations type B) or C) are used.
The force control [CPV_:] is clocked by the ON-delay of the
2.control valve or the ON-delay of the second setpoint of
the proportional valve. In case a proportional valve is used
the
analog
output
PRESET
in
menu
SETUPCONFIGURATION WELD334m (see section 3.1.1.4) and
MAX
ELECTRODE
FORCE
in
menu
SETUP-GUN
PARAMETERS (see section 3.2.1.1) must be set correctly.

4.4.7.14

Squeeze variation mode [ MPV_: ]


Parameter:

a preset value must be specified

Presettings:

(0 5)

Description:

This selects the mode of electrode squeeze variation


during Squeeze-, Weld-and Hold time. The modes of
squeeze variation depend on the configuration of the
solenoid valves: Type B or Type C (see section 4.4.7.13)
can be selected.
For type B solenoid valve EVSA and EVPA can result in two
different force values, which are called EVSA and EVSA +
EVPA.

Summary of squeeze variation modes with solenoid valve EVSA and


pressure control valve EVPA.
MVP=0
MVP=1

Squeeze, initially equal to EVSA + EVPA goes to level EVSA after


variation cycles and returns to level EVSA + EVPA during hold time.

MVP=2

Squeeze, initially equal to EVSA + EVPA goes to level EVSA after


variation cycles and remains during hold time.

MVP=3

Squeeze, initially equal to EVSA goes to level EVSA + EVPA after


variation cycles and remains during hold time.

MVP=4

Squeeze, initially equal to EVSA goes to level EVSA + EVPA and


after variation of cycles and returns to level EVSA during hold time.

MVP=5

4-18

No squeeze variation: squeeze remains at constant value EVSA

Squeeze remains at level EVSA throughout the sequence and goes


to level EVSA + EVPA during hold time.

GF WELDING

Programming instructions
Weld programs

Electrode force - graph with 2 monostable solenoid valves.


Following graph shows the different modes of operation (0-5), how the
electrode force changes as a function of time for solenoid valve type 2 (see
section 4.4.7.13).

Force EVSA + EVPA is applied after activation of EVSA and EVPA

Force EVSA is applied after activation of EVSA

Force control [CVP_:] is clocked after squeeze time


W ELD

2SQZ

1SQZ

HOLD

OPEN

EVSA

Mode 0

EVSA+EVPA

EVSA+EVPA
EVSA

Mode 1

EVSA+EVPA
EVSA

Mode 2

EVSA+EVPA
EVSA

Mode 3
EVSA+EVPA
EVSA

EVSA

Mode 4
EVSA+EVPA
EVSA

Mode 5
CPV

GF WELDING

4-19

Programming instructions
Weld programs
In case of type C the two different force values P1 and P2, which are
applied by the welding gun, are programmable (see [P1:] and [P2:]). The
force after squeeze time is set with [P1:]. In case of no squeeze variations,
mode 0 must be selected.

Summary of squeeze variation modes with proportional solenoid valve


MVP=0

MVP=1

Squeeze, initially equal to P2 goes to P1 after the variation cycles and


returns to level P1 during the hold time.

MVP=2

Squeeze, initially equal to P2 goes to P1 after the variation cycles and


remains during the hold time

MVP=3

Squeeze, initially equal to P1, goes to level P2 after the variation cycles
and remains during the hold cycles

MVP=4

Squeeze, initially equal to P1, goes to level P2 after the variation cycles
and returns to level P1 during the hold time.

MVP=5

4-20

No squeeze variation: squeeze remains at constant value P1.

Squeeze remains at level P1 throughout the sequence and goes to level P2


during the hold time.

GF WELDING

Programming instructions
Weld programs

Electrode force - graph with 1 monostable solenoid valve and 1


proportional valve
Following graph shows the different operation modes (0-5), the change of
electrode force as a function of time for valve configuration type C (see
section 4.4.7.13).

Force P1 is applied by activation of EVSA and the proportional valve with


the parameter P1 (in this example P1 is equal to a minor force)

Force P2 is applied by activation of EVSA and the proportional valve with


the parameter P2 (in this example P2 is equal to a high force)

P1 and P2 are the parameters as described in section 4.4.7.15 and


section 4.4.7.16.

The force control [CPV_:] is started after squeeze time.


1SQZ

2SQZ

WELD

HOLD

OPEN

P1
Mode 0

P2
Mode 1

P1

P1

P2
P1
Mode 2

P2
P1
Mode 3
P2
P1

P1
Mode 4

P2
P1
Mode 5

CPV

GF WELDING

4-21

Programming instructions
Weld programs
4.4.7.15 Electrode force 1. [ P1: ]
Parameter.

A numeric value must be specified

Range:

(00.00 30.00)

Description:

This parameter must be set only, when a proportional


valve is used.

(Unit = kN)

How to input electrode force P1:


The control calculates the setpoint of the analog output
signals for the proportional valve by using the maximum
electrode force given in the SETUP menu and the
programmed electrode force P1.
The welding control does not manage control of force or
pressure. The pressure control is done by the proportional
valve.
The MAX.ELECTRODE FORCE must be specified in the
menu SETUP - GUN PARAMETER correctly (see section
3.2.1.1).
4.4.7.16

Electrode force 2. [ P2: ]


Parameter: a numeric value must be specified
Range:

(00.00 30.00)

(unit = kN)

Description:

This parameter must be specified only, when a


proportional valve is used and pressure variation is
needed.
How to input electrode force P2:
The control calculates the setpoint of the analog output
signals for the proportional valve by using the maximum
electrode force given in the SETUP menu and the
programmed electrode force P2.
The welding control does not manage control of force or
pressure. The pressure control is done by the proportional
valve.
The MAX.ELECTRODE FORCE must be specified in the
menu SETUP - GUN PARAMETER correctly (see section
3.2.1.1).

4.4.7.17

CosPhi nominal [ CosPhi: ]


Parameter:

a numeric value must be specified

Range:

(0.25 0.99)

Description:

This parameter is used in operation mode Normal and


Monitor for proper control of the thyristor in dependency
on the secondary circuit.
To perform a correct setup it is recommended to run some
test weldings in Constant current or Monitor mode (a
current transducer must be present). All data, which were
calculated by the control, can be seen in menu SETUP GUN PARAMETER. The CosPhi value must be set as
parameter [CosPhi:].
This parameter is used in following operation modes only:
Normal,Monitor, Const.Cur., Seam N.,Seam M., Seam
C.C., Cycle N. and Cycle M.

4-22

GF WELDING

Programming instructions
Weld programs
In case CosPhi does not match perfectly the range of
current settings will be limited or the measured values by
the current transducer do not show actual current values
correctly.
4.4.7.18

Maximum Current tolerance [ %I.max:]


Parameter:

a numeric value must be specified

Range:

(05 50)

Description:

This parameter is used in Monitor and constant current


mode.
% I.max is the maximum error tolerated in case actual
current does exceed the setpoint.
In operation mode Monitor, the setpoint is given in
[I.Dgs.:].
This Limit of tolerance has no effect on the Weld alarm
threshold parameter which is given in menu SETUPCONFIGURATION WELD334m.
Error 'E006 - Meas.curr.>max threshold' will be issued in
case the average effective current value of one weld
exceeds the maximum current tolerance.
The message 'E006 - Meas.curr.>max threshold' can be
configured in menu SETUP -ALARMS CONFIGURATION with
abort function (see section 3.3).
In the HHT this parameter is present in following operation
modes only: Monitor, Const.Cur, Seam M., Seam C.C.,
Cycle M.

4.4.7.19

Minimum current tolerance [ %I. min: ]


Parameter: a numeric value must be specified
Range:

(05 50)

Description:

This parameter is used in operation modes Monitor and


Const.Cur.
%I.min is the admissible minus tolerance for the current
for a number of weldings in sequence.
In operation mode Monitor the setpoint is given with
[I.Dgs.:].
In case the actual average effective current is between the
minimum tolerance and the limit current tolerance (see
section C in following example) the counter for faulty
welds will be increased by one. In case the value exceeds
the number defined in menu SETUP-CONFIGURATION
WELD334m, the error 'E005 - Meas.Curr.< min threshold'
will be issued.
The error message E005 - Meas.Curr.< min threshold
can be set in menu SETUP -ALARMS CONFIGURATION with
abort function (see section 3.3).
In the HHT this parameter exclusively is present in
Monitor, Const. Current, Seam M., Seam C.C., Cycle M.

GF WELDING

4-23

Programming instructions
Weld programs
4.4.7.20

Tolerance range (min-max-lim) of welding current:


A welding program contains following parameters:

Programmed welding current in kA [I.Prg:]=10 kA

Max.current tolerance [%I.max:] = 18%, which is 11.8 kA

Min.current tolerance [ %I. min: ] = 15%,which is 8.5kA.

Limit current tolerance [ %I. lim: ] = 27%,which is 7.3kA.

Weld alarm threshold A (menu SETUP - CONFIGURATION WELD334m) = 2

It may occur during welding, that the average measured current does not
match the programmed setpoint current.
The actual measured current may be within one of the 4 ranges described in
the following:
Area A: The actual measured current is above 11.8kA and the message
E006 - Meas.curr.>max threshold will be issued.
Area B: The actual measured current is between 8.5kA and 11.8kA, current
is judged as OK.
Area C: The actual measured current is between 7.3kA and 8.5kA for 2
weldings in series and the error 'E005 - Meas.Curr.< min
threshold' will be issued.
In case the current is within area C one time, no error message
will be issued (Weld alarm threshold A = 2).
Area D: The actual measured current is below 7.3 kA and the error 'E031Meas.curr.<lim threshold' will be issued.

Alarme Zone A: E006 Meas. Curr. > max threshold


11.8 kA

%I.max:18

I.Prg:10.0

Zone B: Weld OK

10.0 kA

8.5 kA

%I.min:15

Alarm Zone C: E005 Meas. Curr. < min threshold subordinate to alarm threshold (see 3.1.1.5)

7.3 kA

%I.lim:27
Alarm Zone D: E031 Meas. Curr. < lim. threshold

4-24

GF WELDING

Programming instructions
Weld programs

4.4.7.21

Limit current tolerance [ %I. lim: ]


Parameter:

a numeric value must be specified

Range:

(05 50)

Description:

This parameter is used in operation modes MONITOR and


CONSTANT CURRENT.
%I.lim is the absolute maximum error tolerance in case
the current is below the setpoint.
In operation mode Monitor the setpoint current is set with
parameter [I.Dgs.:].
The tolerance limit does not refer to the value 'Weld
alarms threshold' given in menu SETUP - CONFIGURATION
WELD334m. For this reason error 'E031 - Meas.cur. <
lim threshold' will be issued as soon as the measured
effective average current is below the absolute limit.
The tolerance range between minimum and absolute
maximum error (area C in previous example) is also called
conditional tolerance range.
The error message 'E031 - Meas.cur. < lim threshold'
can be configured in menu SETUP - ALARMS
CONFIGURATION with abort function (see section 3.3).
In the HHT this parameter is present in following operation
modes exclusively: Monitor, Const.Cur., Seam M., Seam
C.C.

4.4.7.22

Electrode force tolerance [%T. Prs:]


Parameter type: Editable field with numerical value
Limits:

(00 50)

Description:

This parameter is necessary for process control on the


welding spot in progress.
[%T. Prs:] is the positive and negative percentage
deviation of the electrode force from the programmed
nominal value that is allowed. The nominal reference value
is that set at parameter P1, which expresses the
electrode force in kN (kilo-Newton).
The welding control continually monitors the electrode
force, through an analog signal generated by the installed
force sensor. During the welding cycles the value of the
force measured is accumulated, and at the end of welding
the mean value is calculated, then verified with the limits
set. When the set limit is passed the error message E015
Electrode force outside tolerance is generated.
Error message E015 Electrode force outside
tolerance
this may be configured as a blocking
alarm in the SETUP menu ALARM CONFIGURATION (see
point 3.3).
By setting it to 0 (zero) the diagnostic control is
disenabled. Values between 0 and 5 are considered as 5 in
calculating the control band.
When diagnostics is enabled, the presqueeze and squeeze
cycles are performed in automatic mode: if the set value
of the electrode force is reached before the phases of
Presqueeze and Squeeze have been performed, the
welding phase follows immediately.

GF WELDING

4-25

Programming instructions
Weld programs
Use of this diagnostic function depends on an electrode
force sensor being included in the plant, and on the correct
parameter designation of the sensor characteristics in the
SETUP menu GUN PARAMETERS (see point 3.2).
In the software versions in which it is supported, this
parameter is present on the key-board for all welding
modes.

4.4.7.23

Electrode Force Diagnostic Mode [%T. Prs:]


Parameter type: Editable field with preset value
Preset values:(PROC - WAIT)
Description:

This parameter is necessary to configure the electrode


force diagnostic method before welding.
By setting it to the PROC mode, the welding control
exclusively makes diagnostics of the electrode force.
By setting it to the WAIT mode, at the end of the
Squeeze cycles, the welding control checks whether the
instant value of the electrode force is within the set
tolerance.
In the affirmative case, the welding cycle continues. In the
negative case, the device waits until the set field of force
is reached.

In the software versions in which it is supported, this parameter is present


on the key-board for all welding modes.
4.4.7.24

Spot repetition [Rtr:]


Parameter:

a numeric value must be specified

Range:

(00 10)

Description:

This parameter enables welding to be repeated up to a


maximum of N ( max. 10 ) repetitions. Following error
messages may occur:
E005 - Meas.curr.<min threshold
E031 - Meas.curr.<lim threshold
E032 - Null welding current
This parameter is used for operation modes MONITOR and
CONSTANT CURRENT only.

4-26

GF WELDING

Programming instructions
Weld programs
4.4.7.25

Firing angle limitation [Ang:]


Parameter:

a numeric value must be specified

Range:

(20 100)(Unit = degree)

Description:

This parameter is for diagnostics only. The message E011


- Firing angle < min.value is issued in case the
thyristor is controlled by a firing angle, which is less as the
value specified in [Ang.].
This determines the power limitations of a welding
equipment. Changes of the electric circuit are indicated,
which may be caused by cable wear for instance.
Please consider the phase angle when specifying this
value. For example CosPhi = 0,707 the lower limit for Ang
is 45 degrees, for CosPhi = 0 the lower limit for Ang is 90
degree.
This parameter is used for Const.Current and Seam.C.C.
only.

Example: Firing angle with ohmic load


Following graph shows the moment, where the firing of the thyristor is
executed. The firing angle is the delay between voltage zero crossing and
one of the two thyristors is fired and current is initiated.
In case firing angle is 0, the thyristors will let current pass throughout one
half of a wave, resulting in a rather high current in the secondary circuit of
the transformer.
In case firing angle is 45, the resulting current will be high.
In case firing angle is 90, the resulting current will be average.
In case firing angle is 135, the resulting current will be less.

In operation mode CONSTANT CURRENT the firing angle will change


dynamically due to parasitic effects in order to keep the programmed
welding current [I.Prg:] in kA constant (see section 4.4.7.32).

SCR firing
V[ V ]

180
20

angle.[ ]

100
area, where the firing
angle limitation can be
defined

GF WELDING

4-27

Programming instructions
Weld programs
4.4.7.26

Sheet thickness [Th.1, Th.2, Th.3]


Type of parameter :Editable field with numerical value
Limits:

(00.00 99.99)

Description:

Thickness of the sheet metal to which the welding spot is


applied with possibility to define three thicknesses.
The set values are summed to define the overall thickness
of the spot to be welded.
These data are used to inform the robot with the electric
gun of the thickness to be reached with electrode closing.
Once this thickness is reached, through the proportional
servovalve, the electric gun applies the pressure
programmed in the welding programme menu.
In the case of a welding control connected to the WMS
centralizer, the thicknesses of the sheet metal may be
defined in the welding programme menu at User
Parameters.

4.4.7.27

Up-slope [ Up_S:]
Parameter:

a numeric value must be specified

Range:

(00 99) (Unit = cycle)

Description:

This is the time for the current to increase from the


minimum value to the setpoint. The number of cycles is
within welding time.
This function is useful to avoid sparking and increase
lifetime of electrodes.
The linear increase of the current from the minimum to the
setpoint is called up-slope.
At 00 the first weld cycle is executed with the programmed
welding current.
In case of a higher number of cycles than 00 , the current
will increase constantly within the given cycles to the
setpoint.
It is not allowed to specify more up-slope cycles than Weld
cycles.
In case of pulsation type Normal the up-slope will be
effective for the first pulse only.
In case of pulsation type Special the up-slope will be
effective and specified for each pulse.
In all three types of seam welding (Special pulse only), the
up-slope of the second pulse will start at the same value,
where the previous pulse has ended. The same is valid for
the succeeding pulses.

4-28

GF WELDING

Programming instructions
Weld programs
4.4.7.28

Down-slope cycles [ Dw_S: ]


Parameter:

a numeric value must be specified

Range:

(00 99) (Unit = cycle)

Description:

This is the time for current to decrease from the setpoint


to the minimum value at the end of the weld time. The
time is within weld time.
The linear decrease of the welding current from the
setpoint to the minimum value is called down-slope.
In case 00 is specified the last welding cycle will be
executed with the programmed welding current I.Prg. In
case a higher number of cycles is specified, the welding
current will decrease constantly from the setpoint to the
minimum value.
It is not allowed to specify the down-slope with a higher
number than weld cycles.
The parameter down-slope does not exist for the three
kinds of seam welding.
For pulse type Normal the down-slope is effective during
the last pulse only.
For pulse type Special the down-slope is specified for each
pulse.

GF WELDING

4-29

Programming instructions
Weld programs
Graph with applied up-slope and down-slope for pulse type Normal
Following graph shows a welding program, which consists of 3 pulses type
normal [PLS:N:03] in operation mode Normal, Monitor and Const.Current.

the current is the same for each pulse

4 up slopes [Up_S:4]and 2 down slopes [Dw_S:2] are specified

Each pulse takes 6 cycles [Weld:6]

The cool time between each pulse is 2 cycles [Wait: 02]

I
[KA]

T[cycles]

Graph with up-slope and down-slope for pulse type Special


Following graph shows a welding program, which consists of 3 pulses type
Special [PLS:S:03] with the operation mode Normal, Monitor and
Const.Current.

The first pulse (warm-up) takes 4 cycles [Weld:04].

The cool time, which separates it from the next pulse, takes 2 cycles
[Wait:02]. The current is set to 6 kA [I.Prg:6.0].

The second pulse (actual welding) takes 7 cycles [Weld:07]. 4 cycles upslopes are specified [Up_S:04]. The cool time, which separates it from the
next pulse, takes 3 cycles [Wait: 04]. The welding current is set to 8kA
[I.Prg:8.0].

The third pulse takes 10 cycles [Weld:10]. 3 cycles up-slope [Up_S:03] and
2 cycles down-slope [Dw_S:02] are specified. The cool time, which separates
it from the begin of the hold time, takes 0 cycles [Wait: 00]. The welding
current is set to 4 kA [I.Prg:4.0].

I
[KA]

8
6
4
2

T [cycle]

4-30

GF WELDING

Programming instructions
Weld programs
Graph with up-slope for pulse type Special in seam-weld operation
Following graph shows a welding program, which consists of 3 pulses type
Special [PLS:S:03] in operation mode Seam weld. Down-slope does not
exist for seam-welding.

The first pulse takes 4 cycles [Weld:04]. 2 cycles up-slopes are specified
[Up_S:02]. The welding current is set to 6kA [I.Prg:6.0].

The second pulse takes 7 cycles [Weld:07].4 cycles up-slopes are


specified [Up_S:04]. The welding current is set to 8kA [I.Prg:8.0].

The third pulse takes 10 cycles [Weld: 10]. 3 cycles up-slopes are
specified [Up_S:03] and the cool time, which separates it from the next
pulse, is set 0 [Wait:00]. The welding current is set to 4kA [I.Prg:4.0].

I
[KA]

8
6
4
2

1st Impuls

4.4.7.29

2nd Impuls

3rd Impuls

T [cycle]

Cool time [ Wait: ]


Parameter:

a numeric value must be specified

Range:

(00 99) (Unit = cycle)

Description:

This is the time without current between pulses (see


section 4.4.7.5).
For the pulse type Normal the cool time [Wait:] is
specified once and valid for each pulse.
For the pulse type Special the cool time [Wait:] must be
specified for each pulse.

4.4.7.30

Weld time [Weld] :


Parameter:

a numeric value must be specified

Range:

(00 99) (Unit = cycle)

Description:

This is one of the two most important parameters, which


define the quantity of heat in the weld nugget. (The
second parameter is the Weld current [I.Prg: ].)
The number of cycles is defined, where current shall flow.
For pulse type Normal the weld cycles [Weld: ] are set
once and are valid for each pulse.
For pulse type Special the weld cycles [Weld: ] are set for
each pulse.

GF WELDING

4-31

Programming instructions
Weld programs
4.4.7.31

Delayed firing of first half-cycle [ 1^Ang: ]


Parameter:

a numeric value must be specified

Range:

(030 135)

Description:

Sets an upper limit to the firing point of the thyristor for


the first half cycle. This parameter is used to adapt the
firing angle to the electric characteristics of the welding
equipment and to avoid transformer saturation and
transient actions of primary circuit.

(Unit = degree)

Standard: 90
Sets an upper limit to the firing point of the thyristor for
the first half cycle. Any wrong setting will result in a wrong
current consumption from the mains which, in turn, might
cause the intervention of safety devices along the supply
line.
4.4.7.32

Welding current [ Pwr %: ]


Parameter:

a numeric value must be specified

Range:

(000 100)

Description:

Pwr % is the percentage value of the max available


electric current value of the weld device at correct CosPhi
setting.
The control operates with a fixed firing angle of the
thyristors. This angle does not change throughout the
welding operation (range 20 - 100%).
This parameter does exist for NORMAL, MONITOR, SEAM
N., SEAM M, Cycle N. and Cycle M.

4.4.7.33

Diagnostics current

[ I.Dgs.:]

Parameter:

a numeric value must b specified

Range:

(000.0 150.0)

Description:

This current value is used as reference value for


calculation of the tolerances in the MONITOR operation
mode. It must be measured with external tools.

(Unit = kA)

This parameter exists for MONITOR and SEAM M. and


Cycle M.
4.4.7.34

Blanking cycles [Blank: ]


Parameter: a numeric value must be specified
range:
Description:

(00 99)

(Unit = cycle)

This specified the number of weld cycles after begin of


weld time where no current monitoring and regulation is
done in order to compensate parasitic effects.
Blanking cycles enable unstable operations which are
coming from bad contacts, oxidized layers on the metal
surface, bad matching shapes etc.
Override unstable condition at start of current flow.
This parameter is used for the operation
CONSTANT CURRENT and SEAM C.C. only.

4-32

GF WELDING

modes

Programming instructions
Weld programs
4.4.7.35

Welding current programmed in kA

[ I.Prg.: ]

Parameter:

a numeric value must be specified

Range:

(000.0 150.0)

Description:

Set point of welding current in kA, which is used for


operation mode CONSTANT CURRENT.

(Unit = kA)

This parameter is used for the operation


CONSTANT CURRENT and SEAM C.C. only.
4.4.7.36

Measured welding current

modes

[ I: kA ]

Parameter:

variable text, can not be edited

Range:

(000.0 150.0)

Description:

The average effective current is displayed in real time.


Blank time and up-down-slope is not taken into account.

(Unit = kA)

The current value appears only in case a welding operation


with the selected program is executed.
The current value is updated after each weld.
This parameter is only used in the operation modes
MONITOR, CONSTANT CURRENT, SEAM M., SEAM C.C.,
Cycle N. and Cycle M.

GF WELDING

4-33

Programming instructions
Weld programs

4-34

GF WELDING

Programming instructions
Stepper programs

<F3 STEPPER>

5 STEPPER Menu

This program is used for compensation of electrode wear.


It is applied to current and pressure and also organize tip dressing and tip
change.
To execute a stepper program, following conditions must be fulfilled:

One or more welding programs must be assigned to the stepper


program.

In the welding programs the equivalent energy value (VEE) must be


bigger than 1 (10 is recommended, so each spot will be counted).

16 steppers are available. Each stepper means one spot counter, which is
assigned to one welding gun or one pair of electrodes.
Following parameters have to be set in the stepper menu:

Request and prewarnings concerning dressing and change of electrodes

Increase of welding current and electrode force

The electrodes wear due to welding and the quality of the spots
deteriorates.
Due to electrode wear the contact area of the electrodes increases, which in
results in less current density and less force per area.
To compensate, current and force are increased in dependency of the
number of spot welds and the electrodes will be dressed.
When executed, each welding program increments the value of current of
related stepper (see point 5.4) in a way proportional to the Equivalent
Energy Value stated in the program (see Art. 4.4.7.12).
In the stepper menu all parameters of the 16 current increment programs
(stepper) are defined. In the STEPPER menu a list of all steppers appear
together with all main parameters, date, time of last modification.
Following table shows a part of the menu STEPPER (only 7 out of 16
steppers):

STEPPER
S01

P 900

S 1000

S02

Gun 2

P 900

S 1000

C 124

Tu 10/02/1998 10:11:32

S03

Gun 3

P 1200

S 1400

22

Mon 16/02/1998 11:51:04

S04

PART.33

P 700

S 1000

S05

PART.47

P 700

S 800

C 650

Tu 10/02/1998 09:21:44

S06

>

Gun 1

Gun 8

P 900

S 1000

C 342

Mon 16/02/1998 09:11:19

17

Mon 16/02/1998 09:14:23

Tu 16/02/1998 18:11:55

S07

Column A: here the cursor is moved by using the arrow keys .


Column B: Order number (from S01 to S16)
Column C: Name of Stepper (mnemonic)
Column D: Number of spot welds, when prewarning shall be issued (see
section 5.6.3.5).
Column E: lifetime (see section 5.6.3.6)
Column F: number of spot welds executed, actual counter status (see
section 5.4)
Column G: date and time of creation or modification.

GF WELDING

5-1

Programming instructions
Stepper programs
The content of the columns can be changed. To do this select a stepper by
using key F1 EDIT. Column F, the actual counter status, can be changed
with key F2 PRESET (see section 5.4)
Column G is displayed in alternative to columns D E F after pressing
the arrow keys .
The + and - keys shift the stepper, where the cursor > is located, by 5
positions.
Page of Stepper menu
STEPPER

>

S01
S02
S03
S04
S05

GUN 1
GUN 2
GUN 3
PART.33
PART.47

EDIT

COPY

95

S 1000

90

S 1000

C 124

95

S 1400

22

95

S 1000

95

S 800

C 650

PRINT

ETC

CLEAR

17

Other commands available in the Stepper menu


RESET

PRESET

ETC

Function keys in menu STEPPER PROGRAMS


F1 EDIT:
F2 COPY:

copy function will be initiated (see section 5.1)

F3 CLEAR:

clear function will be initiated (see section 5.2)

F4 PRINT:

all parameters of the stepper, which is selected by the


cursor, will be printed

F5 ETC:

all remaining functions, which are not displayed yet, will


be shown

F1 RESET:

resets spot counter (see section 5.3)

F2 PRESET:

5-2

marked stepper will be edited, where cursor > is located in


column A

function to change the content of spot counter (see section


5.4)

GF WELDING

Programming instructions
Stepper programs

5.1 Copy steppers

F2 COPY

In this menu steppers can be copied. This means to transfer data from one
stepper to another stepper.

COPY Page of Stepper menu


COPY STEPPER PROGRAMS

>

S01
S02
S03
S04
S05

GUN 1
GUN 2
GUN 3
PART.33
PART.47

95

S 1000

90

S 1000

C 124

95

S 1400

22

95

S 1000

95

S 800

C 650

SELECT

17

COPY

Example: Copy parameters of stepper 2 (S02) to stepper 7 (S07). Stepper


2 must contain data whereas stepper 7 may contain data but
must not be edited.
1. Push function key F2 COPY in menu STEPPER and COPY
STEPPER PROGRAMS will appear in the upper display bar. Key
F1 will select and key F5 will copy.
2. Move the cursor by using the arrow keys to the stepper
(source) which shall be copied.
3. Use F1 SELECT or ENT key to select the stepper, which shall
be copied (in column A, line S02 a star * will appear)
4. Move the cursor to S07 by using the arrow keys to the
stepper (target) where the parameters shall be copied.
5. Push F5 COPY and all parameters of stepper S02 will be
transferred to S07.
6. To return back to the STEPPER menu use the ESC key.

5.2 Clear Stepper

F3 CLEAR

CLEAR page of Stepper menu


CLEAR STEPPER PROGRAMS

>

S01
S02
S03
S04
S05

SELECT

GUN 1
GUN 2
GUN 3
PART.33
PART.47

95

S 1000

90

S 1000

C 124

95

S 1400

22

95

S 1000

95

S 800

C 650

ALL

17

CLEAR

GF WELDING

5-3

Programming instructions
Stepper programs

Example: Clear stepper S05.


1. Push F3 CLEAR and CLEAR STEPPER PROGRAMS will appear in
the upper display bar. Function key F1 selects and key F2
selects all steppers. Function key F5 will initiated clear
function.
2. Move the cursor by using the arrow keys to stepper
S05,which shall be cleared.
3. To select the stepper, which shall be cleared, push F1 SELECT
or ENT key (the star * will appear in column A, line S05). In
case all steppers of the control shall be cleared, push key F2
ALL (the star * will appear next to all steppers, which contain
data). In order to cancel the selection, press F2 ALL again.
4. Push key F5 CLEAR and following message will appear:
'CONFIRM? [ENT = YES / ESC = NO ]'
5. Confirm with ENT key.
6. Return to menu STEPPER by using the ESC key.

5.3 Reset spot counter

F1 RESET

In menu RESET following operations will be carried out:

Confirmation of successful dressing of electrodes (also possible with


external input signal RAVOK).

Confirmation of successful electrode exchange (also possible with


external input signal CHGEOK).

In order to reset the spot counter perform following steps:


1. Press ESC key to go back to main menu.
2. Press F3 STEPPER and the directory of steppers will appear.
3. Press F5 ETC
4. Press F1 RESET and menu RESET STEPPER PROGRAMS will be entered.
The Table below partially describes an example of the RESET STEPPER PROGRAMS
menu (6 out of 16 steppers).

RESET STEPPER PROGRAMS


S01

S 1000

17

S02

GUN 2

S 1000

C 124

S03

GUN 3

S 1400

22

S04

PART.33

S 1000

S05

PART.47

S 800

C 650

S06

>

GUN 1

GUN 8

S 1000

C 342

S07

Column A: in this column the cursor is moved by using the arrow keys
to select the stepper, which shall be reset
Column B: Order number (from S01 to S16)
Column C: Stepper name (mnemonic)

5-4

GF WELDING

Programming instructions
Stepper programs
Column D: Lifetime (see section 5.6.3.6)
Column E: actual counter status (see section 5.4)
Column F: number of dressings executed (status of dressing counter, see
section 5.6.1)
PAGE RESET STEPPER PROGRAMS

RESET STEPPER PROGRAMS

>

S01
S02
S03
S04
S05

GUN 1
GUN 2
GUN 3
PART.33
PART.47

SELECT

S
S
S
S
S

1000
1000
1400
1000
800

C 17
C 124
C 22
C 0
C 650

ALL

DRESS

4
5
0
0
0
CHANGE

Function keys in menu RESET STEPPER PROGRAMS


F1 SELECT:

the stepper, where cursor > is located, will be selected for


reset.
In case a stepper is selected, the star * will appear next to
it. The selection can be cancelled by pushing F1 SELECT
again.

F2 ALL:

All steppers will be selected

F4 DRESS:

this key confirms that dressing is finished

F5 CHANGE:

this key confirms that electrode exchange is finished.

The + and - keys shift the stepper where cursor > is located by 5 positions.
Example: Confirmation dressing
A gun (channel A) is assigned to stepper 2 (S02).
This gun works with Program 5 (P05) where the parameters are set as
follows :Stp_:02 and VEE_:10, each spot executed with P05 will increase
the counter S02 by 1.
Stepper 2 is configured with DRESS 1.
The lifetime of a new electrode is 1000 spots. After dressing it must be
started with a higher current, which is the same as for a new electrode after
30 weldings. Therefore offset must be set 30 (Stop_:1000 Offset___:30).
The electrodes are dressed 8 times before exchange (Dressing__: 8).
After execution of 1000 spot stepper 02 issues the message E049 and
dressing of the appropriate electrodes must be done.
In order to confirm, that dressing of the electrodes is finished, following
steps must be performed:
1. Press ESC key, to return back to main menu
2. Press F3 STEPPER
3. Press F5 ETC key
4. Press F1 RESET and menu RESET STEPPER PROGRAMS will be entered
5. Move the cursor to stepper S02 by using the arrow keys.
6. Push key F1 SELECT
7. Push key F4 DRESS

GF WELDING

5-5

Programming instructions
Stepper programs
In column E the offset value C 30 (actual counter status of stepper) will
appear. In column F '1' will appear (status of dressing counter).

5.4 Modify stepper counter content

F2 PRESET

The actual counter status of the stepper shows the number of executed spot
since:
Last dressing or last electrode exchange (in operation mode DRESSING 1)
Last electrode exchange (in operation mode DRESSING 2)
In case of changed electrode wear the actual counter status may have to be
adapted.
In menu STEPPER the counter status is shown in column F: 'C_____' (see
section 5).
Example: change of stepper counter content of Stepper S30
1. Push key F5 ETC in menu STEPPER. Key F1 is assigned to function
RESET. Key F2 is assigned to function PRESET.
2. Move the cursor to Stepper S03, which shall be modified.
3. Push key F2 PRESET and following window will appear

Preset counter __:00022

4. Use +/- keys to increase or decrease the counter.


5. Use arrow keys to move the cursor to the position which shall be
changed. Use also +/- keys for change actual counter position.
6. Confirm the new value with ENT key or cancel it by pushing ESC key.
The old counter status will remain.

5-6

GF WELDING

Programming instructions
Stepper programs

5.5 Relevant I/O Signals for steppers:


Input RESALSA (reset counter A) will reset error message E049 (Stepper
alarm channel A).
Input RESALSB (reset counter B) will reset error message E050 (Stepper
alarm channel B).
Input RAVOK (dressing done) will set back output RICHRAV and following
operations will be carried out in dependency on the selected dressing mode:

Dressing 1: the dressing counter will be increased by 1. In case an offset


is set, the actual stepper counter will start with the offset value (see
section 5.6.3.7). In case no offset is set, counter will be set to 0.

Dressing 2: the dressing counter is decreased by the number of spots /


dressings (see section 5.6.4.2).

Input CHGEOK (exchange of electrodes is done) will set back output


RICHRAV and following operations will be carried out in dependency on the
selected dressing mode:

Dressing 1: the dressing counter will be reset (see section 5.6.1) and
the actual counter status is set to 0.

Dressing 2: the counter will be set to 0 (see section 5.6.2).

RESALSA
(reset Counter A )

WELD
334m

RESALSB
(reset counter B)

WALLST.A
(Prewarning Stepper A)
WALLST.B
(Prewarning Stepper B)
ALLSTA
(Alarm Stepper A)

RAVOK
(Dressing done)

ALLSTB
(Alarm Stepper B)

CHGEOK
(Electrode exchange done)

ALARM2
(Alarm)
RICHRAVV
(Request dressing)
RICHEL
(Request Electrode exchange)

Output WALLST.A (Alarm E001 Stepper prewarning channel A) will be high


as soon as the limit is reached, which is defined in the stepper for the
electrodes of channel A (see section 5.6.3.4).
Output WALLST.B (Alarm E002 Stepper prewarning channel B) will be high
as soon as the limit is reached, which is defined in the stepper for the
electrodes of channel B (see section 5.6.3.4).

GF WELDING

5-7

Programming instructions
Stepper programs
Output ALLSTA (Alarm E049 Stepper alarm channel A) will be high as soon
as the lifetime is reached, which is defined in the stepper for the electrodes
of channel A (see section 5.6.3.7).
Output ALLSTB (Alarm E050 Stepper alarm channel B) will be high as soon
as the lifetime is reached, which is defined in the stepper for the electrodes
of channel B (see section 5.6.3.7).
Output ALARM2 (Hardware error) will be high as long as error E066
(dressing not done) or E067 ('Electrode not changed') is active.
Output RICHRAV (Request dressing) will be high dependant on the selected
dressing mode:

Dressing 1: output RICHRAV will be high as soon as the lifetime is


reached, which is defined in the stepper (see section 5.6.3.5)

Dressing 2: output RICHRAV will be high as soon as the number of


counts is reached, which is specified with 'Pt.x Dressing_:' (see section
5.6.4.2).

Output RICHEL (request exchange of electrodes) will be high dependant on


the selected dressing mode:

5-8

Dressing 1: Output RICHEL will be high as soon as the lifetime is


reached, which is defined in the stepper, and all programmed dressings
were done.
Dressing 2: Output RICHEL will be high as soon as the lifetime is
reached, which is defined in the stepper (see section 5.6.4.1).

GF WELDING

Programming instructions
Stepper programs

5.6 EDIT (Creation and modification of stepper)

F1 EDIT

The control allows, to configure the stepper for two kind of dressings:
1. Stepper with Dressing1: Dressing in cycles (saw tooth curve)
2. Stepper with Dressing2: Dressing in intervals

5.6.1

Dressing 1
Stepper page in Dressing 1 mode
S:09

: Dressing 1

:GFX

Prewarning__: 000

Pt.x Pieces____: 000

Stop_______: 00000

Pt.x Emergency : 00

Dressing____: 000
Offset_____ : 00000
: OFF
INC

SAVE

STEP -

STEP +

ETC

Other commands available in the Stepper menu


INC

CLR I

CLR P

ETC

Dressing, which is repeated in cycles, as programmed by the operator


(dressing according curves).
After completion of all dressing cycles, electrode exchange will be
requested.
The actual counter status of the stepper is resetted after each dressing and
be set according the offset value.
In operation mode Dressing 1 a second counter is activated, which is called
Dressing counter. It counts all dressing cycles. The counter content of the
dressing counter is shown in column F. In case the dressing counter reaches
the value as specified in parameter 'Dressing___:', exchange of the
electrodes will be requested (see section 5.6.3.8).
The error messages concerning electrode-prewarning (E001) will be issued
before each request for electrode exchange (as soon as the prewarning
limit is reached as defined in %).
The messages concerning lifetime (E049 and E050) will be issued together
with request for dressing or electrode exchange.
The message E066 Electrode not dressed will be issued when the
parameter 'Pt.x Emergency:' is surpassed. Counting of 'Pt.x Dressing:'
starts after the lifetime has been reached.
The message E067 Electrode not changed will be issued when the
parameter 'Pt.x Emergency:' is surpassed. Counting of 'Pt.x Emergency:'
starts after the request for electrode exchange was issued.

GF WELDING

5-9

Programming instructions
Stepper programs

5.6.2

Dressing 2
The menu for editing a stepper set to the DRESSING 2 mode looks as
follows:

S:09

: Dressing 2

:GFX

Prewarning__: 00000

Pt.x Pieces____: 000

Stop_______: 00000

Pt.x Dressing__: 00000


Pt.x Emergency: 00

INC

SAVE

STEP -

STEP +

ETC

Other commands available in the Stepper menu


INC

CLR I

CLR P

ETC

This will request dressing of the electrodes in predefined intervals.


(Interval dressing)
The request to change the electrodes is issued when the number of spots
programmed in the Stop parameter is reached.
The actual counter status will be reset after electrode exchange only.
The value of the dressing counter will have no effect and is displayed in
column F as shown in section 5.3.
The prewarnings E001 and E002 are issued before each request to
exchange electrodes.
The stepper alarms E049 and E050 (when Stop parameter is attained) are
issued together with the request to exchange the electrodes.
The 'Electrode not dressed' error E066 is issued when the parameter 'Pt.x
Emergency:' is surpassed. Counting of 'Pt.x Emergency:' starts after the
value of the parameter 'Pt.x Dressing' has been reached.
The 'Electrode not changed' error (E067) will be issued as soon as the
parameter 'Pt.x Emergency' is surpassed. Counting of the 'Pt.x Emergency'
starts as soon as the number of spots defined in the Stop parameter.
Example: Edit stepper
A stepper shall be edited, which does not contain data yet:
1. Press ESC key to return back to the main menu
2. Press key F3 STEPPER
3. Move the cursor next to S09 using the arrow key
4. Press key F1 EDIT
First the dressing mode must be specified:
In this example the dressing mode Dressing 2 shall be selected.
In order to change the dressing mode, perform following steps:
1. To move the cursor to the field where the dressing mode can be edited,
push the arrow key twice.
2. Push + key one time to change the dressing mode from Dressing 1 to
Dressing 2.
By using the function keys, the user can edit parameters relating to the
stepper to be edited.

5-10

GF WELDING

Programming instructions
Stepper programs
All the editable fields must be within the predetermined limits (if not, the
Save function of data will not be enabled).
Function keys in menu EDIT STEPPER:
F1 INC:

calls the page for programming stepper curve (see section


5.6.5)

F2 SAVE:

saves all changes in the stepper program. In case all data


have been specified correctly, the star in the upper right
corner will disappear.

F3 STP -:

proceeds to the previous stepper program

F4 STP +:

proceeds to the next stepper program

F5 ETC:

the function keys F1 INC; F2 CLR I; F3 CLR P; F5 ETC will


be displayed

F2 CLR I:

clears the current increment curve

F3 CLR P:

clears the pressure increment curve

F5 ETC

5.6.3

the function keys F1 INC ; F2 SAVE ; F3 STP - ; F4 STP + ;


F5 ETC will be displayed

Parameter for Dressing 1


All parameters for editing a stepper with Dressing 1 mode are described in
the following.

5.6.3.1

Stepper number [ S: ]
Parameter:
Range:

(01 16)

Description:

5.6.3.2

a numeric value must be specified

this is the order number of the stepper, which shall be


edited. In case the cursor is located on another field, the
next (STP +) or the previous (STP -) stepper can be called.
When the stepper number is changed, all parameters will
adapt automatically. This parameter is also shown in
column B in the stepper table (see section 5).

Stepper name

[:]

Parameter:

a character value must be specified

Range:

(8 signs, the first sign must be a letter)

Description:

definition of an individual name

Stepper name (mnemonic only). This parameter is also shown in column C


in the stepper table (see section 5).
5.6.3.3

Dressing mode

[:]

Parameter:

a preset value must be selected

Settings:

(Dressing 1 - Dressing 2)

Description:

See section 5.6.

GF WELDING

5-11

Programming instructions
Stepper programs
5.6.3.4

Stepper data format [ : ]


Parameter:
Settings:

(GFX - TAB)

Description:

5.6.3.5

a preset value must be selected

selection of the increment method. Two types of increment


curve are available: Graphic (GFX) or Tabular (TAB)
mode. Refer to paragraph 5.6.5.

Prewarning__:
Parameter:

a percent value must be specified

Range:

(1 100)

Description:

This limit defines the interval of welding for indication


when the electrode must be exchanged. The value must
refer to the lifetime of the electrodes.

Unit: %

Example: For Stop=1000 and Dressing__:7, the lifetime


of the electrodes is 1000x(7+1)=8000.
In case a prewarning shall be issued 450 spots before end
of electrode lifetime, then the welding interval for the
prewarning will be: 8000-450 = 7550.
In percentage: 100 x 7550/8000 = 94,37%
approx. 94%
As soon as this limit is reached the error message E001 or
E002 will be issued. This error messages are issued before
each request to exchange the electrodes.
5.6.3.6

Stop_______:
Parameter:

a numeric value must be specified

Range:

(1 65500)

Description:

Number of spot welds which generates the Electrode Alarm


(E049 and E050).

Unit: number of spots

This message comes together with the request for tip


dressing or electrode exchange.
5.6.3.7

Dressing_:
Parameter:
Range:

(0 250)

Description:

5.6.3.8

a numeric value must be specified

this is the maximum number of dressings before a change


of electrodes is performed.

Offset_______:
Parameter:

a numeric value must be specified

Range:

(0 65500)

Description:

After each dressing the stepper counter is set to the offset


value. This means the welding current after dressing is not
the same as the current after electrode exchange (starting
point of each cycle).

Unit: number of spot

The offset is only valid when the parameter below is set to


ON.

5-12

GF WELDING

Programming instructions
Stepper programs
5.6.3.9

Pt. x Pieces _______:


Parameter:

a numeric value must be specified

Range:

(1 - 100)

Description:

Number of spots per piece. This value is mandatory only


for WMS for indication of remaining spots in the
prewarning table.

5.6.3.10

P.x Emergency :
Parameter:

a numeric value must be specified

Range:

(00 - 99)

Description:

This parameter (when it is set higher than 0) permits, to


execute a certain number of welds higher than lifetime of
the electrodes, before a stop caused by following errors
will occur: It is recommended to specify a value, which is
equal to the number of spots per piece.

Unit: number of spot welds

5.6.4

The error 'Electrode not dressed (E066) is issued as


soon as the number of spots surpasses the value Pt.x
Emergency. Counting of Pt.x Emergency starts after
lifetime is surpassed.
The error 'Electrode not changed (E067) will be issued
as soon as the number of spots surpasses the value
Pt.x Emergency. Counting of Pt.x Emergency starts
after exchange of the electrodes has been requested.

Parameter for Dressing 2


How to edit all stepper parameters in operation mode Dressing 2 is
described in the following.
The following parameter are the same as in operation mode Dressing 1. For
this reason refer to previous sections:

Stepper number [ S: ] (see section 5.6.3.1)

Stepper name

[ : ] (see section 5.6.3.2)

Dressing mode

[ : ] (see section 5.6.3.3)

Tabular/Graphic mode (GFX-TAB) (see section 5.6.3.5)

Prewarning

Stop_______:(see section 5.6.3.6

Pt.x Pieces_______:

[:] (see section 5.6.3.5)

(see section 5.6.3.9)

GF WELDING

5-13

Programming instructions
Stepper programs

5.6.4.1

Pt.x Dressing_ :
Parameter:
Range:

(0 65500)

Description:

5.6.4.2

a numeric value must be specified

the dressing interval is the number of spots between two


dressing operations.

Unit : number of spot welds

Pt.x Emergency:
Parameter:

a numeric value must be specified

Range:

(00 - 99)

Description:

This parameter (when it is set higher than 0) permits, to


execute a certain number of welds higher than lifetime of
the electrodes, before a stop caused by following errors
will occur: It is recommended to specify a value, which is
equal to the number of spots per piece.

Unit: number of spot welds

5-14

The error 'Electrode not dressed (E066)' is issued as


soon as the number of spots surpasses the value Pt.x
Emergency. Counting of Pt.x Emergency starts after
lifetime is surpassed.
The error 'Electrode not changed (E067)' will be issued
as soon as the number of spots surpasses the value
Pt.x Emergency. Counting of Pt.x Emergency starts
after the number of spot welds set in the Stop
parameter has been reached.

GF WELDING

Programming instructions
Stepper programs

5.6.5

Stepper: Current - and pressure increment curve


The increase of welding current and electrode force (only if a proportional
valve is used) can be specified in the appropriate page.
Assuming a stepper with current increment is assigned to welding program,
the welding current will increase due to the number of executed spots
(counter status CNT) according the curve.
Assuming a stepper with pressure increment is assigned to a welding
program, the electrode force will increase due to the number of executed
spots (counter status CNT) according the curve.
The increment curve follows the stepper counter. For this reason following
is valid:
If the increment curve is assigned to a stepper with DRESSING 1-MODE,
the coordinate origin is equal to the new condition of the electrode or
dressed electrode. The end of the curve is equal to the parameter
Stop___:.

If the increment curve is assigned to a stepper with DRESSING 2-MODE,


the coordinate origin is equal to the new condition of the electrode. The
end of the curve is equal to the parameter Stop___:, which is the same
as the lifetime of the electrode.

The increment trend during the electrode lifetime may be created either in
the Graphic form (GFX), by a curve, or managed in the Tabular form
(TAB). Both methods are programmed in the Increment page and each of
them features a specific programming procedure.
The Increment method can be selected directly in the Edit menu of the
Stepper program concerned. To do this, move the cursor to the field next to
the Dressing Mode and, by means of the or + keys, select the GFX or
TAB option (see figure below).
GFX
S:09

+
TAB

: Dressing 1

Prewarning__: 00000

:
Pt.x Pieces____: 000

Stop_______: 00000
Dressing_: 000

Pt.x Emergency: 00

Offset______: 00000
: OFF

INC

SAVE

STP -

GF WELDING

STP +

ETC

5-15

Programming instructions
Stepper programs

5.6.6

Increment with Graphic method


In the Graphic mode, the value corresponding to the electrode lifetime is
divided into 100 equal steps; for each of them and based on the increment
curve you intend to obtain, it is possible to apply the value in % of
current/pressure increment you want. Interpolation on steps is optional and
the increment curve develops on the 100 predefined steps.
The increment page of a stepper according to the Graphic method looks as
follows:

Status field for counter and increment

CURRENT
Programming page for
graphic stepper

CNT : 1
INC : 0

PAGE+

INTERP

Select current/pression

Cursor

Programmable step

On the x-axis (horizontal) the CNT of the stepper is shown.


On the y-axis (vertical) the percentage value of the increment INC is
shown.
The increment curve is specified by moving and positioning the cursor (use
arrow keys) within the coordinates vertical and horizontal.
Starting point of the cursor is the origin of the coordinates. The curves can
be increasing only.
Both variable fields, which can not be edited, specify the coordinates of the
cursor:

CNT: actual counter status. Limits (1 value set in Stop_ parameter: in


the current stepper)

INC: Increment in %. range (0 - 60 %)

Function keys in
incrementation)
F1 PAGE +:

stepper

menu

(Current

and

pressure

switch between current- and pressure-stepper

F2 INTERP:

linear interpolation of the curve

keys :

move the cursor horizontal

keys +

move the cursor vertical (by 1)

-:

keys ::
ESC key:

back to menu EDIT STEPPER

REMARK:

5-16

move the cursor vertical

Please notice in menu EDIT STEPPER the function keys F2


CLR I and F3 CLR P are available, to delete all increment
curves.

GF WELDING

Programming instructions
Stepper programs
Example: Edit Stepper - Current increment curve
A Welding gun on channel A is assigned to stepper 2 (S02). This gun is
commanded by program 5 (P05) with the parameters Stp_:02 and VEE_:10
(each welding spot carried out by P05 will increase the spot counter of S02
by 1).
Stepper 2 is set in the DRESSING 1 Mode.
New electrodes carry out 1000 spot welds and 970 spot welds are defined
between each dressing (Stop____:1000 Offset___:30).
The welding current for welding program, which is assigned to stepper 2,
shall be increased.
The increment curve shall be linear and the maximum shall be 50% before
the electrodes need to be dressed (this means: after 1000 spots).
In order to input the increment mentioned above, perform following steps:
1. Press ESC key in order to return to the main menu.
2. Press key F3 STEPPER
3. Push arrow key and move the cursor next to Stepper S02.
4. Push key F1 EDIT and you will enter the STEPPER menu.
5. Push key F1 INC and you will enter the menu: CURRENT - PRESSURE
INCREMENT CURVE.
6. If necessary push key F1 to switch from the pressure to the current
increment curve.
7. Push arrow key to move the cursor to the end of the x-axis
(parameter CNT: 1000).
8. Push arrow key or + key to move the cursor along the y-axis to the
value 50% (parameter INC: 50%).
9. Press key F2 INTERP to interpolate the axes origin and the defined point
10.Press ESC key in order to return to the previous menu
11.Push key F2 SAVE in order to dedicate the increment curve to Stepper 2.
Following graph shows the page with the increment curve:

Current
CNT : 1000
INC : 50

PAGE+

INTER

GF WELDING

5-17

Programming instructions
Stepper programs

5.6.7

Increment with Tabular method


The Tabular method allows defining freely either the entry-point of
current/pressure steps and the percent value of the increment. Practically,
the spot interval between one increment and the next one is no more
binding. Maximum number of increments which can be entered is 25 and
they may be both in the increasing and decreasing order.
Example:

stepper featuring electrode lifetime set to 10000. It is possible


to set the first increment by 7% (hypothetical) at the 2321st
sample-weld and a second increment by 5% at the 3276th
sample-weld. As you may observe, both the step interval and
the value of current increment (the second is below the first
one) are arbitrary.

In the Tabular mode, the welding control automatically performs


interpolation (between one increment and the next one) on the difference in
the % value between two increments and the resolution is 1%.
Example:

Stepper with two increments spaced by 1500 spot welds,


difference in increment 3%. Interpolation is performed
automatically by the welding control; over 1500 sample-welds
the control applies two intermediate increments resulting from
the ratio of the welds interval between the two steps and the
percent value of increment: 1500/3.
Due to interpolation, we shall have: intermediate increment by
1% at the 500th weld; intermediate increment by 1% at the
1000th weld and increment by 1% at the 1500th weld

Tabular method may be applied both for Current and Pressure Increment.
A Tabular increment cannot be converted into a Graphic increment and vice
versa; if a stepper program is edited and the method is changed, when
saving the change, the increment curve will be cleared.

The Tabular option can be selected directly on


the Edit menu of the Stepper program
concerned. To do this, place the cursor in the
field adjacent to the Dressing Mode, select TAB
option and press + key (see figure below).
S:09

GFX

TAB

: Dressing 1

Prewarning__: 00000

:
Pt.x Pieces____: 000

Stop_______: 00000
Dressing____: 000

Pt.x Emergency_: 00

Offset______: 00000
: OFF

INC

SAVE

STP -

Edit menu of stepper

5-18

GF WELDING

STP +

ETC

Programming instructions
Stepper programs
5.6.7.1

Tabular stepper Menu


The stepper curve can be programmed through the INC F1 function
key in the EDIT menu.
On the display, 3 zones are shown:
zone showing the 25 programmable steps
Field used to program the counter and % increment (+ and keys).

PAGE+ function key for current/pressure selection

Field used to program the counter and increment


CURRENT
CNT :
INC :

00000
00%

Programming page for


Tabular stepper
(1)

(25)

------------------------

PAGE +

Programmable step
Select current/pression
5.6.7.2

Cursor

Programming the Tabular increment


Programming of Steps is performed in two times:
1. Through F1 PAGE+ key select the Current or Pressure parameter to
control by means of increment.
2. Place the cursor onto the first dash of the increment bar (to move the
cursor, use the arrow keys :) and press ENT.
3. The cursor flashes in the field: making use of + and keys, type a value
of the sample-weld from which you intend to apply the increment. In the
field below, type the value of increment you want then press ENT.
The counter is programmed. If you want to log out and save, press the
ESC key and then SAVE F2 key.
If you want to proceed to the next increment, do not escape the tabular
menu but, using the arrow key , move the cursor to the adjacent position
and repeat steps from 1 to 2

CURRENT
CNT :
INC :

02325
03%

5 6

3
2
1

PAGE +

-------------------------

1:
2:
3:
4:
5:
6:

CNT=
CNT=
CNT=
CNT=
CNT=
CNT=

2325
4600
4925
5100
7000
8000

INC=
INC=
INC=
INC=
INC=
INC=

Example of Tabular Stepper:


The display type is not a linear representation of the increment curve. It is
a progressive representation of tabular values where each bar represents
an active increment (6 are shown in the figure) and the extension of the bar
itself represents the value of % increment of current or pressure.

GF WELDING

5-19

3%
5%
6%
7%
8%
9%

Programming instructions
Stepper programs

WHITE PAGE

5-20

GF WELDING

Programming instructions
Welding analysis and I/O status

<F4 TRACE>

6 TRACE menu
In the TRACE menu are displayed:

Data about the last weld (SPOT TRACE)

Status of all I/O's (I/O TRACE )

Certain special functions, if provided for, may also be performed, depending


on the type of cards present in the control.
Function keys:
F1 PROG:

Access to page SPOT TRACE (see section 6.1)

F2 I/O:

Access to page I/O TRACE (see section 6.2)

F3 TEST:

Enables special functions (see point 6.3)

F4 PRINT:

Print

Use ESC key to return to the main menu.

6.1 Parameter of page SPOT TRACE

F1 PROG

On this page to most important data of the last welding are shown.
The page SPOT TRACE looks as follows:
P :0 4 : S E IT E N T :

C o n s t. c u rr.

SPO T TRACE
C y c le s : 6
I P rg : 9 .0
I N o m : 9 .4

I . M is :

9 .4 k A

S tp :1
C n t :1 1 2 1
In c % :4
P rs 1 :0
P rs 2 :0
C P h i :0 .9 3

E000 - OK

N u m b e r o f th e
w e ld in g p u ls e
(m a x im u m 9 )

A re a w h e re a n e rro r
m e s s a g e w ill b e
d is p la y e d d u rin g
w e ld in g .

The welding pulse to be analysed can be selected by the arrow keys


(up to maximum 9 pulses).

GF WELDING

6-1

Programming instructions
Welding analysis and I/O status

6.1.1
6.1.1.1

Parameter SPOT TRACE


Program number [ P: ]
Parameter:
Range:

(01 255)

Description:

6.1.1.2

variable text, can not be edited

Number of the last executed welding program. See section


4.4.4.

Program name

[:]

Parameter:
Range:

8 signs, the first must be a letter

Description:

6.1.1.3

variable text, can not be edited

name of the active welding program. See section 4.4.7.2.

Welding mode

[:]

Parameter:
Presettings:

Normal, Monitor, Const.Curr., Seam N., Seam M., Seam


C.C.

Description:

6.1.1.4

variable text, can not be edited

Welding mode of the last executed welding program. See


section 4.4.7.3

Welding time [ Cycles: ]


Parameter:
Range:

(00 99) (Unit = cycle)

Description:

6.1.1.5

variable text, can not be edited.

time of current of the selected pulse given in periods. See


section 4.4.7.30

Nominal welding current [ I Prg.: ]


Parameter:

variable text, can not be edited.

Range:

(000.0 150.0) (Unit = kA in operation mode Const.Cur.)


(0 100)
Monitor)

Description:

(Unit = % in operation mode Normal and

Shows the starting setpoint current (without increment) of


the selected pulse.
For Normal / Monitor this is the PWR %: as specified. See
section 4.4.7.32.
For Const.Curr. this is I.Prg.: as specified. See section
4.4.7.35.

6-2

GF WELDING

Programming instructions
Welding analysis and I/O status

6.1.1.6

Setpoint current [ I Nom: ]


Parameter:

Variable text, can not be edited

Range:

(000.0 150.0) (Unit = kA in operation mode Const.Curr.)


(0 100)
Monitor)

Description:

(Unit =% in operation mode Normal and

Shows the actual setpoint current of the selected pulse


This value can be higher as specified, when current
incrementation is programmed. See section 5.6.5.

6.1.1.7

Measured welding current

[ I. Mis:

kA ]

Parameter:
Range:

(000.0 150.0)

Description:

6.1.1.8

variable text, can not be edited

Shows the actual welding current of the selected pulse.


See section 4.4.7.33.

(Unit = kA)

Stepper number [ Stp : ]


Parameter:
Range:

(0 16)

Description:

6.1.1.9

Variable text, can not be edited

This parameter shows stepper program, which is assigned


to welding program. See Section 4.4.7.7.

Stepper counter [ Cnt : ]


Parameter:
Range:

(0 65500)

Description:

6.1.1.10

Variable text, can not be edited

This parameter shows the actual counter status of the


stepper, which is assigned to the welding program. See
section 5.4.

Current increment in (%)

[ INC% : ]

Parameter:
Range:

(0 60)

Description:

6.1.1.11

Variable text, can not be edited.

This parameter shows the percentage of the specified


current increment. See section 5.6.5.

Setpoint Electrode force 1

[ Prs1: ]

Parameter:

Variable text, can not be edited

Range:

(00.00 30.00)

Description:

Shows the setpoint electrode force for the selected pulse


of phase P1.

(Unit = kN)

The pressure increment as defined in the welding program


is taken into account. See section 5.6.5.

GF WELDING

6-3

Programming instructions
Welding analysis and I/O status

6.1.1.12

Setpoint Electrode force 2

[ Prs2: ]

Parameter:

Variable text, can not be edited

Range:

(00.00 30.00)

Description:

Shows the setpoint electrode force the selected pulse of


phase P2.

(Unit = kN)

The pressure increment as defined in the welding program


is taken into account. See section 5.6.5.

6.1.1.13

CosPhi

[ CosPhi: ]

Parameter:
Range:

(0.25 0.99)

Description:

6-4

Variable text, can not be edited

Shows the CosPhi calculated by the control, which belongs


to the selected pulse. See section 3.2.1.5.

GF WELDING

Programming instructions
Welding analysis and I/O status

F2 I/O

6.2 I/O TRACE

On this page all logic states of all Inputs and Outputs of the control are
shown.
The page I/O TRACE looks as follows:
I/O Trace

Input

Start

0 0 000000 0

Valves

00 0

0 00 00

W.Cycle

00000 0000

000 0 0

Alarms

000 0

Stepper

00 0 0

00 00 00

Other

0 00 0 00 000

000

Output

Following table shows all abbreviations of the displayed inputs:


STARTA

Start

0
CEVASB

CODE4

CODE3

CODE2

CODE1

CODE0

CODEP

CEVASA

Valves

CODE5

STARTB

STSERV

W.Cycle

REPEAT

SOLOPR

SALDAJ

CONSALD

0
ENDCYCL

TSCR

PRESS

FLUSS

RESAH

Alarms

0
RESALSA

Stepper

RESALSB

RAVOK

CHGOK

Other

SAF. M

SAF. A

SAF. B

+24V

CONDUZ

PRESV

SPARE

SPARE

SPARE

Following table shows all abbreviations of all outputs:

Start
EVSA/B

Valves

EVPA

0
RICHSALD FINESALD

W.Cycle

EVPA

FINESEQ

EVASA

UNDCURR

OVRCURR

ALARM2

WALLSTA

Stepper

WALLSTB

0
ALLSTA

0
SPARE

RICHRAV

RICHEL

SPARE

ALLSTB

0
SPARE

Other

STATUS

ALARM1

Alarm

EVASB

Remark: The output EVS in the second line shows the logic state of the OR
of the outputs EVSA and EVSB.

GF WELDING

6-5

Programming instructions
Welding analysis and I/O status

6.2.1

Index of I/O abbreviations

Abbreviation Description

Typology

+24V

24Vdc present

Logic input

ADR0

Network address code 0

Logic input

ADR1

Network address code 1

Logic input

ADR2

Network address code 2

Logic input

ADR3

Network address code 3

Logic input

ADR4

Network address code 4

Logic input

ADRP

Parity code address

Logic input

ALARM1

Weld alarm

Logic output

ALARM2

Hardware alarm

Logic output

ALLSTA

Lifetime A

Logic output

ALLSTB

Lifetime B

Logic output

CEVASA

Start pre-stroke valve A

Logic Input

CEVASB

Start pre-stroke valve B

Logic Input

CHGOK

Confirmation electrode exchange

Logic Input

CODE0

Program selection code 0

Logic Input

CODE1

Program selection code 1

Logic Input

CODE2

Program selection code 2

Logic Input

CODE3

Program selection code 3

Logic Input

CODE4

Program selection code 4

Logic Input

CODE5

Program selection code 5

Logic Input

CODEP

Program selection parity

Logic Input

CONSICA

Release channel A

Logic Input

CONSICB

Release channel B

Logic Input

CONSALD

Weld enable

Logic Input

voltage signal of SCRs

Logic Input

OVERRIDE END OF WELD SEQUENCE

Logic Input

COSPHI
ENDCYCL
EVASA
EVASB

OUTPUT PRESTROKE CHANNEL A

Logic output
Logic output

OUTPUT PRESSUREVARIATION CHANNEL A

Logic output

EVPB

6-6

OUTPUT PRESTROKE CHANNEL B

EVPA

OUTPUT PRESSUREVARIATION CHANNEL B

Logic output

GF WELDING

Programming instructions
Welding analysis and I/O status
Abbreviation

Description

Typology

EVSA

OUTPUT WELD VALVE CHANNEL A

Logic output

EVSB

OUTPUT WELD VALVE CHANNEL B

Logic output

FINESALD

END OF WELD TIME

Logic output

FINESEQ

END OF WELD SEQUENCE

Logic output

I/VSERV

CONTROL VOLTAGE/CURRENT FOR PROPORTIONAL Analog output


VALVE

MODO320

CONFIGURATION OPERATION MODE

Logic input

OVRCURR

E006 OVERCURRENT

Logic output

PRESV

VOLTAGE AT SCR

Logic input

RAVOK

CONFIRMATION TIP DRESSING

Logic input

READY

READY

Logic output

REPEAT

REPEAT MODE

Logic input

RESAH

ERROR RESET

Logic input

RESALSA

STEPPER RESET CHANNEL A

Logic input

RESALSB

STEPPER RESET CHANNEL B

Logic input

RICHEL

ELECTRODE CHANGE REQUEST

Logic output

RICHRAV

TIP DRESSING REQUEST

Logic output

RICHSALD

REQUEST WELD ENABLE NBS REQUEST

Logic output

SALDA SI

WITH CURRENT

Logic input

SOLOPR

ONLY PRESSURE

Logic input

STARTA

START CHANNEL A

Logic input

STARTB

START CHANNEL B

Logic input

STATUS

STATUS CURRENT / NO CURRENT

Logic output

STSERV

PRESSURE OK SERVOVALVE

Logic input

TSCR

OVERTEMPERATURE SCR

Logic input

UNDCURR

E005 UNDERCURRENT

Logic output

WALLSTA

PREWARNING STEPPER A

Logic output

WALLSTB

PREWARNING STEPPER B

Logic output

GF WELDING

6-7

Programming instructions
Welding analysis and I/O status

6.3 Special functions

F3 TEST

When a card type F388-IOE is present in the control, the special function "Test
lamp" is enabled.
This test enables the outputs:
Number

Description

P39-1

Gun 1 Warning

P39-2

Gun 2 Warning

P39-3

Change electrode gun 1 Alarm

P39-4

Change electrode gun 2 Alarm

P39-5

Dressing gun 1 Alarm

P39-6

Dressing gun 2 Alarm

P39-7

Weld error Alarm

P39-8

Hardware Error Alarm

These are enabled for 5 seconds, after which they return to their pre-test
status.
The Test lamp function is performed after confirmation, with the ENT key on
the mini-keyboard.
After the test, the TRACE menu screen appears on the mini-keyboard.

6-8

GF WELDING

Programming instructions
Diagnostic and alarm history

<F1 Alarms>

7 ALARMS menu
A logfile is written in the menu ALARMS.

Up to 500 error messages are stored. In case of memory overflow the


earliest message will be deleted in order to store the latest message (first
in - first out).
Following table shows an example of the error log (only 10 out of 40
messages).
ALARM HISTORY
40

P00

E086-Temperatura SCR out of range

Tu 10/02/1998 14:35:32

39

P02

E005Meas.curr.< min threshold

Tu 10/02/1998 09:54:44

38

P08

E006Meas.curr.> max threshold

Mon 09/02/1998 19:02:04

37

P04

E031Meas.curr.< lim threshold

Mon 09/02/1998 18:23:55

36

P05

E032Null welding current

Mon 09/02/1998 09:16:23

35

P00

E074-Card on/reset

Mon 09/02/1998 07:54:19

34

P00

E088-Anomalia Pressure switch

Fri06/02/1998 14:23:56

33

P08

E005Meas.curr.< min threshold

Fri06/02/1998 10:43:03

32

P08

E005Meas.curr.< min threshold

Fri06/02/1998 09:56:54

31

P04

E031Meas.curr.< lim threshold

Fri06/02/1998 05:32:32

Column A:

Serially numbered from 1 to 500. The error message with


the highest number is the latest alarm.

Column B:

number of welding program, where the error message


occurred. In case of control error, P00 will be issued.

Column C:

Error code and description.

Column D:

date and time of occurrence. The content of the columns


can not be modified.

REMARK: column D will be displayed in alternative to column C by using


arrow keys
The + and - keys as well as the arrow keys increase / decrease the
position by 5 within the alarm list.
ESC key: return to previous menu by using ESC key

GF WELDING

7-1

Programming instructions
Diagnostic and alarm history

Function keys in menu ALARM HISTORY

ALARM HISTORY
40
39
38
37
36
RESET

P00
P02
P08
P04
P05

E086- SCR over-temperature


E005 Meas. curr.< min threshold
E006 Meas. curr.> max threshold
E031 Meas. curr.< lim threshold
E032Nul welding current
RES-EOS

F1 RESET:

RES-RS

PRINT

Reset Hardware error.


Key F1 RESET will clear the actual issued error message.
This can be successful only if the cause of the error was
fixed. The output progression contact (FINESEQ) will be
switched on and ready message will appear. The reset may
also be performed by the input RESAH.

F2 RES-EOS: Reset error and activate output FK end of sequence contact


(FINESEQ).
Key F2 RES-EOS clears the actual error message. This will
be successful only if the cause of the trouble was fixed.
Output progression will be activated in following 2 cases:

F3 RES-RS:

In case input WELD START is high, output progression


remains high until input Start will change to low.
In case input Start is low, the output progression
remains high as long as specified with the parameter
EOS Output minimum time in SETUP - CONFIG
WELD334m (see section 3.1.1.14). If result is ok status
of welding control will go to READY.

Reset error with spot repetition.


In case the welding control is operated by automata (PLCs
or Robots), it may be necessary to force out the End of
Sequence signal in order to continue the automatic cycle.
Key F2 RES-RS will reset the actual error only, if the cause
of the trouble was fixed. As soon as input WELD START will
go high, the status of the welding control will go to READY
and the spot weld will be repeated.

ATTENTION: As long as signal WELD ACTIVE is high, the control


WELD334m will initiate execution of the next welding
operation. This may cause some mechanical components of
the welding equipment start moving. For this reason please
make sure before starting any command, that nobody is
around the Welding gun or robot.
F4 PRINT:

7-2

Prints out the ALARM HISTORY.

GF WELDING

Programming instructions
Diagnostic and alarm history

7.1 Error categories


There are three categories of errors:

Process diagnosis (Error code from 01 to 50)

Normal or hardware errors (Error code from 51 to 100)

Fatal errors (Error code beginning from 101)

For the description of alarms (Causes and Remedies), refer to Appendix B.


Each error may activate some outputs of the control (see following tables).
In order to reset the errors different procedures must be considered (see
following tables).

7.1.1

Index: abbreviations of reset procedures:


a

automatic with following start

reset by PC (WMS) or HHT (Software menu)

initialize the control by reset key (hardware reset)

reset by hardware input

is

reset counter by hardware input

cis

reset counter by PC (WMS) or HHT

pr

Software parameters

GF WELDING

7-3

Programming instructions
Diagnostic and alarm history

7.1.2

Process diagnostics (Error code from 01 to 50)


These are all errors, which are caused by process deviations like surpassing
limits.
This error will cause a red LED SPOT on the front panel of the control to
turn on.
In case of controls with a 4 digit display, the error code will be displayed.
Alarms for faulty welds (if not configured as Abort Function, see section
3.1.1.15), do not shutdown the welding operation in progress.
Alarms for faulty welds can shutdown the next weld if they had been
configured as Abort functions (see section 3.1.1.15); therefore, it is
necessary to proceed with the Reset procedures (see section 7.1.1).
Most of all the reset is done by the input signal RESAH or by pushing F1 key
in the ALARM HISTORY menu.
If the abort function is configured (see section 3.3.2), the error must be
reset by the execution of the following start.

Table process diagnostics (Error code 01 to 50)


Code

Description

Activated output

Reset

E001

Stepper warning channel A

WALLSTA

cis - is

E002

Stepper warning channel B

WALLSTB

cis - is

E003

Warning threshold cable channel A

cis

E004

Warning threshold cable channel B

cis

E005

Meas.curr.< min threshold

UNDCURR - ALARM1

a-c-i

E006

Meas.curr.> max threshold

OVRCURR - ALARM1

a-c-i

E007

Dresser wear prealarm

E011

Firing angle < min.value

ALARM1

a-c-i

E015

Tip force out of tolerance

ALARM1

a-c-i

E031

Absolute current tolerance

UNDCURR - ALARM1

a-c-i

E032

Null welding current

UNDCURR - ALARM1

a-c-i

E045

Dresser wear alarm

cis

E046

Cable wear alarm ch.A

cis

E047

Cable wear alarm ch.B

cis

E048

Without current configuration

ALARM1

E049

Stepper alarm channel A

ALLSTA

cis - is

E050

Stepper alarm channel B

ALLSTB

cis - is

7-4

cis

GF WELDING

Programming instructions
Diagnostic and alarm history

7.1.3

Normal or hardware errors (error code 51 to 100)


These are error messages, which were caused by hardware failures.
Any Normal error will cause the red LED HW FAIL on the front panel of the
control to turn on.
In order to reset a hardware error, certain procedures have to be followed
in order to reset ( see section 7.1.1).
For controls with a 4 digit - display the error code will be shown.
The reset button on the front panel of the control is not designed for error
reset. This button will initialize the control.

Table of error messages (Error code 50 to 100)


Code

Description

Activated
output

Reset

Abort

E052

anomaly Communic. with remote CPU

ALARM2

c-i

E053
E055
E056
E057
E058
E059
E060
E061
E062
E063
E065
E066
E067
E070
E073
E074
E075
E076
E077
E078
E079
E080
E081
E082
E083
E084
E085
E086
E087
E088
E089
E091
E092

Run down battery


Rogowski coil open
Rogowski coil in short circuit
24Volt I/O fault
Missing firing SCR-1
Missing firing SCR-2
Main Power switch OFF
InterBus-S card fail (not present or power off)
InterbusS communication fail
Start code not valid
Program not present
Electrode not dressed
Electrode not changed
Frequency out of tolerance
Card initialized
Card on/reset
Weld log data overflow
Weld log data corrupted
No weld history data
Event log data corrupted
Card address wrong
Black-box data corrupted
Weld program data corrupted
Timeout Synchronization Input
Stepper program data corrupted
Setup data corrupted
MF Inverter fault
SCR overtemp
Error rectifier diodes
Pressure switch not active
Flowmeter not active
Program not enabled
I/O modules failed

ALARM2
ALARM2
ALARM2
ALARM2
ALARM2
ALARM2
ALARM2
ALARM2
ALARM2
ALARM2
ALARM2
ALARM2
ALARM2
ALARM2

ALARM2
ALARM2
ALARM2
ALARM2
ALARM2
ALARM2
ALARM2

n
c-i
c-i
a-c-i
a-c-i
a-c-i
a-c-i
a-c-i
a-c-i
a-c-i
a-c-i
cis - is
cis - is
n
a-c-i
a
a-c-i
a-c-i
c-i
a-c-i
a-c-i
a-c-i
a-c-i
n
a-c-i
a-c-i
c-i
c-i
c-i
c-i
c-i
pr
c-i

Y
Y
Y
Y
Y
N
Y
Y
Y
Y
N
N
Y
N
N
Y
N
Y
N
Y
N
N
Y
N
N
Y
Y
Y
Y
Y
Y
Y

E093

Output overcharge

ALARM2

c-i

ALARM2
ALARM2

ALARM2

E094

Spot-Index data corrupt

ALARM2

c-i

E095

Spot-Index not valid

ALARM2

c-i

E098

Fault SVV 4-20mA command

ALARM2

c-i

E099
E100

Wrong Tip Maintenance


Emergency activated

ALARM2
ALARM2

c-i
c-i

Y
Y

GF WELDING

7-5

Programming instructions
Diagnostic and alarm history

7.1.4

Fatal error (Error code 101 and higher)


The control detects an error on the secondary circuit.
Any Fatal error will cause the red LED P.BREAK on the front panel of the
control to turn on.
The control will activate an exchange contact which, in turn, causes the coil
of the circuit-breaker to trip
Check the correct operation of power circuit before resetting the circuitbreaker.

Table of fatal errors (Error code 101 and higher)


Code

Description

E101 SCR short circuit out of weld


E102 SCR short circuit during weld

7-6

Activated output

Reset

Abort

SGDNC-SGDNO

SGDNC-SGDNO

GF WELDING

Programming instructions
Diagnostic and alarm history

7.2 I/O Signals, which are caused by errors


Input signal RESAH (Alarm Reset) deactivates the error message same as
key F1 RESET in the ALARM HISTORY.
Output signal ALARM1 (Alarm abnormal weld) will go high in case of a
process diagnostics message.
Output signal ALARM2 (HW error) will go high in case errors E0051 up to
E0100.
The contacts SGDNC, SGDNO are switched in case of an error as described
in section 7.1.4.

RESAH
(Error Reset)

WELD
334m

ALARM1
(Abnormal welding)
ALARM2
(HW Alarm)
UNDCURR
(E005 Meas. Curr.< min threshold)
OVRCURR
(E006 Meas. Curr.< max threshold)

SGDNC
SDCOM

Circuit breaker release

SGDNO

GF WELDING

7-7

Programming instructions
Diagnostic and alarm history

WHITE PAGE

7-8

GF WELDING

Programming instructions
Report

8 Menu REPORT

<F5-ETC F2-REPORT>

Menu REPORT offers the option, to display and statistically collect certain
error messages and the number of spot welds during the last 24 hours.
For improvement of product quality interruptions should be statistically
analysed.
This analysis is done for each program within a defined range of time.
This analysis refers to the frequency of specified errors (see section 3.3)
and refers to the assigned welding programs.
A good understanding of the reports is necessary to correct the welding
parameters, which are cause of the errors.
The reported data must be printed out after completion, because the old
data will be deleted by the data of the new report the day after.
In menu REPORT following settings can be done:
input name of 3 programmable reports
input begin and end of 3 programmable reports
Following data are displayed, which refer to the defined time range:
number of spots executed by each welding program
total number of welds executed by each welding program (the welding
control counts the execution of only one weld also for programs
consisting of several impulses)
number of messages 'Process diagnostics', which was programmed for
each welding program.
Total number of error messages, which were configured.
Bar graph with the number of messages 'Diagnostics' configured during
the running of the single program
Date and time of the reported events

GF WELDING

8-1

Programming instructions
Report

8.1

Define Reports
If no inputs have been done, the REPORT page where the 3 configurable
reports are entered, looks as follows:

REPORT
Name
> First Shift
Second Shift
Third Shift

Start
06:00:00
14:00:00
22:00:00

End
13:59:59
21:59:59
05:59:59

Function keys in menu REPORT


F1 VIEW:

shows the data of the selected report

F4 PRINT:

prints the selected report

F5 MODIFY:

to edit the reports

Arrow keys : Moves the cursor (>) up or down, to select the report,
which shall be edited by using the keys F1, F4, F5.
ESC key:

back to main menu

F5 MODIF

8.2 Modify reports

In menu REPORT all parameters, by which a report is specified, can be


edited by using function key F5 MODIFY.
The 7 parameters are:

Name of report (max.16 digits)

Start (from when on the report shall start)hour: (00-23)

Start (begin of report) minute: (00 - 59)

Start (begin of report) second: (00 - 59)

End (end of report) hour: (00 - 23)

End (end of report) minute: (00 - 59)

End (end of report) second: (00 - 59)

Function keys on page MODIFY Report:


arrows :
ENT key:

move the cursor horizontal for selection of the parameter,


which shall be modified.

arrows :

move the cursor within the line of a parameter

keys + -:

change the sign, where the cursor is located

F5 SAVE:

Saves all changes (after all changes were saved


successfully, the star * in the upper right corner will
disappear)

ESC key:

8-2

move the cursor vertical for selection of the parameter,


which shall be modified.

terminates the ongoing activity and returns to the previous


menu (data entry is not saved)

GF WELDING

Programming instructions
Report

8.3 View reports

F1

VIEW

To view a report, perform following steps:

Check date and time displayed on the control (see section 2.1.1.4)

Set time for start and end of the report (see section 8.2)

Set the Diagnostics messages, which shall be analysed, in menu SETUP ALARMS CONFIGURATION (see section 3.3.2).

Some error messages (E001 - E002 - E003 - E004 - E046 - E047 - E049 E050) will not increase the counter, even they are shown in menu SETUP ALARMS CONFIGURATION. For these messages no bar graphs will be
created.
Referring to electrode- and cable wear these error messages have no effect
on the statistical analysis of the abnormal weldings.
These error messages are found in the SETUP ALARM CONFIGURATION
Menu only because they must be configured as Abort functions (refer to
section 3.3.2).
Page VIEW REPORT may look as following:
Example: REPORT
The box shows the program, which relates to the bar graph.
CNT: number of welds, executed by the welding program during the specified
range of time.
TOT: number of welds, executed by all welding programs during the specified
range of time
Name of the report (1-2-3) date and time of start, date and time of
the end of the report.

REPORT 2

P:01:TEST 111

Start
28/04/98
14:00:00
End
28/04/98
21:59:59

FINISHED
Actual status of the report.
3 states are possible:
FINISHED
RUNNING
EMPTY

CNT:52
TOT:239

E005:15

Bar graph shows the error


frequency (during the specified
time range and execution of the
welding program as specified in
the box)

Error code selected by the cursor(*).


Occurrence of the error (during the
specified time range and execution of
the specified welding program)

The context of the analysis as shown above is as following:

Time range, defined in REPORT 2 (called: Second shift)

Executed with Program P01, which is actually in operation

GF WELDING

8-3

Programming instructions
Report

Now it can be compared, how often the error messages occurred, which
were specified in the menu SETUP - ALARMS CONFIGURATION (only 4 with
increased counter).
The analysis is done 16 hours after 21:59:59 of 28/04/98, because
REPORT2 is finished and not deleted yet.
Program P:01, which is called TEST111, has executed 52 spots out of totally
239 spots.
The star (*) selects the first bar of the graph, which is assigned to error
message E005, which occurred 15 times in the given time range.
Further information about the messages, which must be selected by the
star, can be shown using the ENT key. A window will overwrite the
displayed report.

REPORT 2

Start
28/04/98
14:00:00
End
28/04/98
21:59:59
FINISHED

P:01:TEST 111

CNT:52
E005:Meas.curr.< min
threshold TOT:73 TOT:239

E005:15

The window contains the description of the selected error message.


Furthermore the total number of events is shown, how often this error
occurred for all programs during the defined range of time.
For closing the window push the ESC key.

Function keys of page REPORT


arrows :

keys + -:

increase / decrease of the program number, which is in


relation to the bar graph (shown in the upper right box).

arrows :

move the star(*) horizontal to one of the 16 error


messages, which were configured in SETUP - ALARMS
CONFIGURATION.

ENT key:

shows the description of the selected error message and


how often this error occurred (during the specified time
range).

ESC key:

8-4

increase / decrease of the program number, which is in


relation to the bar graph (shown on top of the upper right
box)

back to REPORT

GF WELDING

Programming instructions
Memory Card Menu

9 CARD menu (backup of data)

<F5-ETC F1-CARD>

The control offers a plug, where e Memory card type PCMCIA can be
inserted. This card is delivered by Co.GF WELDING S.p.A.
Memory card is an ancillary device which allows saving or loading 2 types of
data concerning the welding control operation.
The operational limitations of the Memory Card (battery, temperature,
magnetic field) are provided by the maker and must be considered.
Following data deal with the Memory Card:

Firmware, for loading a compatible software revision to the welding


control (load only)

Welding programs, Stepper programs, Setup, Reports (load/save)

The window MEMORY CARD looks as following (in case no MEMORY CARD is
inserted into the control):

MEMORY CARD

WELD 334m
CARD

Module Name
FASE 334m
Card name
???????????

The cross over CARD indicates,


that the control does not detect a
Memory card.

The Module name is the same as specified in menu SETUP-CONFIG


WELD334m (see section 3.1.1.2).
The card name is read from the Memory Card.
One Memory Card may contain the data of one control only. For this reason
2 Memory Cards are necessary for saving welding program data of 2
different controls.

9.1 Load firmware to the control


Loading Firmware offers the possibility to do Software upgrades.
The Firmware present on the welding control cannot be saved to a memory
card.
The Memory Card for the firmware is exclusively delivered by GF WELDING
S.p.A.
The Memory Card must be inserted correctly.
There is a write protector on the Memory Card. When the switch is in
position WRITE PROTECT, following will be displayed:

on the MEMORY CARD a key will be displayed

GF WELDING

9.1

Programming instructions
Memory Card Menu

the data on the MEMORY CARD can not be changed

In case a Memory Card with firmware is inserted, following will be


displayed:

MEMORY CARD
Module - name

FASE 334m
WELD 334m

Card name

Rel 1.1

CARD
UPGRADE

FORMAT
The arrow indicates the
direction of data
transfer (from Mem ory
card to the control )

The indicates,that
the Mem ory Card is
write protected.

Function keys of menu MEMORY CARD with Firmware Card


If a Memory Card with Firmware is inserted in the control, following keys
are available:
F1 UPGRADE:

enables the control, to read data from the Memory Card.

F4 FORMAT:

formats the card and all data on the Memory Card will be
deleted.

ESC key:

back to the main menu

Example: Update Firmware of the control


Firmware Version 1.07 is running
CONFIGURATION section 2.1.1.1).

on

the

control

(see

menu

A Memory Card with Firmware Version 1.1 is available.


In order to upgrade the Firmware on the control, perform following steps:

insert the Memory Card into the control (Card name must be Rel 1.1)

press key F1 UPGRADE. Following window will appear:

Upgrade SW from Rel. 1.0 to 1.1


Confirm?
[ ENT = YES / ESC = NO ]

9.2

press ENT key to start the upgrade


as soon as the upgrade is finished, the control must be initialized by
pushing the RESET button on the front panel of the control and switch off
27V AC and all DC voltages ).

GF WELDING

Programming instructions
Memory Card Menu
Example: Format Memory Card
During format all data on the Memory Card will be deleted. After format,
the Memory Card is prepared for new applications.
The write protection switch on the Memory Card shall not be in position
WRITE PROTECT.
To format the Memory Card proceed as following:

insert the Memory Card into the control

push F4 FORMAT. Following window will appear:

Confirm?
[ ENT = YES / ESC = NO ]

push ENT key to start the execution of Format

9.2 Store/load of Programs


The following files from a control can be stored (Back-up) on a Memory
Card

Weld program

Stepper

Setup

Report

Loading the programs from the memory card to the welding control allows
resetting all of operational data to the original situation when Save function
was performed.

MEMORY CARD
Module Name
FASE 334m

WELD334m

Card Name

CARD
SAVE

Rel 1.1
LOAD

FORMAT

RUN

For the storage procedure a formatted card is required


The Memory Card must be inserted correctly.
There is a write protector on the Memory Card. When the switch is in
position WRITE PROTECT, following will be displayed:

on the MEMORY CARD a key will be displayed

the data on the MEMORY CARD can not be changed

GF WELDING

9.3

Programming instructions
Memory Card Menu
Function keys of menu MEMORY CARD with Program Card
If a Memory Card with program is inserted in the control, following keys are
available:
F1 SAVE:

enables the control, to write data from the control to


Memory Card.

F2 LOAD:

enables the control, to read data from the Memory


Card.

F4 FORMAT:

formats the card and all data on the Memory Card will be
deleted.

F5 RUN:

Start of operation.

ESC key:

back to the main menu

Key :

Arrows indicate the direction of data transfer (from


welding control to memory card or vice versa)

Example: Transfer programs from control to memory card


Use a formatted Memory Card.
In order to transfer data from the control to memory card, perform
following steps:

Remove write protection of Memory Card

insert the Memory Card into the control (No card name )

Press key F1 SAVE. The arrow, which shows the direction of dataflow
,looks to memory card symbol (see section 9.1).

Press key F5 RUN .Operation is started (at the end of Save function, the
Card name is the same as Module Name).

Example: Load programs from Memory Card to welding control


Memory Card with Programs is required.
In order to transfer data from the control to memory card, perform
following steps:

insert the Memory Card into the control (card name occurs)

Press key F2 LOAD. The arrow , which shows the direction of dataflow
,looks to control symbol (see section 9.1).

Press key F5 RUN .Operation is started (at the end of Save function, the
Module Name is the same as Card Name).

9.4

Remove write protection of Memory Card

Reset the welding control at the end of operation (to do this, press the
push button located on the front part of the control or power off).

GF WELDING

Programming instructions
APPENDIX

APPENDIX

GF WELDING

Programming instructions
APPENDIX

GF WELDING

Programming instructions
Appendix A - Operating diagrams

Appendix A

Operating diagrams

GF WELDING

Programming instructions
Appendix A - Operating diagrams

Operating diagram 1 - Single cycle sequence


ON STATE +24V
PROGRAM CODE INPUTS
STABLE FOR T=1 NETWORK CYCLE

WELDING CYCLE EFFECTIVE START

OFF STATE 0V

AUTO HOLD SEQUENCE


CYCLE START
PROGRAM
CODES

PROGRAM CODE ACTIVE ONLY


FOR PROPORTIONAL COMMAND

PROGRAM CODE IGNORED UNTIL THE END


OF THE PROGRAM EXECUTION

PROGRAM CODE ANKKNOWLEDGED


THEN VALIDATED AND EXECUTED

SQUEEZE

PRESSURE
1 HALFCYCLE TRIGGERS AT 90
WELDING

N6 WELDING-R CYCLES

NORMAL
N3 WELDING-R CYCLES

N 1 CYCLE-R INTERVAL

NORMAL PULSES (N2)

N 2 CYCLES-R WELD.
N 3 CYCLES-R WELD.

N 2 CYCLES-R INTERVAL
N 1 CYCLE-R INTERVAL

SPECIAL PULSES (N2)

N 1 NETW.CYCLE

WELDING
ALARMS

HOLD

OPEN

PRESSURE TEST

RIPEAT ?
DIAGRAM
N 2

SI
NO

END OF SEQUENCE

WELDING
REQUEST

10 mSec before

END OF
WELDING
ELVS A / B
SOLENOID VALVE GUN
CLOSING

IMPULSE
=TIME = 160mSec

File 32021820.ds4

GF WELDING

Programming instructions
Appendix A - Operating diagrams

Operating diagram 2 Repetitive cycle

PROGRAM CODES INPUTS


STABLE FOR T=3 NETWORK CYCLES

CYCLE START

AUTO HOLD SEQUENCE

WELDING CYCLE EFFECTIVE START

PROGRAM
CODES

PROGRAM CODE ACTIVE ONLY


FOR PROPORTIONAL COMMAND

ON STATE +24V

PROGRAM CODE IGNORED UNTIL THE END


OF THE PROGRAM EXECUTION

OFF STATE 0V

PROGRAM CODE ANKNOWLEDGED


THEN VALIDATED AND EXECUTED

SQUEEZE

PRESSURE
1 HALFCYCLE TRIGGERS A
NORMAL WELDING

N6 WELDING CYCLES-R

N3 WELDING CYCLES-R
N 1 INTERVAL CYCLE-R

NORMAL PULSES (N2)

N 2 CYCLES-R WELD.
N 3 CYCLES-R WELD.
N 2 INTERVAL CYCLES-R
N 1 INTERVAL CYCLE-R

SPECIAL PULSES (N2)

N 1 NETWORK CYCLE
WELDING
ALARMS
HOLD

OPEN

YES
RIPEAT ?

YES

NO

START?
NO

END OF SEQUENCE

WELDING
REQUEST

10 mSec before

END OF
WELDING
ELVS A / B
CLOSE ELECTROVALVE
GUN

file:32021821.DS4

GF WELDING

Programming instructions
Appendix A - Operating diagrams

Operation diagram 3 Type of weld

AUTO HOLD SEQUENCE


SQUEEZE

PRESSURE

WELDING

1 HALF CYCLE TRIGGERS AT 90

N6 WELDING R-CYCLES

STANDARD TYPE
ONE PULSE

N3 CYCLES-R SLOPE-UP

N12 WELDING R-CYCLES


N 3 CYCLES -R SLOPE-DOWN

STANDARD TYPE
WITH SLOPE UP AND DOWN

N 1 CYCLE-R INTERVAL
NORMAL PULSES TYPE (N4)

N 3 WELDING R-CYCLES
N 1 CYCLE-R INTERVAL

N3 CYCLES -R DI SLOPE-DOWN

NORMAL PULSES TYPE (N3)


WITH SLOPE UP AND DOWN

N 5 WELDING R-CYCLES
N 3 CYCLES -R SLOPE-UP

SPECIAL PULSES MODE (N3)

1 IMPULSE:
- N3 WELDING R-CYCLES.
- N 1 CYCLES -R INTERV.
-6400 Aeff WELDING CURRENT

2 IMPULSE:
-N7 WELDING R-CYCLES
-N4 CYCLES -R SLOPE-UP
-N2 CYCLES INTERVAL
- 9500 Aeff WELDING CURRENT

3 IMPULSE
-N 10 WELDING R-CYCLES
-N 3 CYCLES SLOPE-UP
-N 3 CYCLES SLOPE-DOWN
-N1 CYCLES -R INTERVAL
- 5500 Aeff WELDING CURRENT

HOLD

OPEN

END OF SEQUENCE

ELVS A / B
ELECTROV. CLOSE
GUN

File:32021822 DS4

GF WELDING

Programming instructions
Appendix A - Operating diagrams

Operating diagram 4 - Dressing 1 stepper mode (part 1 of 2)

situation with dressing not executed


ALARM

PREWARNING
MACHINE STOPPED

RESET & RESTART

Current increment

Program Parameters
Offset = 12
Prewarning = 95%
Warning = 2000
Emergency spots = 20
Number of dressing = 2

CNT OFFSET

CNT OFFSET

Prewarning (E01&02)
Outs = PREALLSTA,B

Warning (E49 &E50)


Outs = ALLSTA/B
Tip dressing Request
Out = RICHRAVV
Electrode not dressed (E066)
Out = ALARM2
Confirmation tip dressing
Input = RAVOK
100 mSec

100 mSec

Electrode change request


Out = RICHEL

Confirm. electrode exchange


Input = CHGOK
100 mSec

SPOT COUNTER

2001
2000

DRESS COUNTER

2001

12

2020

2000

2010

CYCLE OK

CYCLE NOK

12

1701

2020

1700

2001
2010

2000

CYCLE OK
File:32021823.ds4

GF WELDING

Programming instructions
Appendix A - Operating diagrams

Operating diagram 5 - Dressing 1 stepper mode (part 2 of 2)


Situation with tips change not executed
RESET & RESTART
STEPPER ALARM

MACHINE STOPPED

STEPPER ALARM

Current Increment %

PREWARNING

Program Parameter
Offset = 12
Prewarning = 95%
Warning = 2000
Emergency Spots = 20
Number of dressing = 2
CNT OFFSET

CNT OFFSET

Prewarning (E01&02)
Outs = PREALLSTA,B
Warning (E49 &E50)
Outs = ALLSTA/B
Tip dressing request
Out = RICHRAVV
Confirmation tip dressing
Input = RAVOK

xxxxxxxx
100 mSec

100 mSec

Electrode change request


Out = RICHEL
Electrode not changed
(E067)
Out = ALARM2
Confirm. electrode
exchange
Input = CHGOK

SPOT COUNTER

100 mSec

12

2001
2000

DRESS COUNTER

12

1701

2010

CYCLE OK

1700

2001

2000

2020

CYCLE NOK

0
2000

12

2001

2020

2010

CYCLE OK

xxxxxx = Signal level has no effects

GF WELDING

Programming instructions
Appendix A - Operating diagrams

Operating diagram 6 - Dressing 2 stepper mode


One profile, with many dressing cycles; every number of spots "spot for dressing"
MACHINE STOPPED

WARNING
PREWARNING

RESET & RESTART

Program Parameters
Prewarning = 1900
Warning = 2000
Emergency spot = 20
Spot x dress = 200

Prewarning (E01&02)
Outs = PREALLSTA,B
Warning (E49 &E50)
Outs = ALLSTA/B
Tip dressing request
Out = RICHRAVV
Confirm. tip dressing
Input = RAVOK
100 mSec

100 mSec

Electrode change request


Out = RICHEL
Electrode not dressed
(E066)
Out = ALARM2
Confirmation electrode
exchange
Input = CHGOK
100 mSec

SPOT COUNTER

211

201
200

401
400

210

420
420

421

1901
1900

2000

2001

2010

DRESS COUNTER

CYCLE OK

CYCLE NOK

CYCLE OK

In case of situation "confirmation electrode exchange" timing & procedure are the
same of type dressing 1

GF WELDING

Programming instructions
Appendix A - Operating diagrams

Operating diagram 7 Seam mode

START CYCLE

The welding continues until the Start cycle is active

SQUEEZE.

PRESSURE
1 HALF CYCLE TRIGGERS AT 90
WELDING
STANDARD TYPE
ONE PULSE
N3 CYCLES-R SLOPE-UP
STANDARD TYPE;
WITH SLOPE UP

N 2 CYCLE-R INTERVAL
NORMAL PULSES TYPE

N 1 CYCLE-R INTERVAL

N3 welding cycles
1 is SLOPE-UP

SPECIAL PULSES
MODE (MAX n 4)

1 IMP.S.

3 IMP.S.
4 IMP.S.

2 IMP.S.

WITHOUT
SLOPES

Standard type one pulse

with change of current

from outside, by changing the

Program code

UNTIL END
OF WELDING

Progr # 1

Progr # 3

Progr # 1
Progr # 4

(time range compressed)

CODE
CHANGE
PGM

WITH SLOPE
BETWEEN CURRENTS

CODE
CHANGE
PGM

HOLD

OPEN
160 mSec
END OF SEQUENCE

ACTIVATION ALARM
WELDING DIAGNOSIS

Example of
Moment of event generation

ELVS A / B
ELECTROV. GUN
CLOSE

GF WELDING

Programming instructions
Appendix A - Operating diagrams

Operating diagram 8 Cycle mode


AL-S

GF WELDING

Programming instructions
Appendix A - Operating diagrams

10

GF WELDING

Programming instructions
Appendix B Diagnostics Alarms: causes and remedies

Appendix B

DIAGNOSTICS ALARMS

GF WELDING

Programming instructions
Appendix B Diagnostics Alarms: causes and remedies

GF WELDING

Programming instructions
Appendix B Diagnostics Alarms: causes and remedies

Description of alarms
Code

message

remarks

activities
Indication that tip change or
dress on channel A must be done
soon

E001 Tip warning

Stepper A in prewarning (see section


5.6.3.4)
The red led W.STEP. A on the front
panel is on.

E002 Tip warning

Stepper B in prewarning (see section Indication that tip change or


dress on channel B must be done
5.6.3.4).
The red LED W.STEP. B on front panel soon
is on.

E003 Warning

Cable wear counter A in prewarning.


(see section 3.4.1.2)

Indication that maintenance for


the cable on channel A must be
done soon

E004 Warning

Cable wear counter B in prewarning.


(see section 3.4.1.2)

Indication that maintenance for


the cable on channel B must be
done soon

E005 Meas.curr.< min

The measured current value was ntimes between %I.min and %I.lim
( n = programmed numbers of weld
alarm threshold )
The red LED LOW CURR on frontpanel
is on.
Possible reasons :

Tips do not close

Tips are damaged

Voltage drop in power line

Current sensor damaged

Squeeze time too short

Programmed current >max.

Cables or band damaged.

channel A

channel B

threshold cable
channel A

threshold cable
channel B

threshold

E006 Meas.curr.> max. Monitored current .> %I.max


threshold

Possible reasons:

Fault in WELD 334

Weld transformer faulty

E007 Warning dressing Dressing tool has reached the


tool

E011 Firing angle.<


min value

prewarning threshold

Check value of tolerance (see


section 4.4.7.19)
Increase weld alarm
threshold. (see section
3.1.1.5)
Check tip force
Check surface of tips
Check line voltage
Check current sensor ( cabling
and positioning )
Check squeeze
Check cables and secondary
loop

Check value of max tolerance


(see section 4.4.7.18)
Check secondary loop for
shunt or short circuit
Check for ground contact of
tip.

Indication that dressing tool


maintenance must be done soon .

The actual firing angle is less than the


allowed value (see section 4.4.7.23),
or the performance limit has been

reached.

Diminish its value


Check stepper incrementation
Check secondary loop and
tips.

Possible reasons:
Too high stepper incrementation
High voltage drop
Tips damaged., wear in secondary
loop ,
cable wear , bad contacts.
Power of transformer insufficient.
Wrong cosphi programming
( not in cc mode )

GF WELDING

Programming instructions
Appendix B Diagnostics Alarms: causes and remedies
Code

message

remarks

E015 Tip force out of Wrong electrode force (for WELD334


with the option tip force tolerance
tolerance
only)
E031 Measured current The monitored current is under the
< min threshold %Iim threshold
Possible reasons:
Insufficient tips force
Tips damaged
Bad conductivity of the sheets
Power supply too low
Defect in current sensor
Defect in secondary loop
Cable wear
Control defect
E032 No current
Null welding
current

E045 Dressing tool


wear alarm

activities
Check air pressure and electrode
force system

Monitored current < 100 Amps


Possible reasons:
Insufficient tips force
Tips damaged
Sheets dirty or with bad
conductivity
Defect on current sensor
Sensor cable broken
Squeeze time too low or
insufficient tips force
Control defect

The STOP value for the dressing tool


wear was reached (see section 3.5)

Check value of programmed


tolerance (see section
4.4.7.21)
Check gun stroke
Check tips condition
Check sheets conductivity
Check line voltage
Check current sensor
positioning and cabling

Check gun stroke


Check contact area of the tips
Check sheets conductivity
Check line voltage
Check current sensor position
and cabling
Check squeeze time or air
pressure parameters
Check control

Do maintenance
Reset dressing tool counter in
HHT

E046 Cable wear alarm End of cable lifetime A

Replace cables for the channel


A
Reset counter cable wear A in
HHT

E047 Cable wear alarm End of cable lifetime B

Replace cables for the channel


B
Reset counter cable wear B in
HHT

channel A

channel B

Maintenance required for equipment in


weld channel A

Maintenance required for equipment in

weld channel B

E048 Without current

Indication that control is in no weld


current mode

E049 Stepper alarm

End of stepper A, end of electrode


lifetime (see section 5.6.3.6)
The red LED STEP.A on front panel is
on

End of stepper B, end of electrode


lifetime (see section 5.6.3.6)
The red LED STEP.B on front panel is
on

configuration

channel A

E050 Stepper alarm


channel B

E052 Communication
anomaly with
remote CPU

Tip dressing or change


required
Reset by push button or HHT
Activate input RESALSA
Tip dressing or change
required
Reset by push button or HHT
Activate input RESALSB

An error or a complete
Check connection between
communications failure has been
control and remote CPU
found with the remote CPU. This alarm
Check possible communication
is only diagnosed in systems in which
configurations (jumpers,
the welding control is in
parameter settings, etc.)
communication with another process
Check correct operation of
control (eg. a robot)
remote CPU

GF WELDING

Programming instructions
Appendix B Diagnostics Alarms: causes and remedies
Code

message

E053 Low battery

E055 Rogowski coil


open

remarks
Battery is low.
The device remain on alarm condition
permanently (the red LED on the CPU
card is on).
No alarms outputs are activated ; a
message is sent to the WMS ; the
control continue its activity.
Resistance of current sensor too high
( >30 )
Possible reasons :

Broken cable

Not fixed connectors

Sensor defect

Control defect

activities

Replace the battery (see the


Maintenance chapter on
technical documentation)
If the problem persists, a
repairing service on the CPU
card is required.

Check
value :
Check
Check

Check
Check
Check
Check

coil resistance (default


22 ohms)
cable and connectors
control

E056 Rogowski coil in

Resistance of current sensor to low


( <30 )
Possible reasons :

Short circuit in cable:

Sensor defect

Earth fault

Control defect

E057 24 volts I/O

The control does not detect the 24


volts (internal or external) supply
needed by the I/o circuits.

Null current detected on one or both


the conduction half-cycles.
Possible reasons

Broken cable to gate of SCR 1

Broken cable firing board control

Wrong polarity
This message blocks start.
Null current detected on one or both
the conduction half-cycles.
Possible reasons

Broken cable to gate of SCR 2

Broken cable firing board control

Wrong polarity
This message blocks start.
The signal PRESENZA
DISGIUNTORE is absent (only for
controls responding to CNOMO
normative.)

Check the 3.15 A fuse on the


control
Check the externally supplied
voltage.
Check wiring
Check firing board

Check wiring
Check firing board

short circuit

missing

E058 Missing firing


SCR 1

E059 Missing firing


SCR 2

E060 Main power


switch off

coil resistance
cable and connectors
control
sensor

Check main power switch

E061 InterbusS card Interbus-S board not active by

Check power supply and board

E062 InterbusS

Check connection

fails

communication
fail

internal reasons.
Possible reasons:

External 24 V supply missing

Board broken
Break down on optical transmission
line

E063 Invalid start code Wrong program code.


Program select parity error
Occurs only by using parity even or
odd.
(See section 3.1.1.9)

E065 Program not


present

Missing or faulty data

GF WELDING

Check led status (CODE0CODE5)


Or set program parity OFF

Check program

Programming instructions
Appendix B Diagnostics Alarms: causes and remedies
Code

message

E066 Electrode dress


alarm on

remarks
For the used Stepper, after Stop
threshold has been reached, the
number of emergency spot has been
expired, without confirmation of the
required tip maintenance operation
(Tip Dressing Request).

E067 Electrode change For the used Stepper, after Stop

activities
Execute tip maintenance activity
as required, and confirm
operation activating Tip Dressing
Done confirmation.

Execute tip maintenance


activity as required, and
confirm operation activating
Tip Change Done
confirmation.

alarm on

threshold has been reached, the


number of emergency spot has been
expired, without confirmation of the
required tip maintenance operation
(Tip Change Request)

E070 Line frequency


fault

After W334m Reset or Power On, the


internal diagnostic has recognised an
error of +/- 2.5Hz from expected
nominal value.

E073 Initialized

After W334m Reset or Power On, the


internal diagnostic has recognised a
errors inside non volatile RAM data.
Memory is automatically initialized.

E074 Module Power

W334m ha recognised a Reset or


Power On procedure.
This is not a true alarm, but an
operator indication with date & time of
this event.

E075 Spot log data


overflow

Data acquisition and the option Avoid


data overflow by WMS are enabled,
and W334m memory area dedicated
to Spot log is full.

Check if Spot Logger WMS


function is active.
If this function is not required,
disable Avoid data overflow or
the complete data acquisition
function in WMS-Setup window.
Additional indication regarding
how to use Spot Logger in WMS
programming manual.

E076 Weld log data

Invalid data in memory


Memory is cleared automatically

If the error persists, contact


technical
assistance
at
GF
WELDING S.p.A.

E077 No weld history

It occurs under these circumstances :


Execution of the first weld in Constant

Current mode, and with the current


sensor disabled or without it .

E078 Event log data

Invalid data in memory


Memory is cleared automatically

module

ON (Reset)

corrupted

data

corrupted

GF WELDING

Check connection line


synchronisation signal.

Check Release Software type


(50 or 60Hz)
Change battery on CPU card.
If necessary, contact GF
WELDING technical service.

Execute first weld with the


current sensor enabled
Use programs sets in
MONITOR mode.

If the error persists, contact


technical assistance at GF
WELDING S.p.A.

Programming instructions
Appendix B Diagnostics Alarms: causes and remedies

Code

message

E079 Wrong card


address.

remarks

activities

Used only if the control is connected to


a network.
The card code is wrong ; this error
occurs only when the parity for the
card code is enabled. (See section
3.1.1.10)

Check correspondence
between device address set
in the setup and the address
set by dip-switch or
jumpers.(see the
documentation for the 334
network card).
Set Parity to OFF (Warning :
in this case, an error reading
the card code is not
detected).

E080 Black-box data

Invalid data in alarm history memory


Black-Box memory is cleared
automatically

E081 Weld program

Invalid data in weld program memory If the error persists, contact


Memory is cleared automatically
technical assistance at GF
WELDING S.p.A.

E082 Time out at

AC voltage was missing for more than

40msec during welding.

corrupted

data corrupted

synchronization
input

If the error persists, contact


technical assistance at GF
WELDING S.p.A.

Check voltage
If the error persists, contact
technical assistance at GF
WELDING S.p.A.

E083 Stepper program Invalid data in weld stepper memory

If the error persists, contact


technical assistance at GF
WELDING S.p.A.

E084 Setup data

If the error persists, contact


technical assistance at GF
WELDING S.p.A.

data corrupted

corrupted

Memory is cleared automatically


Invalid data in setup memory
Memory is cleared automatically

E085 MF Inverter fault Generic error message from MF

Inverter
The inverter detected a failure in its
system

Check if MF inverter is functioning


properly.

E086 SCR

SCR or weld transformer temperature


overtemperature is too high. Logic state of TSCR input
is zero.

Possible reasons :

Thermostat open due to high


temperature

Contacts problems ,intermittent


electrical contacts.

Defective thermostat.

E087 Error rectifier


diodes
temperature

Diodes or weld transformer


temperature is too high. (For threephase systems only).
Logic state of TEMPD input is zero.
Possible reasons :

Thermostat open due to high


temperature

Contacts problems ,intermittent


electrical contacts.

Defective thermostat.

GF WELDING

Check water flow


Check cable and connections
Verify that the thermostat is
functioning properly (Check if
the SCR green led on front
panel is on)

Check waterflow
Check cable and connections

Programming instructions
Appendix B Diagnostics Alarms: causes and remedies

Code

message

remarks

activities

E088 Pressure switch

Logic state of input PRESS is zero.


Possible reasons :

Insufficient air pressure

Check air pressure


Check cable and connections
Ensure that the pressure
switch is functioning properly.
(Check that the AIR green led
on front panel is on)

E089 Flowmeter not

Logic state of input FLUSS is zero.


Possible reasons :

Pressure switch open due to


insufficient waterflow

Check waterflow
Check cable and connections
Ensure that the flowmeter is
functioning properly. (Check
that the H2O green led on
front panel is on)

E091 Program not

The started program dont has the


permission to execute (see section
4.4.7.4).

E092 Fault on I/O

Bad inputs reading or output


command out of allotted time.

not active

active

enabled

modules.

E093 Output overload Current overload on the output circuit.


Probable shot circuit on an output line,
or internal fault in the output section

Deselect program inhibit


Check external program
selection
Replace the defective I/O card

Verify the output load.


Replace the base I/O card.

E094 Spot-Index data The autodiagnostic function that runs If the error is repeated contact
corrupt

E095 Spot-Index
valid

on switching on detects an anomaly in GF WELDING S.p.A. technical


data resident in the area reserved for assistance
"Spot-Index data" in the non-volatile
RAM memory.
The Spot-Index data area is
automatically erased.
not The Spot-Index selected by the Check the Spot-Index data in the
control memory
external input is not in the memory
Check the Spot-Index selection.

E098 4-20mA

Welding servovalve command current Check connection between


interruption detected.
control and servovalve

E099 Electrode

During the electrode maintenance Check inductive sensors on


cycle the gun input on the dressing dressing tool
tool or the dressing tool electrovale
rotation input is lacking or the START
signal is released.

servovalve
command
anomaly

maintenance
anomaly

Outside the maintenance cycle a


dressing is attempted without any
request.

E100 Emergency
activated

Emergency signal generated by a


remote command.
Logical state of EMERG input is low.

GF WELDING

Check the cause that


generated the event
Check wiring with the
emergency command

Programming instructions
Appendix B Diagnostics Alarms: causes and remedies

Code

message

remarks

E101 SCR short circuit Voltage is present on input of current


outside of
sensor at no weld time.
welding interval. Possible reasons :

SCR defect

Broken cables

Spikes on sensor cable

Earth fault

Wrong connections

Defect control

E102 SCR short circuit The current measured during weld


during weld

time is out-of-range.

activities

GF WELDING

Check for SCR short circuit.


Check for anomalous voltage
at sensor input
Check current sensor cabling

Check for SCR short-circuit


Check for anomalous voltage
at sensor input.
Check current sensor cabling.