4-1 Isiwelding Manual

Integrated Inverter MFDC2 Weld334m
Use and maintenance handbook
B1
B2
BH2
BR2
BRH2
Ed.4 – September 2011 Code 39003128

GF WELDING S.p.A.
18/24 , Strada del Portone – 10137 – TURIN (Italy)
Ph.: 011-3031.278 (Italy Sales dept.)
011-3031.270 (Foreign Sales dept.)
Ph.: 011-3031.277 (Italy Service)

011-3031.274 (Foreign Service)
Fax: 011-3139716
e-mail: mail@gf-welding.it
web: www.gf-welding.it
Information inside this handbook belongs to GF WELDING S.p.A.

Copy or disclosure to third party, even partial, is forbidden without previous the authorization of GF
WELDING S.p.A.
GF WELDING S.p.A. reserves the right to change the features of the product introduced with this
manual without warning. Protection right reserved.
2 39003128_M.doc
Table of contents
1 FOREWORD.................................................................................................................................................. 6
1.1 USE AND CONSERVATION OF THE USE AND MAINTENANCE HANDBOOK ..................................................... 6
2 INVERTER VIEW......................................................................................................................................... 7
2.1 LABELS ...................................................................................................................................................... 8
2.2 DIMENSIONS .............................................................................................................................................. 9
2.2.1 Type with water cooling (600A )........................................................................................................ 9
2.2.2 Type with air cooling ....................................................................................................................... 10
3 INVERTER EXPECTED USE CONDITIONS......................................................................................... 11
3.1 NOTES ON SAFETY CONNECTIONS ............................................................................................................ 12
3.1.1 Grounding and insulation ................................................................................................................ 12
3.1.2 Safety against short circuits............................................................................................................. 12
3.2 FORBIDDEN CONDITIONS OF USE .............................................................................................................. 14
3.3 EXPECTED USE CONDITIONS ..................................................................................................................... 14
4 SAFETY WARNING................................................................................................................................... 15
4.1 DANGER WARNING................................................................................................................................... 15
4.2 RESIDUAL DANGER .................................................................................................................................. 16
5 TECHNICAL DATA ................................................................................................................................... 18
6 SYSTEM ARCHITECTURE AND HARDWARE PARTS ..................................................................... 21

6.1 INVERTER BLOCK DIAGRAM ..................................................................................................................... 22
6.2 HARDWARE FEATURES ............................................................................................................................. 24
6.2.1 List of available cards for system customization ............................................................................. 24
6.2.2 Layout Inverter MFDC2 Weld334mHardware arrangement of the inverter parts.......................... 25
6.2.3 Hydro fluidic system ........................................................................................................................ 26
6.3 CURRENT SENSOR .................................................................................................................................... 28
7 PROGRAMMING ....................................................................................................................................... 29
7.1 THE HCM 4300 HHT PROGRAMMING UNIT ............................................................................................ 29
7.2 THE LAPTOP ............................................................................................................................................. 30
7.3 CONNECTING MFDC2 WELD334M TO THE WMS CENTRALIZATION NETWORK ...................................... 30
8 INVERTER UNPACKING ......................................................................................................................... 31
9 INVERTER INSTALLATION ................................................................................................................... 32
10 POWER APPLICATION DIAGRAM ................................................................................................... 33
11 24 V I/O USE............................................................................................................................................. 34
11.1 EXTERNAL 24V .................................................................................................................................... 34
12 DIAGNOSTICS ALARMS ...................................................................................................................... 35
WELD334M CONTROL ERROR MESSAGES ............................................................................................................ 35
WELD334M MFDC INTEGRATED INVERTER ....................................................................................................... 45
13 F346-BUS INTERCONNECTION CARD ............................................................................................. 53
14 F375-PS POWER SUPPLY ..................................................................................................................... 54

14.1 CHARACTERISTICS ............................................................................................................................... 54
14.2 POWER SUPPLIES AND I/O.................................................................................................................... 55
14.2.1 P49 . Power supplies and input/output signals ............................................................................ 55
14.3 ANALOGICAL SERVO-VALVE INTERFACE .............................................................................................. 56
14.3.1 P2 – Servo-valve control port....................................................................................................... 56
14.3.2 Warning lights .............................................................................................................................. 57
14.4 CARD LAYOUT ...................................................................................................................................... 58
39003128_M.doc 3
15 F374-IMF MEDIUM FREQUENCY INTERFACE ..............................................................................59

15.1 CHARACTERISTICS ................................................................................................................................59
15.2 CONNECTORS TO FIELD .........................................................................................................................60
15.2.1 P53 – V-Sensor .............................................................................................................................60
15.2.2 P54 – I-Sensor ..............................................................................................................................60
15.3 CARD LAYOUT ......................................................................................................................................62
16 F384-CPU MICROPROCESSOR CARD...............................................................................................63
17 BASIC I/O CARD F399-IOB ...................................................................................................................66

17.1 STATUS LEDS ......................................................................................................................................67
17.2 P57. INPUTS ..........................................................................................................................................67
17.3 P31 . OUTPUTS .....................................................................................................................................71
17.3.1 Circuit breaker release .................................................................................................................73
18 BASIC I/O CARD F413-IOB ...................................................................................................................75
18.1 STATUS LEDS ......................................................................................................................................76
18.2 P66. INPUTS ..........................................................................................................................................76
18.3 P65 . OUTPUTS .....................................................................................................................................80
18.3.1 Circuit breaker release .................................................................................................................82
19 F414-IOE I/O EXPANSION CARD........................................................................................................84
1.2 SIGNAL STATUS LEDS..............................................................................................................................84
1.3 P67 . OUTPUT SIGNALS – FUNCTIONAL DESCRIPTION ..............................................................................85
19.1 P68 – INPUT SIGNALS – FUNCTIONAL DESCRIPTION .............................................................................88
19.2 PROGRAM SELECTION CODES/NETWORK ADDRESS WITH PARITY TABLE ...............................................91
20 F381-ETHERNET MODULE WITH KEY............................................................................................93
20.1 P10 ETHERNET 10BASE-T CONNECTOR................................................................................................94
20.2 CONNECTION CABLES ...........................................................................................................................94
20.2.1 Characteristics..............................................................................................................................94
20.2.2 Type of connection........................................................................................................................94
APPENDIX A - MAINTENANCE.....................................................................................................................96
MAINTENANCE ...................................................................................................................................................96
APPENDIX B – DIAGRAMS AND NETWORK CONFIGURATIONS .......................................................98
OPERATIONAL DIAGRAMS ...................................................................................................................................98
4 39003128_M.doc
DURING THE CONSULTATION OF THIS HANDBOOK ALL STEPS GENERATING RISK

WILL BE HIGHLIGHTED. USERS SHALL STRICTLY OBSERVE ALL PRESCRIPTIONS
GIVEN BY THE FOLLOWING SIGNS:
WARNING Incorrectly performed operation may damage equipment.
DANGER Incorrectly performed operations may lead to serious danger

situation for personal safety.
39003128_M.doc 5
1 FOREWORD
The goal of this handbook is to help user to keep the inverter in a perfect operational
status.
The assembly including the inverter is to be considered a “machine part”, not a
"machine" pursuant to the EEC directive. The assembly will be made up with other
devices or machine parts to become a regular machine.
Reading of this document is mandatory for GF WELDING S.p.A.; inverter
operational and maintenance staff and personnel in charge for transportation and
assembling must read it.
We recommend the over mentioned staff to be trained in order to ensure a perfect
inverter knowledge and familiarity.
This document belongs to GF WELDING S.p.A. It cannot be used to manufacture the
represented object nor forwarded to a third party or copied without written authorization
from GF WELDING S.p.A.
The owner defends its right pursuant to the law.
This handbook is the instruction handbook of the device. It is drawn up in compliance with
Directive 98/37/CE annex I paragraph 1.7.4
GF WELDING Spa reserves all the rights.
1.1 Use and conservation of the use and maintenance handbook

The use and maintenance handbook is to be considered part of the inverter and shall be
kept until the final disposal.
The document is to be kept by the person in charge for the equipment after final
installation.
The document represents the state-of-art of the technique at the moment the inverter is
sold. Manufacturer reserves the right to update production and handbooks without being
compelled to update previous production and handbooks.
WARNING
On professional use equipment the handbook cannot replace a proper user
experience. On some pieces of equipment or for particularly difficult operations the
handbook is to be considered only a reminder of main operations, advising in case
it is needed to use specifically trained staff.
NOTE:
in case the equipment is sold, please inform manufacturer of the new owner address to
ease servicing and/or the inverter update.
6 39003128_M.doc
2 INVERTER VIEW
39003128_M.doc 7
2.1 Labels
Open device only after discharge time
8 39003128_M.doc
2.2 Dimensions
2.2.1 Type with water cooling (600A )
4 FIXING HOLES - Ø7.5
BRACKET SUPPORT
39003128_M.doc 9
2.2.2 Type with air cooling
4 FIXING HOLES - Ø7.5
BRACKET SUPPORT
10 39003128_M.doc
3 INVERTER EXPECTED USE CONDITIONS

The integrated inverter MFDC2 Weld334m is a static transducer that generates a 500V or
650V alternate monophase voltage at a frequency of 1000Hz from mains three-phase
voltage. In this way it can manage medium frequency transformers with secondary
rectifier. Operational units to manage welding process have been built-in. It adjusts the
welding current through the square wave width modulation applied to the power
transformer using a technique called PWM.
The MFDC2 Weld334m can be locally programmed using the HHT4300 graphic terminal or
using a laptop computer with the WMS software installed. It can be programmed also from
a remote computer through the centralization network using WMS software and an
interface card.
You can store and run up to 255 welding programs and 16 different stepper programs.
The inverter is ready to work at network frequencies of 50Hz or 60 Hz.
You can interface the inverter to many types of devices and actuators such as welding
solenoid valves, PLC and robots, connecting toward the field either with regular cables or
with field-bus lines (Interbus, Profibus DP and so on) to be chosen among the available
modules.
The inverter design does not allow using it as a standalone device. You must always put the
inverter inside a proper box.
The inverter task is:
to supply the welding transformer;
to modulate the square ware pulse width applied to the power transformer;
to check the field, force and current parameters set on welding control.
Please keep in mind:
do not use the inverter or upkeep it before having fully read and understood this handbook.
More specifically you must adopt all precautions listed in this chapter and in chapter 4.
NOTE:
1. Do not use the inverter under conditions or for a use but the ones stated on this
handbook. GF WELDING S.p.A. shall not be held liable for breakdowns,
inconvenience or injuries due to non compliance to point 1 above.
2. Do not tamper with, alter o change, even partly, the equipment described in this
handbook. More specifically do not open the equipment without having waited the
time necessary (over 6 minutes) to ensure the power condensers to be
discharged. You are not allowed to operate differently to what stated or disregard
operation necessary for safety.
39003128_M.doc 11
3.1 Notes on safety connections
3.1.1 Grounding and insulation

This paragraph is about equipment grounding, which is to be workmanlike carried out.
• Correct grounding of the entire electric system is required for plant staff safety.
• It is extreme importance to prevent damage to the plant itself. Periodically check
cables and terminal board grounding.
• Pay the utmost attention to connections with moving and metal parts. Often ensure
there is no oxidation and electric connection not to be made on painted parts.
• In order to make a good ground connection avoid to series connecting the whole
ground installation or part of it with only one cable. It is also important to check that,
for each machine, the ground is star connected at the fixing point of the ground
cable.
• Some types of welding equipment require the grounding of the transformer
secondary to be connected externally.
• The MFDC2 Weld334m inverter is a state-of-art microchip device. It use is allowed
also in electromagnetic field polluted environment. Comply with the most scrupulous
operating conditions that is the control box to be closed and all ground wires
connected.
3.1.2 Safety against short circuits

A short circuit on the primary side of the transformer may occur on welding equipment.
This may lead to serious results such as:
• the destruction of the parts where the short circuit current discharge, on a Robot or
an automatic equipment;
• operator electrocution and damage to equipment on a manual workstation.
The short circuit may happen between primary and ground or primary and secondary.
MFT
500Vac
Robot arm
12 39003128_M.doc
In safety regulations it is specified that the secondary coil of the welding transformer must
be part of the protection measures against excessive contact voltage. Specific measures to
take are stated by local safety regulations.
Hereunder are stated some actions to take in order to prevent damage to things and/or
injuries to operators:
1. Ground the welding transformer secondary.
2. Use a 1000 Hz differential connected upstream the inverter, set to the minimum
current of 30 mA.
MFT
L1
differential
Inverter
1000 Hz
L2
L3
N
3. Use a safety device provided with circuit breaker to monitor the value of gun voltage
in comparison to ground.
MFT
L1
Differential
L2
Inverter
L3
N
Secondary irregular
tension sensor
39003128_M.doc 13
3.2 Forbidden conditions of use

It is forbid:
• to use the MFDC2 Weld334m without proper cooling;
• to supply the MFDC2 Weld334m with a voltage different than the stated one;
• to carry out unauthorized modifications or interventions;
• to use item non genuine or non specific parts;
• to use a degraded system due to lack of maintenance;
• to install the device differently from what stated in chapter 9;
• to let unskilled staff using the MFDC2 Weld334m inverter.
3.3 Expected use conditions

Welding current is a direct current with a minimum residual ripple. This is the reason why
there is no inductive resistance thus a lesser need of energy. This way you can use the
inverter for:
- welding guns with huge useful depth;
- high welding currents;
- quality check systems;
- three sheet metals welding;
- on view welding spots;
- safety spots.
Moreover, having a 1 msec setting time, it is fit to be used in quick parameter change
manufacturing.
14 39003128_M.doc
4 SAFETY WARNING
In order to ensure the maximum working reliability, GF WELDING S.p.A. made a careful
choice of materials and parts to manufacture the equipment. The equipment has passed a
standard testing before delivery.
A good yield in time of the inverter depends also on a correct use and a proper preventive
maintenance according to instructions of this handbook.
All constructive elements, connection and command parts have been engineered and
manufactured with such a grade of safety to resist anomalous stress or a stress higher than
the one stated in this handbook.
These are premium quality materials and their incoming in the company premises, storage
and use in workshop is constantly monitored in order damages or wear and tear or
malfunctioning not to arise.
Any time a procedure that may involve damage or injury risk is required, accident-
prevention measures are recalled and further detailed in this handbook.
4.1 Danger warning

As the inverter operates with high voltage we recommend keeping in mind safety
information hereinafter.
High voltage shock may lead to death. Always operate with the utmost care and according
to current safety regulations.
Before carrying out maintenance on the equipment always cut off both mains and
accessory power supply. Put up specific notice panels:
MAINTENANCE DO NOT SWITCH ON MAINS

nearby main switches. Lock main switches on the OFF position using the proper lock.
Never bypass safety devices installed on the equipment. Should it be necessary, put up
proper notice and operate with the utmost care. Restore all safety devices as soon as
possible.
No grounding of equipment may cause severe injuries to people. Always be sure the
equipment is grounded according to regulations.
Avoid the use of flammables or toxic solvents such as gasoline, benzene, ether or alcohol.
Always be sure, before operating the equipment, maintenance staff to be at safety distance
and tools or materials not to be left near the equipment.
Equipment installation must always comply with industrial injuries legislation.
Always ensure all protection to be present and properly closed before operating equipment.
Lengthy overloads or breakdown may overheat electrical apparatuses resulting in toxic
fumes. Cut off power supply and do not approach the equipment before the proper
ventilation has dispersed such fumes. Avoid breathing fumes still inside the equipment
during repairs.
In case of fire on the equipment never use water; disconnect all power supplies and use
CO2 fire extinguishers.
Ensure not to wear object that could get entangled in equipment and act as conductors
such as chains, bracelets and so on.
Ensure the tools to be in perfect conditions and provided of insulated handle,
where required. Check the cable and conductors insulation of equipment not to have the
slightest damage or break.
Welding control programming must be carried out by skilled personnel. Wrong welding
programs parameters may cause damage to people or things due to unwanted molten
material spatter during welding. Always wear protective glasses, fireproof clothes and
safety shoes.
A 24V supply external to the equipment or to the control, may energize the equipment
even if the main switch is off.
Danger may arise when, after electrodes change or after tip dressing, no current re-
matching occurs, especially when using the stepper (stepper reset).
39003128_M.doc 15
Danger situations may occur due to voltage drop or to machine emergency device
engagement, causing the return of pneumatic valves used during manoeuvre. This may
lead to consequences over the entire equipment.
You are not allowed to by-pass flow meter or thermostats engagement if during welding
there is no water flow or water flow is poor.
WARNING
This is a class A resistance welding equipment.

It is not intended to be used on a low-voltage public network which supplies
domestic premises.
It may cause radio frequency interference.
4.2 Residual danger

Pay special attention to the following signs:
DANGER!
Before carry out inverter maintenance cut off mains.
WHEN OPENING THE EQUIPMENT, YOU MUST ALWAYS WAIT 6 MINUTES AFTER
MAINS CUT OFF.
DANGER!
Electrocution danger when carrying out maintenance on live equipment
DANGER!
Pacemaker holders must not go near the inverter during operation
16 39003128_M.doc
DANGEROUS ELECTRICAL VOLTAGE!

Any residual current devices used on the mains side of the MF inverters to
protect persons getting into direct or indirect contact must be of type B. As per
IEC60755, these devices must also be capable of safely detecting possible
residual currents of 1kHz frequency.
DANGEROUS ELECTRICAL VOLTAGE!

Protective grounding is the only protective measure permitted as per
EN 50178 (DIN VDE 0160).
Operation in systems with ordinary residual-current circuit-breakers is not
permitted because of the risk that residual currents may flow from the
intermediate circuit to earth and back into the system without tripping the RCCB.
A differential current monitor must be used.
Do not go near the inverter carrying with you materials that may be damaged such as:
all kind of magnetic card such as credit cards, ATM cards, telephone cards, ID cards,
hour stampings and so on;
any kind of magnetic tape such as audio cassettes, video cassettes, floppy disk and so
on;
any kind of delicate machine such as calculating machines, cameras, video cameras
and watches (mainly mechanical).
39003128_M.doc 17
5 TECHNICAL DATA
GENERAL FEATURES (all versions)
MANUFACTURER GF WELDING S.p.A.
INVERTER NAME M.F. WELDING CONTROL
INVERTER TYPE MFDC2 Weld334m
YEAR OF CONSTRUCTION See inverter label
TOTAL WEIGHT (Kg): ~ 17.8 kg (water) - ~ 22 kg (air)
OPERATIONAL TEMPERATURE (°C): 5 - 50
MAX HUMIDITY: 95% without condensate
STORAGE TEMPERATURE (°C): 0 - 60
PROTECTION ACCORDING TO DIN 40050 IP20
COOLING LIQUID FEATURES (all versions)

Liquid type water
WATER QUALITY:
- PH Between 7.0 and 9.0
Hardness G.F.≤ 10
Max chlorine content 20 PPM
Max nitrate content 10 PPM
Max sulphate content 100 PPM
Max solid content 200 PPM
Max calcium carbonate content 50 PPM
Resistivity at 25° [kΩ m] Over 5
.
PRESSURE AND DELIVERY 0.3 – 0.6 Mpa – 4 - 6 l/m’

INPUT TEMPERATURE 15° - 30°
18 39003128_M.doc
600 A INVERTER ELECTRIC FEATURES – WATER COOLING

SUPPLY 400÷500 Vac 3ph 690 Vac 3ph + N
TOLERANCE ± 10% ± 10%
FREQUENCY 50 Hz / 60 Hz 50 Hz / 60 Hz
WIRING Three-phase three-phase plus neutral
MAX PEAK CURRENT 555 A 555 A
MAX PEAK CURRENT > 10% duty cycle ton = 200ms
555 A 555 A
NOMINAL CURRENT 100% duty cycle 270A 270A
OUTPUT VOLTAGE 500÷650Vac / 1000 Hz 500 Vac/1000 Hz
WELDING CONTROL CARD SUPPLY +5Vdc/24 Vdc +5Vdc/24 Vdc
SWITCH RECOMMENDED SIZE 125 A 125 A
FUSE RECOMMENDED SIZE 100 A 100 A
SUPPLY POWER CABLE SECTION Cable length 20 m – 35 Cable length 20 m – 35
mm2 section with lugs mm2 section with lugs
SECTION OF POWER CABLES BETWEEN INVERTER Cable length 30 m – 25 Cable length 30 m – 25
AND TRANSFORMER mm2 section with lugs mm2 section with lugs
CARD SUPPLY Weld334m cards Weld334m cards
ANCILLARY CONTROL VOLTAGE 24 Vdc ±5% 24 Vdc ±5%
39003128_M.doc 19
600 A INVERTER ELECTRIC FEATURES – AIR COOLING

SUPPLY 400÷500 Vac 690 Vac
TOLERANCE ± 10% ± 10%
FREQUENCY 50 Hz / 60 Hz 50 Hz / 60 Hz
WIRING Three-phase Three-phase
MAX PEAK CURRENT 555 A 555 A
MAX PEAK CURRENT > 10% duty cycle ton = 200ms
555 A 555 A
NOMINAL CURRENT 100% duty cycle 130A 130A
OUTPUT VOLTAGE 500÷650Vac / 1000 Hz 500 Vac/1000 Hz
WELDING CONTROL CARD SUPPLY +5Vdc/24 Vdc +5Vdc/24 Vdc
SWITCH RECOMMENDED SIZE 125 A 125 A
FUSE RECOMMENDED SIZE 100 A 100 A
SUPPLY POWER CABLE SECTION Cable length 20 m – 35 Cable length 20 m – 35
mm2 section mm2 section
SECTION OF POWER CABLES BETWEEN INVERTER Cable length 30 m – 35 Cable length 30 m – 35
AND TRANSFORMER mm2 section mm2 section
CARD SUPPLY Weld334m cards Weld334m cards
ANCILLARY CONTROL VOLTAGE 24 Vdc ±5% 24 Vdc ±5%
Load Pow er erogation vs. ED % : T air = 40 °C , 4.5 m /s air flow

600
550 200 m s
400 m s
500 600 m s
Load 800 m s
current 1200 m s
(transf. 450 1600 m s
prim .) 2000 m s
[A] 400
350
300
250
200
150
100
0 1 2
10 10 10
ED = ton / (ton + toff)
20 39003128_M.doc
6 SYSTEM ARCHITECTURE AND HARDWARE PARTS

The MFDC2 Weld334m is composed of two separate operational units:
1. the first unit is composed of the I/O DSP card and the power parts (SCR IGBT diodes);
2. the second unit is the control including the following operation units: CPU, ADC, I/O,
Proportional EVS, Fieldbus, Network.
Using such cards the inverter can:

• be configures for advanced or specific applications, used in the resistance welding field;
• be enriched with optional functions such as the proportional solenoid valve or the
memory card;
• support a serial communication port towards the welding centralizer.
Below it is shown the inverter architecture.
400÷500VAC 3Ph
690VAC 3Ph+N
≈ 500÷650VDC
1kHz
IGBT IGBT
#1 #3
AC +
L1
L2
L3 DC
N
- IGBT
#2
IGBT
#4
N only for 690V
DRIVER
CONTROL
I/O
WMS Ethernet I/O
CPU Fieldbus (Interbus)

Analogic ADC
or
39003128_M.doc 21
6.1 Inverter block diagram
400÷500Vac 3Ph / 690Vac 3Ph+N
500÷650Vac
A static transducer called Inverter generates and regulates the energy in medium
frequency. Starting from a balanced three-phase power supply provides the needed
transformations, called PWM, so that the transformer primary is supplied with square wave
energy at 1000Hz.
22 39003128_M.doc
The energy regulation is performed defining the duration, in time, of the 1000 Hz pulses.
The Inverter may be water cooled or air cooled.
Inside the Inverters there is a condenser bank that provides to accumulate energy and to
filter the residual ripple from the mains supply rectification.
Two version of inverter are available, the 600A (555A - 10% duty cycle) and the 1200A
(1150A - 10% duty cycle). Mains supply 3x400 and 3x690 Vac + N.
To calculate the diameter of mains cables keep in mind:
- 3x 400÷500V 6 pulse rectification
- 3x690V+N 3 pulse rectification
You can integrate it with all modules of the Weld334m control family.
Measuring the current on the secondary and the regulation of the same are performed at
closed ring with answer time 1 msec.
Welding time resolution is indicated as usual in cycles/network. The 1 msec resolution is
available on demand.
Welding current programming is directly made in kA.
Voltage applied to welding transformer: network voltage, rectified from three-phase to full
wave.
There is an automatic protection against short circuit and accidental overloads.
You can insert up to six modules in the inverter (fieldbus cards, I/O cards, network cards
and so on).
The box may contain all inverter sizes.
The inverter has built-in diagnostics.
The automatic adjustment of the welding current is associated to the various types of guns.
The air or water cooling unit, separated from the inverter, can be configured on field.
The inverter must be connected to a specific MF welding transformer. The medium
frequency welding transformer is sized for operation at 500 Vac - 1000Hz, in case of main
power supply of 400V 3Ph o 690V 3Ph+N; or 650 Vac - 1000Hz, in case of main power
supply of 500V 3Ph. The output voltage must be rectified using a diode bridge upstream
the welding gun.
The minimal cross section of power cable for connection inverter to transformer must be
25mmq with lugs.
39003128_M.doc 23
6.2 Hardware features

Hereinafter you will find the list of cards and power modules that allows the operational
configuration of the inverter. The base configuration always provides:
• the power module;
• the CPU;
• a 6 slot MF bus card;
• a 4 digit display;
• an Analog & SV bay card;
• a base I/O module with terminal;
• a network card.
6.2.1 List of available cards for system customization

32611000
32611040
33034600
33037500
33037400
33038400
33039900
33031300
33031400
33038100
Order
code
denomination
2-WD4006
2-WD5006
F346 BUS
F384 CPU
F381 ETH
F399 IOB
F313 IOB
F374 IMF
F314 IOE
F375 PS
Card
Power module 400-440Vac – 600A – WATER

Power module 400-500Vac – 600A - WATER
Power unit + 4 digit Display + Electrovalve

Description
Inverter control + Analog inputs
10 Mbit Ethernet with Data Key

BUS card 7 slot MF (5+2)
I/O Expansion Card

I/O Base card
I/O Base card
C.P.U.
Order Inverter denomination

code
32610360 MFDC2-WD4006C-B1 X X X X X X
32610418 MFDC2-WD4006N-B2 X X X X X X
32610420 MFDC2-WD4006C-BH2 X X X X X X X
32610410 MFDC2-WD4006C-BR2 X X X X X X X
32610412 MFDC2-WD4006C-BRH2 X X X X X X X X
24 39003128_M.doc
6.2.2 Layout Inverter MFDC2 Weld334mHardware arrangement of the inverter

parts
WELDING CONTROL CARDS
L1-L2-L3
NETWORK
TERMINALS
INPUT
U – V TERMINALS
OUTPUT POWER CONDENSATOR
SCR
--------------------------------------------------------------------------------------------------------------
COPPER BAND
L1-L2-L3 NETWORK
INPUT
CHILL PLATE
(water cooling)
COPPER BAND
U – V + PE OUTPUT
SCR
MFDC2 Weld334m Inverter layout
39003128_M.doc 25
6.2.3 Hydro fluidic system
MORSETTI DI POTENZA
REAR SIDE
¼”G rear plugs
LOWER SIDE
Drip-proof quick couplings ¼”G

or hose-tail for tube DN6 +
adapter ¼”G
Carry out hydro fluidic connection using ¼ GAS type fittings. Temperature, delivery and
water pressure must be the ones stated on Technical Data table on chapter 5 of this
handbook.
Monitor water delivery using a flow meter to prevent any damage to inverter power parts
(IGBT) during welding.
26 39003128_M.doc
The hydro fluidic connection can be made on the rear side or lower base of the inverter.
Example of rear side hydro fluidic connection
NETWORK CABLES ENTRANCE
Optical fiber, ethernet,

servovalve cable min.
Drip-proof quick couplings ¼”G 80mm radius of
or hose-tail for tube DN6 + curvature
adapter ¼”G
REAR SIDE WATER

CONNECTION
AIR FLOW WITH NATURAL

CABLES EXIT TOWARDS WELDING CIRCULATION THROUGH SLOTS FOR
TRANSFORMER ¼”G plug ELECTRONIC CARDS COOLING
Example of lower base water connection
NETWORK CABLES ENTRANCE
Optical fiber, ethernet,

CABLES EXIT TOWARDS WELDING servovalve cable min.
TRANSFORMER 80mm radius of
curvature
¼”G plug
LOWER BASE WATER

CONNECTION
Drip-proof quick couplings ¼”G AIR FLOW WITH NATURAL

or hose-tail for tube DN6 + CIRCULATION THROUGH SLOTS FOR
adapter ¼”G ELECTRONIC CARDS COOLING
39003128_M.doc 27
6.3 Current sensor

The current sensor called also amperometric belt or Rogowskij belt, toroid or
amperometric transformer (TA or KSR) is the device used by the control to sense the
welding current and to adjust its value during welding.
Independently from specifications and from transducer electrical features, there are
some basic rules to apply as to transducer position and relevant wiring, to minimize
errors due to electrical and, mainly, magnetic disturbance.
Reliability and accuracy of the ammeter directly depends on the correct positioning and
on a proper protection from external disturbance.
In case the sensor is embedded into the welding transformer, problems concerning the
compliance with some of the rules herein stated, have been solved in the transformer
design phase.
As to sensor positioning:
• sensor has to be positioned in the welding secondary circuit;
• the plane the sensor is positioned on must be orthogonal to the conductor the
current to be measured flows in;
• the sensor, if external to the welding transformer, shall be positioned as near as
possible to the welding electrodes; in this way you get the maximum accuracy. The
above is not always possible. A good accommodation is to insert sensors in the rear
part of the guns, near the cable adapter position. Provide for protection against
shocks. you can always put it on the secondary output of the transformer;
• live conductor must be at the center of the toroid;
• the sensor shall be positioned as far as possible from angles or L shape bends of the
secondary conductor;
• as regards the secondary circuit coil put the sensor in such a position the distance
between outgoing conductor and the incoming one be as greater as possible.
As to sensor connections:
• the connection cable must be tightly twisted, shielded and be as short as possible;
keep the cable as far as possible from electric or magnetic disturbance sources; it
must not be run in parallel with the welding components (primary + secondary);
• cable shield must be properly grounded from just one side to the welding control. No
sensor cable head must be grounded;
• carefully avoid temporary junctions or connections between sensor and welding
control connector to avoid all induction and capacitive effects; avoid sectioning such
as terminals or plugs when possible;
• avoid to insert fuses on current sensors conductors.
All users installing or wiring as well as those who engineer and manufacture electric
cabinets, transformers and other devices connected to current sensors shall keep in
mind the above rules. Non compliance with such rules will result in a lack of accuracy
and repetitiveness of welding with constant current control device and may cause
serious failures;
• we recommend to use 150 mV/kA/1kΩ current sensors and a 20-25 Ω internal
resistance, available from GF WELDING S.p.A.
• MFDC2 Weld334m allows you to use up to 6 sensors in series, only one at a time
welding. Connected sensor number must be parameterized in control. Refer to
programming handbook, Setup chapter.
28 39003128_M.doc
7 PROGRAMMING
7.1 The HCM 4300 HHT programming unit

The HCM4300 HHT is an external optional device which allows you to locally program
the Weld334m IFM.
Size: L=200mm, H=90mm, W=35mm

Operating temperature: 0°C to +45°C Humidity 0% to 80% without
condensation
Storage
temperature: -40°C to +80°C Humidity 0% to 80% without
condensation
Weight: ~500g
Female Sub-D 9 pin type connector

Pin Signal Description
1/6 0VH Ground
2/7 +VH HHT4300 terminal supply
3 Not connected Polarization pin
4 RXD+ Data reception +
5 TXD+ Data transmission +
8 RXD- Data reception -
9 TXD- Data transmission -
For further information refer to Weld334m programming handbook
39003128_M.doc 29
7.2 The laptop

The laptop connects to the P1 connector of the control and communicates through a
RS485 Full duplex serial line, using compatible releases of the WMS application.
Connection cable between Weld334m IFM and laptop PC: F2118;

Order code 32102110;
RS485/RS232 converter included;
L=2.5 m
7.3 Connecting MFDC2 Weld334m to the WMS centralization network

To centralize welding areas, GF WELDING S.p.A. has developed the Welding
Management System software hereinafter called WMS. You can access all control
devices installed in a specific welding zone using a PC connected serial line.
The program allows interacting with all control devices. In the same time you can
control the entire welding process in the concerned zone.
The network interface may be: PROFIBUS FMS or ETHERNET TCP/IP.
The welding control serial port has been designed to operate inside an industrial
environment, where there are many electrical and pulse disturbances. To protect the
input stages, such stages are equipped with disturbance blackout circuits. The output
stages supply highly clean signals.
To apply welding controls on a Profibus FMS or an Ethernet TCP/IP centralization
network refer to the relevant specifications.
User shall observe some rules while setting up the network.
• Network cables shall not run beside power cables. Be aware of this warning when
planning power lines and network lines.
• Network cable should be as short as needed. Comply with Ethernet or Profibus
specifications.
To achieve the best results consider the following:

• terminate the line as stated on the network card installation manual;
• when using Profibus, daisy chain connect all control devices to the network interface
card, in order to have only a single transmission line.
Cable must comply with Profibus or Ethernet specifications.
For further information refer to WMS handbook
30 39003128_M.doc
8 INVERTER UNPACKING
Inverter
unpacking
Proceed with
Open case Refer to flow-chart
inverter
in chapter 9
hardware
installation
Unpacking
Repack the
Remove protection complete
damaged inverter
properly
repositioning all
protection
materials
Send the inverter

Take the
to GF WELDING
inverter out of
servicing
the packing
Check the inverter

Take a new
for physical
inverter
damages
Is the inverter NO
damaged?
Repeat the same
procedure
YES
39003128_M.doc 31
9 INVERTER INSTALLATION
Installation start
Let H2O run in

Refer to chapter 8 Unpack new cooling circuit
flowchart inverter and check seal
Check the
inverter supply Tighten or replace
Are there YES the cooling circuit
voltage compared
to the available H2O leaks? fitting when no
network voltage water is in the
system
NO
Connect X2
Put the Connect connector, current
inverter in its L1, L2, L3 (N), PE sensor and the
case power supply external 24 Vdc
cables with field power
supply
Connect U, V, PE to Connect
Secure the communication
connect welding
inverter using card connectors
transformer
bolts or securing installed onboard
tools the inverter
Installation
Connect I/O X1 completed
Connect the connector with
¼ GAS H2O field
fittings
32 39003128_M.doc
10 POWER APPLICATION DIAGRAM
39003128_M.doc 33
11 24 V I/O USE
11.1 External 24V

24Vdc to energies the I/O section must be supplied by an external power supply, connected
to card F375, P49, pins 3 and 4.
WELDING CONTROL CARDS
34 39003128_M.doc
12 DIAGNOSTICS ALARMS
Weld334m control error messages
Code Description Cause of Alarm Recommended operations

E001 Tip warning The Warning value set in the stepper used by It is almost time for tips maintenance
channel A the tips of channel A has been reached . on channel A (change tip).
The red W.STEP. A LED on the front of the
welding control switches on.
E002 Tip warning The Warning value set in the stepper used by It is almost time for tips maintenance
channel B the tips of channel B has been reached. on channel B (change tip).
The red W.STEP. B LED on the front of the
welding control switches on.
E003 Cable wear The Warning value (for channel A) set in the As above, but for the cable, channel A
warning SETUP – CABLE WEAR menu has been
channel A reached.
E004 Cable wear The Warning value (for channel B) set in the As above, but for the cable, channel B
warning SETUP – CABLE WEAR menu has been
channel B reached.
E005 Meas. curr.< When the average welding current measured - Check value set for Welding current
min threshold is less than the minimum threshold value, the minimum threshold
faulty welding counter is increased by 1. If - Check value set for Weld alarms
this exceeds the WELD ALARMS THRESHOLD threshold.
set in SETUP-CONFIGURATION Weld334m, the - Check tip force
alarm “E005 – Meas. Curr. < min threshold - Check condition of tips
” is generated . - Check electric conductivity of
The red LOW CURR LED, on the front of the material to be welded
welding control switches on . - Check that the power supply voltage
Possible reasons: is correct
- Check current sensor wiring and
- Insufficient tips force
position
- Damaged tips
- Check approach parameters or
- Oxidised or dirty material to be welded
pressure in the welding program
- Low power supply voltage
that has caused the error
- Current sensor malfunctioning
- Check cables/braids and bus bar
- Approach times or pressure too low
-The programmed weld current is higher than
the maximum allowed.
- Damaged cables/current braids or bus bar
E006 Meas. curr.> The average welding current measured is over - Check value set for maximum
max. the maximum threshold. welding current threshold
threshold Possible reasons: - Check that the tip has not
- Faulty transformer discharged current to ground
- Welding control fault
E007 Warning The Stop counter threshold (in percentage) It is almost time for dressing tool
dressing tool set in the Warnings of the DRESSER WEAR maintenance.
menu has been reached.
35
E011 Firing angle.< The SCR firing angle has a value that is less - Set a lower firing angle minimum
min value than the value set in the minimum firing value
angle parameter. - Check the stepper associated to
The efficiency limit has been reached. the program that has generated
Possible reasons: the error
- Wrong setting of associated Stepper - Check tips
- Voltage drop on power supply line - Check secondary circuit
- Damaged tips.
- Damage inside the secondary circuit
(Electric resistance too high due to slow or
corroded contacts, worn cables)
- Transformer too weak
- The cosfi has not been included in the
program
E013 SCR When the average conduction angle of the - Check the programmed value in
conduction > SCRs, measured during the weld, is longer the Conditional threshold field.
conditional than the programmed Conditional threshold - Check the programmed value in
threshold and shorter than the Maximum conduction the alarm threshold field.
angle, the alarm counter is incremented by - Check the electrodes condition
1. - Check the electrical conducibility
If the counter become higher than the alarm of the metal sheets of the joint
threshold programmed in SETUP- - Check if the mains voltage is in
CONFIGURATION Weld334m, the alarm tolerance
“E013 – conduction > conditional threshold. - Check the secondary power
The measured conduction angle is shown in cables and shunts.
the Weld Analysis.
The diagnostic alarm is activated.
Possibile causes for this alarm could be:
- Damaged electrodes
- Low mains voltage
- Programmed welding current too high
(Higher the the max possible current)
- Secondary power cables and shunts are
damaged.
E015 Tip force out Wrong electrode force - Check air pressure on pneumatic
of tolerance (for WELD334m with the option tip force circuit .
tolerance only) - Check condition of weld gun
closing component
- Check condition of weld gun and
for any friction in movement.
E016 Resistance Please consult the WQS manual. Please consult the WQS manual.
peak not
detected (WQS)
E017 Resistance Please consult the WQS manual. Please consult the WQS manual.
drop (WQS)
E022 Short circuit Please consult the WQS manual. Please consult the WQS manual.
welding (WQS)
E023 Sticked spot Please consult the WQS manual. Please consult the WQS manual.
(WQS)
E024 Burned spot Please consult the WQS manual. Please consult the WQS manual.
(WQS)
36
E031 Measured The average welding current measured is - Check value set for welding
current < less than the minimum threshold. current minimum threshold
min threshold Possible reasons: - Check tips force
- Insufficient tips force - Check condition of tips
- Tips damaged - Check electric conductivity of
- Sheets dirty or with bad conductivity material to be welded
- Power supply too low - Check that the power supply
- Defect in current sensor voltage is correct
- Bad matching of part - Check current sensor wiring and
- Damage inside the secondary circuit position
(Electric resistance too high due to slow or
corroded contacts, worn cables)
- Faulty welding control
E032 Null welding The average welding current measured is - Check tips force
current less than 100 A - Check condition of tips
Possible reasons: - Check electric conductivity of
- Insufficient tips force material to be welded
- Tips damaged - Check that the power supply
- Sheets dirty or with bad conductivity voltage is correct
- Power supply too low - Check current sensor wiring and
- Defect in current sensor position
- Approach or pressure times too short - Check approach parameters or
- Malfunctioning of SCR firing card (for pressure in the welding program
single phase systems) that has caused the error
- Faulty SCR unit (for single phase - Replace the Firing card
systems). - Replace SCR unit
- Faulty welding control - Check welding control
E036 SCR The average conduction angle of the SCRs, - Check the programmed value in
conduction > measured during the weld, is longer than the the Maximum conduction angle
threshold programmed Maximum conduction angle. field.
The measured conduction angle is shown in - Check the electrodes condition
the Weld Analysis. - Check the electrical conducibility
The diagnostic alarm is activated. of the metal sheets of the joint
- Check if the mains voltage is in
tolerance
- Damaged electrodes - Check the secondary power
- Low mains voltage cables and shunts.
- Programmed welding current too high
(Higher the the max possible current)
- Secondary power cables and shunts are
damaged.
E037 SCR The average conduction angle of the SCRs, - Check the programmed value
conduction < measured during the weld, is shorter than in the Minimum conduction
threshold the programmed Minimum conduction angle. angle field.
The measured conduction angle is shown in - Check the wiring and the
the Weld Analysis. components of the welding
The diagnostic alarm is activated. circuit.
- One or more sheets missing in the joint to
be welded.
- Current measurement influenced by
externale factors. (i.e. 2 current sensors in
series on the same circuit)
- The transformer has been changed with
one of a bigger size without any parameter
adjustment
E043 Warning: The number of weld spots programmed for - Dress tips used by channel A
dressing dressing operation has been reached by the - In SELF-INCREASE PROGRAMS
channel A Stepper used on channel A. menu, check dressing has taken
The red DRESSING LED on the front of the place.
welding control switches on. - Activate RESRAVA input
37
E044 Warning: The number of weld spots programmed for - Dress tips used by channel B
dressing dressing operation has been reached by the - In SELF-INCREASE PROGRAMS
channel B Stepper used on channel B menu, check dressing has taken
The red RICHRAVB LED on the front of the place.
welding control switches on. - Activate RESRAVB input
E045 Dressing tool The Stop value set in SETUP – DRESSER - Carry out dressing tool maintenance
wear alarm WEAR menu has been reached - Reset the counter in the SETUP –
DRESSER WEAR menu
E046 Cable wear The Stop value (for channel A) set in the - Replace the cables used by channel
alarm SETUP – CABLES WEAR menu has been A
channel A reached - Reset the counter A in the SETUP –
CABLES WEAR menu
E047 Cable wear The Stop value (for channel B) set in the - Replace the cables used by channel
alarm SETUP – CABLES WEAR menu has been B
channel B reached - Reset counter B in the SETUP –
CABLES WEAR menu
E048 Without Indication of Weld NO status (only for

current controls in conformity with CNOMO
configuration standards)
E049 Stepper The Stop value set in the stepper used by - Replace or dress the tips used by
alarm channel A tips has been reached. channel A
channel A The STEP. A LED on the front of the welding - Reset the counter in SELF-INCREASE
control switches on. PROGRAMS menu
- Activate RESALSA input
E050 Stepper The Stop value set in the stepper used by - Replace or dress the tips used by
alarm channel B tips has been reached. channel B
channel B The STEP. B LED on the front of the welding - Reset the counter in SELF-INCREASE
control switches on. PROGRAMS menu
- Activate RESALSB input
E052 Comm. An error or a complete communications - Check connection between control

anomaly with failure has been found with the remote CPU. and remote CPU
remote CPU This alarm is only diagnosed in systems in - Check possible communication
which the welding control is in configurations (jumpers, parameter
communication with another process control settings, etc.)
(e.g. a robot)
- Check correct operation of remote
CPU
38
E053 Low battery Battery low condition. - Replace the battery (see the
The device remains in alarm condition (red Maintenance chapter on technical
LOW BAT LED on CPU card remains documentation)
permanently alight). - If the problem persists, a repairing
Alarm outputs are not activated, a message service on the CPU card is required
is sent to WMS (centraliser).
However, the welding control is able to
operate.
NB: the flashing LOW BAT red LED is not due

to a low battery, but to a failure on the CPU
card. In this situation, shut down the control
then power-on again to reset.
It is not sufficient to carry out a RESET of
the CPU card using the pushbutton on the
front panel.
E055 Current The welding control checks the current Assuming that the ohmic resistance of
sensor sensor resistance before welding. the sensor is 22 Ω, use an ohmmeter
interrupted If the resistance measured is high, the to check that this value is present at
following error is generated . the ends of the input conductors on
Possible reasons: the welding control
- Broken cable
- Loose connectors
- Control defect
- Sensor defect
E056 Current The welding control checks the current Assuming that the ohmic resistance of
sensor in sensor resistance before welding. the sensor is 22 Ω, use an ohmmeter
short circuit. If the resistance measured is low (Short to check that this value is present at
Circuit), the following error is generated. the ends of the input conductors on
the welding control.
Possible reasons: - Check cable and connectors
- Broken cable - Check control
- Loose connector - Check sensor
- Control defect
- Sensor defect
- Resistor ground connection
E057 24 volts I/O The control does not detect the 24 volts - Check the 3.15 A fuse on the control
missing (internal or external) supply needed by the - Check the externally supplied
I/O circuits. voltage
E058 Missing firing While welding the welding control has - The impulse command signal is
SCR 1 detected that current is missing on one or interrupted
both the conduction semi-cycles. - Broken or inverted wire between
This alarm causes a stop. firing module and SCR1
- SCR firing module failure
- SCR1 failure
E059 Missing firing While welding the welding control has - The impulse command signal is
SCR 2 detected that current is missing on the interrupted
second conduction semi-cycle. - Broken or inverted wire between
This alarm causes a stop. firing module and SCR2
- SCR firing module failure
- SCR2 failure
39
E060 Main power The signal «SWITCH ON» is absent (only for Check main power switch
switch off controls responding to CNOMO normative).
E061 FieldBus card Internal failure on fieldBus card in welding If foreseen, check the card external
fault control (Interbus-S, ProfiBus-DP, DeviceNet, power supply connections
etc). If the error persists, replace the
No external 24V FieldBus card.
E062 FieldBus Communication error between FieldBus card - Check the connection between
communication and remote master device. FieldBus card and master device
fault (cable wiring, network termination)
- Check FieldBus card configurations
(network address, baud rate,
communication parameters).
- Check whether the master device
communication is active.
E063 Invalid start The code of the welding program to be run is - Check whether the LED states (from
code not correct. CODE 0 – CODE 5) correspond to
This error is only displayed when the “start the program number selected
code parity” parameter in the SETUP – -Set the Parity code start to Off in the
CONFIGURATION Weld334m menu is set to SETUP – CONFIGURATION
Even or Odd. Weld334m menu (WARNING: the
parity code for the program
selection is disabled)
E064 Start active The START signal was active during the - Switch off the START signal in order
during during reset/power-up of the welding control. the alarm
reset/power-up The welding sequence it’s not being started.
The alarm will be cleared automatically when the
START signal is switched off.
E065 Program not The selected welding program is not in the - Check whether the LED states (from
present welding control memory. CODE 0 – CODE 5) correspond to the
program number selected
E066 Dressing alarm The emergency spots set after reaching the Carry out the maintenance operations
Stop threshold in the program of the stepper and confirm the dressing.
used have been exceeded.
E067 Electrode The emergency spots set after reaching the Carry out the maintenance operations
change alarm Stop threshold in the program of the stepper and confirm the electrodes change.
used have been exceeded and all the
programmed dressings have been carried
out.
E070 Network At welding control power-on the network Check the working frequency of the
frequency fault voltage frequency has a deviation that is Software Release at control power-on
more than the allowed tolerance (±2.5Hz of
nominal frequency)
E071 Remote Cnx The connection with both the primary and -Check the connection configuration
FTP Server the secondary remote FTP server (File data.
Transfer Protocol) to download spots - Check the configurations of the
protocol data has given negative result. connections enabled on the FTP
server.
The configuration data for connection is set
- Check the status of the FTP server.
by WMS software, in the SETUP window, “IP
- Check connections between welding
services parameters ” section
control network card and the
company network
40
E072 Remote Cnx The operation to connect remote MAIL - Check connection configuration data.
MAIL Server server, to send e-mails from the welding -Check configurations of connections
control, has given a negative result. enabled on the MAIL server .
- Check status of MAIL server.
The configuration data for connection is set
- Check connections between welding
by WMS software, in the SETUP window, “IP
control network card and company
services parameters ” section.
network
E073 Initialized The self-diagnostics at power-on has Change battery on CPU card.
module detected a fault in the non-volatile RAM If necessary, contact GF WELDING
memory data. technical service.
Memory is automatically initialized.
E074 Control This is not an alarm, but an operation

On/reset indication (it can be useful to know the
date/time of different welding control
power-on operations )
E075 Results list Data acquisition is managed exclusively from When the function is not required:
overflow remote PC with WMS software. Deactivate the “data loss prevention”
The welding control memory for the welding parameter in the “Data Acquisition”
data is full and "Stop program running " has section of the WMS Setup menu.
been selected by WMS. See the WMS user’s manual for data
acquisition and related problems.
E076 Data results The self-diagnostics at power-on has If the error persists, contact technical
list fault detected a fault in the data of the “Data assistance at GF WELDING S.p.A.
Acquisition” area of the non-volatile RAM
memory.
The data area in the “Data Acquisition" Area
is automatically deleted.
E077 Machine A weld has been tested in Constant Current - Execute first weld with the current
parameters mode, and the welding control has not yet sensor enabled
null acquired any machine data. - Use programs sets in MONITOR and
It only incurs when the first welding is NORMAL mode.
executed for each program and for each
impulse.
E078 Events list The self-diagnostics at power-on has If the error persists, contact technical
data fault detected a fault in the data of the assistance at GF WELDING S.p.A.
"Modifications History" area of the non-
volatile RAM memory.
The data area of the “Modifications History"
is automatically deleted.
E079 Wrong The module code set to identify the welding - Check that the WMS-NET network
module code control in the data centralising network does address set in the SETUP-
not conform with the assigned control mode. CONFIGURATION Weld334m menu
The module code is not correct. and the network address set by dip
The module code verification is run when the switches or jumpers correspond.
“Module code parity” parameter in the (see WMS manual)
SETUP – CONFIGURATION Weld334m menu -Set the module code parity in the
is set to Even or Odd. SETUP – CONFIGURATION
Weld334m menu to Off (WARNING
the certainty of correct code reading
is lost)
41
E080 Black-Box The self-diagnostics at power-on has If the error persists, contact technical
data detected a fault in the data of the "Alarms assistance at GF WELDING S.p.A.
corrupted History" area of the non-volatile RAM
memory.
The “Black-Box” data area is automatically
deleted.
E081 Weld The self-diagnostics at power-on has If the error persists, contact technical
program data detected a fault in the data of the "Program assistance at GF WELDING S.p.A.
corrupted Data" area of the non-volatile RAM memory.
The program data area is automatically
deleted.
E082 Network The welding control power supply voltage - Check voltage
frequency was missing for more than 40 ms. During - Check possible power supply
input fault the welding. voltage drops during welding.
- Replace welding control
E083 Stepper The self-diagnostics at power-on has If the error persists, contact technical
program data detected a fault in the data of the "Stepper assistance at GF WELDING S.p.A.
corrupted Data" area of the non-volatile RAM memory.
The “Stepper” data area is automatically
deleted.
E084 Setup data The self-diagnostics at power-on has If the error persists, contact technical
corrupted detected a fault in the data of the "set-up assistance at GF WELDING S.p.A.
data" area of the non-volatile RAM memory.
The “Setup” data area is automatically
deleted.
E085 MF Inverter Warning of a generic fault coming from the - Check correct functioning of
fault inverter (to be managed only if the welding Inverter at Medium Frequency
control is connected to an MF Inverter ) - For the configurations check the
serial connection between welding
control and inverter where foreseen
.
E086 SCR A high temperature has been detected on - Check SCR and welding transformer
temperature the SCR unit or on the welding transformer. cooling circuit
fault - The logic status of the TSCR input is low - Possible interruption of connection
- Thermostat of connected devices has (+24V), between temperature
triggered. sensor and welding control
- Contact or interruption problems in wiring Check correct thermostat operation
connection between thermostats (The green SCR LED on the front of
- Faulty welding control due to over-voltage the welding control switches on)
from SCR unit thermostat . - Reduce duty-cycle (e.g. spot
sequence)
42
E087 Diodes A high temperature has been detected on - Check rectifier diodes cooling circuit
temperature the rectifier diodes installed in the welding Possible interruption of connection
fault transformer (Only on three-phase systems) (+24Vdc), between temperature
The TEMPD input logic status is low. sensor and welding control
- Reduce duty-cycle (e.g. spot
sequence)
E088 Pressure Insufficient pressure in the pneumatic circuit - Check air pressure
switch fault has been detected . - Possible interruption of connection
Logic state of input PRESS is low. (+24V), between pressure switch
and welding control
- Check correct functioning of
pressure switch (Green AIR LED on
front of welding control switches on)
E089 Flow meter Insufficient coolant flow has been detected in - Check water circulation in machine
fault the machine cooling circuit. - Possible interruption of connection
Logic state of input FLUSS is low. (+24V), between flow meter and
welding control
- Check correct functioning of flow
meter (Green H2O LED on front of
welding control switches on )
E091 Program not The start program does not have consent to Set enabling parameter to run
enabled run. program to ON in the WELDING
PROGRAMS menu
E092 Fault on I/O Internal diagnostics have detected an input Replace the defective I/O card
or a solenoid valve command out of
programmed timing
E093 Output Current overload on the output circuit. - Verify the output load.
overload Probable short circuit on an output line, or - Replace the base I/O card.
internal fault in the output section.
E094 Spot-Index The autodiagnostic function that runs on If the error is repeated contact GF
data corrupt switching on detects an anomaly in data WELDING S.p.A. technical assistance
resident in the area reserved for "Spot-Index
data" in the non-volatile RAM memory.
The “Spot-Index” data area is automatically
erased.
E095 Spot-Index The Spot-Index selected by the external Check the Spot-Index data in the
not valid input is not in the memory control memory
Check the Spot-Index selection.
43
E098 4-20mA Welding servovalve command current Check connection between control and
servovalve interruption detected. servovalve
command
anomaly
E099 Electrode During the electrode maintenance cycle the Check inductive sensors on dressing
maintenance gun input on the dressing tool or the tool
anomaly dressing tool solenoid valve rotation input is
lacking or the START signal is released.
Outside the maintenance cycle a dressing is
attempted without any request.
Emergency signal generated by a remote - Check the cause that generated the
E100 Emergency
command. event
activated
Logical state of EMERG input is low. - Check wiring with the emergency
command
E101 SCR in short An input voltage of the current sensor has - Check whether there is a short
circuit out of been detected (SCR operating out of the circuit on the SCR
welding welding sequence). - Check for anomalous voltage at
Check also the machine power-on. sensor input
If two or more weld guns weld - Check current sensor cabling
simultaneously and at a close distance on
the same part, the weld gun controlled by
the welding control that detects the fault
could act as shunt (current shunt) in relation
to the other.
E102 SCR short During the welding the current measured by - Check for SCR short-circuit
circuit during the sensor is not permissible - Check whether there is an external
weld voltage at the current sensor input
- Check current sensor cabling.
44
Weld334m MFDC integrated inverter

E150 Not used
E151 Internal error Internal circuits anomaly It is not possible to annul the error
condition.
Contact Service Department.
E152 Loss of data This error can occur: - Replace the battery and load
in inverter - after using a new type of backup data in the module;
memory inverter; - Difficult operation since the source
of the anomaly is not easily
- after a software update;
located. Check ground contact of
- after resetting all parameters; all connections; avoid signal cables
- when the inverter battery is flat being in the proximity of power
cables, all metal covers must be
properly closed, etc..
Contact Service Department.
E153 Max Overheating of welding Check cooling circuit;

transformer transformer or diodes. Reduce duty cycle (e.g. spot
temperature sequence)
thermostat
activated
E154 Inverter start The message is emitted when Cancel the error or remove start.
input still start is present on activating the Check connection between inverter
active command; or when start is and welding control.
present at reactivating the
synchronisation voltage;
- reset the emergency
- remove emergency stop with
start present
- activation of welding network
with start present
E156 Fatal error Irreversible software error. If the reset fails, the inverter must
This error is only present if there be replaced.
is damage to the inverter control Contact Service Department
card; or due to a software error.
The reasons that cause this error
may be hardware on the power
or on the inverter cards or
communication problems
between the different cards of
the inverter (LUI, LUAO, UZ2,
ecc).
E157 Eeprom data Inverter program memory fault: Update software and continue.
check-sum loss of data on software Contact Service Department
error version;
new software version;
E158 No Eeprom inverter hardware problem.
data
E159 Eeprom data

writing error
45
E160 Welding Current time-out Check program.
timeout Power components probably short-
circuited. Remove power.
Contact Service Department
E161 Excessive - The power developed is above - Reduce current parameter and
power maximum admissible value; increase welding time.
requested - Wrong inverter configuration; - Change program and repeat the
see the inverter control card calibration.
- Programmed current is above
- Check the current sensor. In
the maximum admissible
"Const. Curr." 10kA 100 msec.
current.
- Wrong calibration. - Check if the measured value is
- Cable error, transformer or plausible; if a further E 161
diodes error. message is generated, tighten
- Faulty inverter. cables U and V and start the
inverter, if E 161 is shown, the
inverter is faulty.
- Check whether there is current
dispersion to ground, either in the
upstream or downstream
connection of the welding
transformer.
- Check the state of the rectifier
diodes in the welding transformer .
E162 Inverter General inverter overheating. - Check cooling circuit.

internal - Check ambient temperature, duty
temperature The trigger threshold of the cycle, current, spot sequence.
excessive thermostat on-card the
Weld334mIMF type inverter
(codes 326000xx) is 85°C. The
thermostat is protected by IGBT
and SCR mounted directly on the
water cooling plate. A water flow
that is less than that required or
missing completely is a critical
condition for the inverter
operation. The thermostat is not
able to measure the temperature
inside the cabin. If there are not
the conditions to guarantee a
correct water flow a watch-dog
flow meter has to be installed.
E163 KSR setup Current regulation system error - Try to redo the calibration.
error - Try again changing welding
parameters (current, welding
time).
- Try again in short circuit or with
material to be welded.
- Check current transducer.
46
E164 Max Maximum current required is not - Dress electrodes.
regulation reached. - Change current setting.
limit - Excessive wear on tips. - Check input voltage.
- Set value too high. - Use transformer with higher
- Voltage drop. secondary voltage.
- Welding transformer voltage too
low, secondary circuit resistance
excessive.
E165 Min The current programmed is less - Change current setting.
regulation than the min current possible of - Check input voltage.
limit the weld gun and/or the
- Use transformer with lower
secondary circuit .
secondary voltage.
- Value set too high.
- Voltage increase.
- Transformer voltage too high.
E166 Diode Stress unacceptable for welding - Reduce duty cycle, current or spot
overload transformer diodes sequence.
- Use welding transformer with more
powerful diode unit.
- Check configuration (diodes
typology in SETUP menu).
E167 Intermediate Intermediate circuit voltage - Check for possible presence of line
inverter below permitted minimum. voltage drops (if necessary
circuit error increase cable section).
- Faulty intermediate circuit
condenser:
Contact Service Department
E168 Measurement Current reading error Change welding times.
field
E169 Current value Incorrect welding program Check data setting.

not in kA
47
New inverter alarms type MFDC-Weld334m (code 326001xx):
E171 Interrupted Interrupted connection to the Check the current sensor cable
current current sensor or sensor and related connections.
sensor resistance measure > 50Ohm
E172 Short circuit Current sensor connected to Check the current sensor cable
current ground or sensor resistance and related connections
sensor measure <10Ohm
E173 Not used
E174 I-Sec internal The inverter self-diagnostics has Check power connections to weld
circuit detected an error in the gun.
measuring circuit of the If the error persists replace the
secondary current. inverter.
Difference in the acquired
current signal and secondary
current delivered
E175 I-Pri internal The inverter self-diagnostics has If the error persists replace the
circuit detected an error in the inverter.
measuring circuit of the primary
current.
Check for fault on IGBT and /or

internal primary current sensor .
E176 Unstable ~3 Problems on power network, - Check connections on inverter

supply asymmetry on phases or levels power supply and on main
<40% or network gap >40msec switch.
- Check resistance value of the
separate sections of main
switch and replace the switch if
the values are very high or
different to each other.
E177 IGBT The inverter diagnostics has - Check for presence of
modules detected surpassing of the dispersion to ground or short
anomaly current threshold values for circuits in connections
internal power devices (IGBT) upstream and downstream of
the welding transformer.
IGBT piloting control fault.
- Check connections between
Excessive inductive charge. inverter and welding
transformer.
- Check intactness of diodes
inserted in the welding
transformer.
- Replace inverter.
E178 Inverter card The inverter self-diagnostics has - Replace inverter.
anomaly detected a fault in data
communication between the
control CPU card and the inverter
control DSP card .
The communication is in parallel

through the BUS card of the
inverter. The error may be
caused indirectly by one of the
other cards inserted in the
inverter.
Asynchrony between control CPU

card and inverter card.
48
E179 SCR modules Faulty SCR control for loading Replace inverter
anomaly condensers
E180 CAN Error inside internal control Replace inverter

communicatio between supply card and inverter
n anomaly card
E181 READY signal The welding control does not - Check the logic state of the
missing acknowledge the condition of the READY signal on P60-4 (LED
READY signal (P60-4) from status and signal level +24Vdc)
active inverter, and there are no - Check connections between
fault indications from the P60-4 and I/O card inserted in
inverter. inverter BUS, and signal level
on I/O card (see application
diagrams)
- Replace inverter.
49
New inverter alarms type MFDC-Weld334m Restyling (code 326003xx):
E182 Primary/grou Difference out of tolerance - Check intactness of connecting

nd dispersion detected regarding the current cables from inverter to
value measured on outputs U transformer.
and V of the inverter (connection - Check insulation of transformer
to primary circuit of welding primary circuit to ground.
transformer).
- Replace welding transformer
Possible reasons: - Replace inverter.
-. Dispersion to ground in
connection between inverter and
welding transformer.
-. Dispersion to ground of
welding transformer primary.
-Current sensor inside inverter
fault
-internal inverter connections are
unstable.
- IMF card fault.
E183 Secondary For a welding transformer power - Check intactness of transformer

diode fault supply phase (semi-wave secondary circuit rectifier diodes.
positive or negative) the primary - Replace welding transformer
current maximum value allowed
has been repeatedly exceeded.
The anomaly is typical of a
situation with rectifier diode in
short circuit in the transformer
secondary circuit.
E185 PSM card The IMF card has not - Check connection of power
fault acknowledged the PSM card supply phases to inverter.
ready condition. - Replace inverter.
The PSM card checks the inverter
power supply, the DC-BUS status
inside the inverter, and the IGBT
power modules. The PSM ready
signal is only active if these
modules are free of
malfunctions..
Possible reasons:
- Error in SCR command for DC-
BUS power supply inside inverter
(DC-BUS voltage value out of
tolerance).
-Inverter power supply phases
with voltage values out of
tolerance .
- The IGBT card has diagnosed
an IGBT modules fault .
- PSM card not powered.
- PSM card fault .
- IMF card fault.
50
E186 Primary For both welding transformer - Check intactness of connecting
current > power supply phases (positive cables from inverter to
max and negative half-waves) it has transformer
been repeatedly found that the - Replace welding transformer
primary current allowed
maximum value is passed. - Replace inverter.
This fault is typical of an inverter
connection to an anomalous
load.
51
52
13 F346-BUS INTERCONNECTION CARD
BUS Interconnection card for signals and power supply.
Connectors P10, JP10, JP11 and JP12 are specifically for card F375-PS.
Connectors P6 and P13 are specifically for card F374-IMF.
Connectors P1...5 are available for generic cards (CPU, IOB, IOE, ETH, etc).
Connector JP15 is for the connection of current sensors inside the inverter.
Connector JP14 is for the connection with card PSM inside the inverter.
Connector JP16 is for the connection with the 24Vdc power unit inside the inverter.
53
Code: 33037500
14 F375-PS POWER SUPPLY
14.1 Characteristics
The Power Supply card integrates these functions for the
welding control:
• 4-digit display for the operator to view information
regarding the welding cycle, such as measured
welding current, and diagnosed error codes.
• 5Vdc power unit for electronic cards inserted inside
the welding control.
• Discreet 24Vdc input/output signals (I/O) for device
remote interfacing.
• Command/control of an analogical servovalve.
By making the appropriate connections, the power unit
section can be configured for a primary 24Vdc power supply
inside the actual device, or otherwise externally.
The logic status of each signal on the terminal-type connector
is displayed by LEDs at the side of the terminal.
The SUB-D P2 connector integrates all the signals required for
the command/control of an analogical servovalve, that can be
used to adjust the air pressure in a pneumatic circuit.
Electrical characteristics
Solid state inputs type 2 (IEC EN61131-2 type 2 DC input)

Nominal voltage 24Vdc
Max continuous voltage 30Vdc
Max non-continuous voltage 36Vdc (max duty cycle 80%)
Max voltage for state 0 5V
Min. voltage for state 1 11V
Min. current for state 1 6mA @11V
Max. current for state 1 30mA @30V
Solid state outputs type 0.5 (IEC EN61131-2 0,5 rated current DC output)
Nominal voltage 24Vdc
Max continuous voltage 30Vdc
Continuous output state 1 0.6A
Max current loss state 0 2mA
Protection intervention current >0.7A
54
14.2 Power supplies and I/O
14.2.1 P49 . Power supplies and input/output signals
Linear disconnectable terminal-type connector, 12-pin 3.5 mm pitch
Pin Signal Description To Type

1 +24VPA For internal connection only Output
2 0VP For internal connection only Output
3 +24PA1 Weld electronic power supply Input
4 0VA1 Weld electronic power supply Input
5 +24S For internal connection only Output
6 +24S1 I/O power supply Input
7 0VB I/O power supply Input
8 FIRING+ Current delivery control Input
9 FIRING- Current delivery control Input
10 READY Device ready Output type 0.5
11 +24T Thermostat power supply Output 24Vdc
12 THERM Transformer /diodes thermostat Input type 2
Signals function description
Pin Signal Function

1 +24VPA 24V power supply output to supply internal electronics, to be used
only for connection with pin 3.
2 0VP 24VPA power supply ground, to be used only for connection with pin
4.
3 +24PA1 Welding control electronics 24V power supply input. If connected

with pin 1 the internal 24 V is used.
4 0VA1 24 PA1 power supply ground
5 +24S 24V power supply output for I/O, to be used only for connection with
pin 6.
6 +24S1 24V power supply input for inverter inputs / outputs. If connected
with pin 5 the internal 24 V is used
7 0VB +24S1 power supply ground
8, 9 FIRING Start current profiles execution command input, for welding controls
in “Remote” configuration, The profiles execution is commanded
when the signal is active. If interrupted there is immediate switching
to “no current” welding program execution mode.
10 READY When active it indicates that the control is ready to run a welding
program. It is deactivated if a system or process fault is
acknowledged.
11 +24T 24Vdc to supply temperature sensor installed in the welding
transformer.
12 THERM Transformer/diodes over-temperature

Input active at OFF.
The temperature sensor is to be the type with normally closed
contact. In the event of over-temperature the THERM signal is not
generated, with the consequent activation of a specific alarm and
locking of the machine cycle.
55
14.3 Analogical servo-valve interface
14.3.1 P2 – Servo-valve control port
Sub-d 15-pin female connector
Pin Signal Function To Type

8 +24SV Servo-valve power supply Output
15 ENSERV Servo-valve enabling output. Output
7 0V Servo-valve power supply Output
14 NC Not connected
6 STSERV Servo-valve status input. Input type 2
13 POL Connector polarizer
5 NC Not connected
12 ISERV- 0V current output Output type 0.5
4 ISERV+ 4-20mA current output Output
11 SHIELD ISERV or VSERV signal shield
3 VSERV- 0V voltage output Output
10 VSERV+ 0-10V voltage output . Output
2 NC Not connected
9 NC Not connected
1 NC Not connected
56
Pin Signal Function

1, 2, NC Not connected. Do not connect.
5, 9
4, 12 ISERV Current command output.
Operating range : 4-20 mA.
Load resistance: 470Ω (range from 200 to 600 Ω).
Signal to pilot a current type servo-valve.
The servo-valve adjusts the pressure on its output in proportion to this
signal. 20mA correspond to 100% of the pressure value set on the
proportional valve.
3, 10 VSERV Voltage command output
Operating range : 0-10V.
Load resistance: 10kΩ.
Signal to pilot a voltage type servo-valve.
The servo-valve adjusts the pressure on its output in proportion to this
signal. 10V correspond to 100% of the pressure value set on the
proportional valve.
6 STSERV Input. Tips pressure OK.
Logic condition 0V or 24V can be defined in the Setup.
Before welding, the control waits for this signal from the servo-valve: if
the logic condition is TRUE (24V), the control executes the weld impulse;
if it is FALSE (0V) the welding sequence remains stationary with the tips
closed.
7 0V 0V servo-valve power supply.
8 24SV Servo-valve power supply

The servo-valve power supply is monitored in voltage: if it drops below
22.5V (5% of 24V), the ENSERV servo-valve enable signal is not
activated.
11 Shield ISERV or VSERV servo-valve signal shield
15 ENSERV Output. Active at 24V.

Proportional servo-valve enabling.
When active, the servo-valve adjusts according to the input analog
control value.
ENSERV is deactivated when:
- The 24Vdc power supply on the terminal 24SV is more than 5%
lower.
- The remote Master device has commanded deactivation via
Fieldbus (see documentation of Fieldbus card).
- The CPU card is in reset status
14.3.2 Warning lights

ON the front panel there are 2 green LEDs: ENSERV and STSERV, to monitor the servo-
valve.
ENSERV : = when ON it indicates that the related output on P2.15 is active
STSERV : = when ON it indicates that the related input on P2.6 is active
57
14.4 Card layout
58
Code: 33037400
15 F374-IMF MEDIUM FREQUENCY INTERFACE
15.1 Characteristics
The IMF card integrates all the specific functions to command and control a
resistance welding inverter, and to supervise the welding process.
Through specific analog inputs it is able to evaluate in real time the execution of
the welding and, by applying appropriate adjustment tactics, it intervenes
immediately so that the programming restrictions are respected.
The card resources permit a further increase in the process control, obtained by
the activation of the weld spot Quality Control (WQS system developed by
GFWelding), with no need for additional modules inside the inverter.
The IMF integrates the following functions:
• Inverter control tactics execution.
• Primary welding current reading.
• Secondary welding current reading.
• Tip voltage reading.
• Weld gun closing force reading.
• Secondary current sensor integrity check.
• Welding transformer saturation check.
• Input rectifier circuit on/off control (SCR).
• Power modules on/off control (IGBT).
• Power devices diagnostics.
• Communication with PSM card inside inverter through a fast serial line:
o Intermediate circuit voltage value (DC-BUS).
o Power supply phases value.
o Inverter internal temperatures.
59
15.2 Connectors to field
15.2.1 P53 – V-Sensor
Sub-d 9-pin male connector

1 FORCE+ Tip closing force positive signal Input
6 NC Not connected
2 FORCE- Tip closing force negative signal Input
7 VSEC+ Secondary voltage positive signal Input
3 NC Not connected
8 VSEC- Secondary voltage negative signal Input
4 NC Not connected
9 SHIELD FORCE or VSEC signal shield
5 SHIELD FORCE or VSEC signal shield
Pin Signal Function

1, 2 FORCE Analog input for tips closing force signal acquisition. This signal is
processed by the weld spot Quality System to determine the welding
quality and to execute specific adjustment algorithms.
Range: 0 to 10V.
3, 4, NC Not connected. Do not connect.

6
7, 8 VSEC Analog input for tips voltage signal acquisition. This signal is
processed by the weld spot Quality System to determine the welding
quality and to execute specific adjustment algorithms.
Range: +/- 20V.
5, 9 SHIELD VSEC or FORCE signal shield
15.2.2 P54 – I-Sensor
Sub-d 9-pin male connector

1 SHIELD TA signal shield
6 SHIELD TA signal shield
2 NC Not connected
7 NC Not connected
3 NC Not connected
8 NC Not connected
4 TA+ Secondary current positive signal Input
9 NC Not connected
5 TA- Secondary current negative signal Input
60
Acquisition input for analog signals.
Used to connect the secondary current sensor.
The acquisition of this signal (welding in direct current mode), checks the current trend
during the welding impulse in real time.
The input is pre-set to accept a Rogowsky type 150mV/kA ±3% sensor with internal
resistance of 20-25ohm, with integrity check of the sensor (sensor interrupted or in short
circuit).
Sensor sensitivity: programmable.
For correct use, see the setting parameters in the programming manual.
For connections see the application diagrams.
61
15.3 Card layout
62
Users’ manual
F384-CPU Microprocessor card
Code:33038400
16 F384-CPU MICROPROCESSOR CARD
This is the system calculation centre and it is fitted with a MCU Motorola 68332 card
(20MHz clock). Data and program RAM resides on flash eprom (1MB).
Permanent data is stored in a buffer battery.
The CPU has 2 ports, an RS485 full/duplex port for the HHT4300 programming terminal or
a Laptop (P1 Sub-d 9-way connector located on the front part), and another one for
connecting the multifunctional display (internal port).
F384-CPU
CPU status Led indicators:
LOWBATT - Red: illuminated during power reset (when switching on the
Control device) and when the reset is given via the push P
button. 1
If it stays On during the operation (RUN led indicator
illuminated) this indicates that the battery is nearly down.
RUN - Green: the processor is operating correctly when
illuminated.
This indicator is OFF during the reset or when the Watchdog
(indication of Fault) condition intervenes.
LOW RUN
BAT.
Reset push button
The Reset push button is placed in the lower part, This control has direct
influence on the 68332 and is used (in case of system shutdown) to re-
start the program with no need to cut off power to the control device.
The Reset control is not an alarm reset and it must not be used to this
end.
Internal battery for data backup

Lithium battery with surveying circuit of the charge status and Supercap
(high capacity capacitor) used to store data during the replacement. The RESET
battery is housed in a container which facilitates the replacement.
To replace the battery, refer to Appendix A - Maintenance
Average battery life
Extinction Operating condition Duration
(years)
Daily 6 working days 3
Weekly 5 working days 4
Weekly 6 working days 5,4
P1 - 9-way, Sub-d socket connector

RS485 serial communication port for the connection to the HHT4300
programming unit or to a PC
1/6 0VH Earth
2/7 +VH HHT4300 unit power supply
3 N.C. Pin bias
4 RXD+ Data reception +
5 TXD+ Data transmission +
8 RXD- Data reception -
9 TXD- Data transmission -
Maximum length of connection cable: 100m
63
Users’ manual
F384-CPU Microprocessor card
Card layout: Standard setting of jumpers.
JP4-5-8-9: (Off)
JP3: 3-4, 6-7
JP6: On
64
User’s Manual
F398 Ethernet 100Base-T and CANopen module
65
User’s manual
F399-IOB Basic I/O Card
Code 33039900
17 BASIC I/O CARD F399-IOB

This is the basic I/O card and consists of:
- 25 pin male connector P57 with 20 dedicated inputs + 2 exchange contacts
- 15 pin female connector P31 with 10 dedicated outputs and 24V for the I/O
- two switches: Pressure only and Weld Yes/No
- 10 status LEDs for some I/O
CYCLE Switch (Pressure Only)

F399-IOB
Pressure Only. P
3
Active when OFF. 1
Stops the sequence in pressure only:

O
When set on Cycle the sequence proceeds normally. U
T
P
U
T
Set on the sequence stops in pressure only.
CYCLE
Used to tune the guns.

EVA EVB
Usually at 24V, if opened during the welding sequence the following AL1 AL2
condition is obtained: ST.A ST.B
the sequence stops with the electrodes closed under pressure T.S IMP
the control waits for 24V on this input H20 AIR
output RICHSALD is low

if the start is released the call is interrupted and the gun opens
if SOLOPR goes high the sequence starts again, the control sends output
RICHSALD high and continues according to the status conditions of P
SALDASI and CONSALD. 5
7
Caution! In Salda SI (Weld YES), when only the pressure is disabled, the
cycle proceeds immediately with a welding impulse. I
N
P
U
T
Salda SI/NO (Weld YES/NO) switch S
Enables/disables the welding current.

Also Salda Si/No in the Setup* and input P57-14 on card F399-IOB must be
enabled.
Salda SI (Weld YES): Set on welding current is enabled.
Salda NO (Weld NO): Set on welding current is cut off.
* See programming manual
66 FASE Saldatura
User’s manual
17.1 Status LEDs
The LEDs on the front indicate the status of these signals:

LED Signal Type On
EVA EVSA output Solenoid valve channel A on
EVB EVSB output Solenoid valve channel B on
AL1 ALARM1 output Current diagnostic alarm on
AL2 ALARM2 output Hardware alarm on
ST.A STARTA input Start welding sequence channel A on
ST.B STARTB input Start welding sequence channel B on
T.S TSCR input SCR temperature OK
IMP COMIMP output Impulse signal on
H2O FLUSS input Water present OK
AIR PRESS input Pressure present OK
17.2 P57. Inputs
25 pin male sub.d connector

Pin Signal Description Capacity
(I)
1 SOLOPR Pressure only 10mA
2 REPEAT Repeat cycle 10mA
3 PRESS Air present 10mA
4 STARTB Start channel B 10mA
5 CEVASB Additional opening channel B 10mA
6 ABSTB Enable start B 10mA
7 CODE0 Program code bit 0 10mA
9 TSCR Temperature SCR 10mA
10 RESASA Reset alarm stepper A 10mA
12 SGNC Relay normally closed contact 10mA
13 SGNO Relay normally open contact 10mA
14 SALDAS Enable welding 10mA
15 FLUSS Water present 10mA
16 STARTA Start channel A 10mA
17 CEVASA Additional opening solenoid valve 10mA
18 ABSTA Enable start A 10mA
19 ABSTM Enable start acknowledge 10mA
22 RESAH Reset Alarm 2 10mA
23 RESASB Reset alarm stepper B 10mA
25 SGCOM Circuit breaker release signal common 10mA
FASE Saldatura 67
User’s manual
P57 – Input signals

Pin Signal Function
1 SOLOPR Pressure only.
Active OFF.
Used to tune guns.
In series to Cycle switch on front.
Normally 24V, if opened during welding sequence the following
conditions occur:
the sequence is interrupted with electrodes closed under
pressure
the control waits for 24V on this input
if start is released the call is interrupted and the gun opens
if SOLOPR is high the sequence starts again, the control sends
output RICHSALD high and continues according to the status
conditions of SALDASI and CONSALD
Caution! In Salda SI (Weld YES), if only the pressure is disabled,
the cycle starts immediately with the welding impulse.
2 REPEAT Repeat cycle.

Active OFF.
Enable/disable input to repeat cycle in welding sequence.
To activate this function Repeat must also be enabled in the
welding programs and the Setup Configuration Weld334m menu
(see programming manual).
3 PRESS Pressure switch signal.

Active high +24Vdc.
The machine pressure switch (if used) is to be connected to this
input. The pressure switch must be normally closed type.
When OFF the control generates alarm E088 Pressure switch
failure.
If it is not used, the input must be connected to 24Vdc.
4 STARTB Start channel B.

Active at +24V.
Calls the gun of channel B.
If it returns low before the pressure cycles, the call drops and the
electrodes open.
If the start lasts up to the pressure cycles, it remains in hold until
the end of the repeated cycles
5 CEVASB Solenoid valve: Additional opening channel B.

Rising edge.
Start of electrodes pre-approach, enabled and disabled with a rising
edge 0-24V, (impulse).
Signal reading access time < 100mS.
If not used, this input must be directly connected to +24V.
6 ABSTB Enable start channel B.

Active at 24Vdc (rising edge).
Enable signal of channel B Start.
Specific input to be used with control of gun call.
From the moment it is high a useful time of 10” is allowed for the
operator to activate the channel B Start. After 10” the start is not
acknowledged.
A series of consecutive spots can be made in the same sequence,
providing the start is given within the useful time
of 10”.
68 FASE Saldatura
User’s manual

Pin Signal Function
7 CODE0 Binary code (bit 0) to select welding program.
Active at +24V.
When Start is on, the control reads the active code on these inputs and
runs the corresponding program (see codes table).

Active at +24V.
9 TSCR SCR Temperature.

Active OFF (signal open).
The sensor must be normally closed contact type. If overheated, the
contact opens and signal TSCR drops to 0V.
The control activates ALLARME2 (ALARM2) and locks the machine cycle
10 RESASA Alarm counter reset stepper A.

Active at +24V.
Resets the spot counter on channel A, if no dressing or electrode change is
in progress.
CAUTION! The counter can be reset at any time.
12 SGNC Relay normally closed contact, available for connection to release coil.
See description in next section
13 SGNO Relay normally open contact, available for connection to release coil.
See description in next section.
14 SALDASI Weld Yes/No.

Active at +24V.
Enables the welding current, Salda Si (Weld Yes) must also be active in
the Setup and on the switch of the I/O base card front.
The control activates the Status output (+24V) when Salda Si (Weld Yes)
is enabled.
15 FLUSS Flow meter.

Input to read presence of coolant.
16 STARTA Start channel A.

Active at +24V.
Calls the gun of channel A.
If it drops before the pressure cycle, the call drops and the electrodes
open.
If the start lasts up to the pressure cycles, it remains in hold until the end
of the repeated cycles.
FASE Saldatura 69
User’s manual

Pin Signal Function
17 CEVASA Solenoid valve: Additional opening channel A.
edge 0-24V (impulse).
Signal reading time < 100mS.
18 ABSTA Enable start channel A.

Active at 24Vdc (rising edge)
Enable signal of channel A Start.
operator to activate the channel A Start. After 10” the start is not
acknowledged.
providing the start is given within the useful
time of 10”.
19 ABSTM START enable mode selection.

Active at +24V.
Acknowledgement of operating mode with/without ABSTA/B.
If the enable Start (ABST) is not used, it must be connected
to +24V.

Active at +24V.
With Start active the control reads the active code on these inputs
and runs the corresponding program (see codes table).

Active at +24V.
22 RESAH Hardware alarm reset.

Normally open, active at +24V
Inhibits machine locking (Alarm 2) arising during the process.
23 RESASB Reset alarm counter stepper B. Active at +24V.

Resets the active spots counter on channel B, if no dressing or
electrodes change is in progress.
25 SGCOM Relay common contact, available for connection to the release coil.
70 FASE Saldatura
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17.3 P31 . Outputs
15 pin female sub.d connector

Pin Signal Description Capacity (I)
1 EVSA Channel A welding solenoid valve 0.3A
2 EVASA Additional opening channel A 0.3A
3 FINESEQ End of sequence 0.3A
4 ALSTPA Stepper channel A counter alarm 0.3A
5 ALARM1 Welding diagnostics alarm 0.3A
6 +24TRIMP Common +24 impulse -
7 0V Common 0V I/O -
8 +24V Common 24V I/O 3W
9 EVSB Channel B welding solenoid valve 0.3A
10 EVASB Channel B additional opening 0.3A
11 ALSTPB Stepper channel B counter alarm 0.3A
12 ALARM2 Failure alarm 0.3A
13 COMIMP Welding impulse 2A
P31 – Output signals

Pin Signal Function
1 EVSA Channel A welding solenoid valve piloting output.
Activated by the corresponding start, it is protected by an interlock of
2 relays that prevent the simultaneous calling of channel B.
If the Start signal drops before the pressure cycles start, the call is not
acknowledged and the electrodes open.
From the beginning of the pressure cycles the start is held until the
Stop cycles have terminated.
(See cycle times diagrams in the programming manual).
2 EVASA Channel A additional opening solenoid valve piloting output, also called
pre-stroke or pre-approach.
Activated by CEVASA, it is protected by an interlock of two relays that
prevent the simultaneous calling of the channel B pre-stroke.
See cycle times diagram for correlated times.
3 FINESEQ Output active at 24V.

At the end of the repeat cycles (opening of electrodes), the control
activates this output and ends the sequence.
If Repeat is enabled, the End of Sequence is not performed and the
control continues, proceeding from the pressure cycles (See the cycle
times diagram).
4 ALSTPA Stepper A alarm. Locks the working cycle.

Operates when the spots counter reaches the value set at Stop in the
relevant stepper program.
It can only be restored by resetting the corresponding counter through
input RESASA or by software reset in the Stepper menu (See
programming manual: Stepper).
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Pin Signal Function
5 ALARM1 Indication. Does not lock the working cycle.
Diagnostic class alarm (from E001 to E050).
Usually it resets automatically but it may be locked in the Setup
menu.
See Alarms and Setup in the programming manual.
6 +24TR. Common +24V output of signal COMIMP (P31-13) for SCR priming.
See application diagram.
7 0V Logic I/O 0V.

0V connection to field.
8 +24VDC Logic I/O +24VDC.

+24VDC output for connection to field (see application diagrams).
9 EVSB Channel B welding solenoid valve piloting output.

Activated by the corresponding start, it is protected by an interlock
of 2 relays that prevent the simultaneous calling of channel A.
If the Start signal drops before the pressure cycles start, the call is
not acknowledged and the electrodes open.
10 EVASB Channel B additional opening solenoid valve piloting output, also

called pre-stroke or pre-approach.
Activated by CEVASB, it is protected by an interlock of two relays
that prevent the simultaneous calling of the channel A pre-stroke.
11 ALSTPB Stepper B alarm. Locks the working cycle.

Operates when the spots counter reaches the value set at Stop in
the relevant stepper program.
It can only be restored by resetting the corresponding counter
through input RESASB or by software reset in the Stepper menu.
(See programming manual: Stepper).
12 ALARM2 Machine alarm. Locks the cycle.

It applies to faults, programming errors, connection errors both on
the control and on the machine.
Can be restored by reset from the keypad or from dedicated input
RESAH.
Remains active until the cause is removed.
13 COMIMP Impulse command (See application diagram).

Primer signal for SCR.
The signal is a Sync Open Collector.
14 0V Logic I/O 0V.

0V connection to field

72 FASE Saldatura
User’s manual
17.3.1 Circuit breaker release

Relay contacts to activate the release coil of the machine main switch.
It is activated by the control when there is a serious failure on the machine power
system (e.g. SCR running out of welding).
Voltage on contacts: 48V 8A max.
P57 F399-IOB
Circ. breaker rel.
SGNC 12
SGNO 13
K
SGCOM 25
For connection see the application diagrams
Card layout: jumpers setting
JP1: Off
J1: 2-3,
J2: 1-2
FASE Saldatura 73
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74 FASE Saldatura
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Code 33041300
18 BASIC I/O CARD F413-IOB

This is the basic I/O card and consists of:
- 25 pin male connector P66 with 20 dedicated inputs + 2 exchange contacts
- 15 pin female connector P65 with 10 dedicated outputs and 24V for the I/O
- two switches: Pressure only and Weld Yes/No
- 10 status LEDs for some I/O
CYCLE Switch (Pressure Only)

F413-IOB
Pressure Only. P
6
Active when OFF. 5
Stops the sequence in pressure only: O

U
When set on Cycle the sequence proceeds normally. T
P
U
T
S
Set on the sequence stops in pressure only.
CYCLE
Used to tune the guns.

EVA EVB
Usually at 24V, if opened during the welding sequence the following AL1 AL2
condition is obtained: ST.A ST.B
the sequence stops with the electrodes closed under pressure T.S IMP
the control waits for 24V on this input H20 AIR

if the start is released the call is interrupted and the gun opens
if SOLOPR goes high the sequence starts again, the control sends output
RICHSALD high and continues according to the status conditions of P
SALDASI and CONSALD. 6
6
Caution! In Salda SI (Weld YES), when only the pressure is disabled, the I
cycle proceeds immediately with a welding impulse. N

P
U
T
S
Salda SI/NO (Weld YES/NO) switch
Enables/disables the welding current.
Also Salda Si/No in the Setup* and input P57-14 on card F399-IOB must be
enabled.
Salda SI (Weld YES): Set on welding current is enabled.
Salda NO (Weld NO): Set on welding current is cut off.
* See programming manual
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18.1 Status LEDs
The LEDs on the front indicate the status of these signals:

LED Signal Type On
EVA EVSA output Solenoid valve channel A on
EVB EVSB output Solenoid valve channel B on
AL1 ALARM1 output Current diagnostic alarm on
AL2 ALARM2 output Hardware alarm on
ST.A STARTA input Start welding sequence channel A on
ST.B STARTB input Start welding sequence channel B on
T.S TSCR input SCR temperature OK
IMP COMIMP output Impulse signal on
H2O FLUSS input Water present OK
AIR PRESS input Pressure present OK
18.2 P66. Inputs
25 pin male sub.d connector

Pin Signal Description Capacity
(I)
1 SOLOPR Pressure only 10mA
2 POKA IN Input Poka Yoke function 10mA
3 PRESS Air present 10mA
4 STARTB Start channel B 10mA
5 CEVASB Additional opening channel B 10mA
6 ABSTB Enable start B 10mA
9 TSCR Temperature SCR 10mA
10 RESASA Reset alarm stepper A 10mA
12 SGNC Relay normally closed contact 10mA
13 SGNO Relay normally open contact 10mA
14 SALDASI Enable welding 10mA
15 FLUSS Water present 10mA
16 STARTA Start channel A 10mA
17 CEVASA Additional opening solenoid valve 10mA
18 ABSTA Enable start A 10mA
19 ABSTM Enable start acknowledge 10mA
22 RESAH Reset Alarm 2 10mA
23 RESASB Reset alarm stepper B 10mA
25 SGCOM Circuit breaker release signal common 10mA
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Pin Signal Function
1 SOLOPR Pressure only.
Active OFF.
Used to tune guns.
In series to Cycle switch on front.
Normally 24V, if opened during welding sequence the following
conditions occur:
the sequence is interrupted with electrodes closed under
pressure
the control waits for 24V on this input
if start is released the call is interrupted and the gun opens
if SOLOPR is high the sequence starts again, the control sends
output RICHSALD high and continues according to the status
conditions of SALDASI and CONSALD
Caution! In Salda SI (Weld YES), if only the pressure is disabled,
the cycle starts immediately with the welding impulse.
2 POKAIN Input Poka Yoke function.

Active ON +24Vdc.
Reset of the counter of the programmed spots for the part to
weld.The signal is working on the two channels A and B. If he is not
activated it is not possible to begin the cycle.
3 PRESS Pressure switch signal.

Active high +24Vdc.
The machine pressure switch (if used) is to be connected to this
input. The pressure switch must be normally closed type.
When OFF the control generates alarm E088 Pressure switch
failure.
If it is not used, the input must be connected to 24Vdc.
4 STARTB Start channel B.

Active at +24V.
Calls the gun of channel B.
If it returns low before the pressure cycles, the call drops and the
electrodes open.
If the start lasts up to the pressure cycles, it remains in hold until
the end of the repeated cycles
5 CEVASB Solenoid valve: Additional opening channel B.

Rising edge.
edge 0-24V, (impulse).
Signal reading access time < 100mS.
6 ABSTB Enable start channel B.

Active at 24Vdc (rising edge).
Enable signal of channel B Start.
operator to activate the channel B Start. After 10” the start is not
acknowledged.
providing the start is given within the useful time
of 10”.
GF WELDING 77
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Pin Signal Function
Active at +24V.

Active at +24V.
9 TSCR SCR Temperature.

The sensor must be normally closed contact type. If overheated, the
contact opens and signal TSCR drops to 0V.
The control activates ALLARME2 (ALARM2) and locks the machine cycle
10 RESASA Alarm counter reset stepper A.

Active at +24V.
Resets the spot counter on channel A, if no dressing or electrode change is
in progress.
12 SGNC Relay normally closed contact, available for connection to release coil.
13 SGNO Relay normally open contact, available for connection to release coil.
See description in next section.
14 SALDASI Weld Yes/No.

Active at +24V.
Enables the welding current, Salda Si (Weld Yes) must also be active in
the Setup and on the switch of the I/O base card front.
The control activates the Status output (+24V) when Salda Si (Weld Yes)
is enabled.
15 FLUSS Flow meter.

Input to read presence of coolant.
16 STARTA Start channel A.

Active at +24V.
Calls the gun of channel A.
If it drops before the pressure cycle, the call drops and the electrodes
open.
If the start lasts up to the pressure cycles, it remains in hold until the end
of the repeated cycles.
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Pin Signal Function
17 CEVASA Solenoid valve: Additional opening channel A.
edge 0-24V (impulse).
Signal reading time < 100mS.
18 ABSTA Enable start channel A.

Active at 24Vdc (rising edge)
Enable signal of channel A Start.
operator to activate the channel A Start. After 10” the start is not
acknowledged.
providing the start is given within the useful
time of 10”.
19 ABSTM START enable mode selection.

Active at +24V.
Acknowledgement of operating mode with/without ABSTA/B.
If the enable Start (ABST) is not used, it must be connected
to +24V.

Active at +24V.

Active at +24V.

Normally open, active at +24V
23 RESASB Reset alarm counter stepper B. Active at +24V.

Resets the active spots counter on channel B, if no dressing or
electrodes change is in progress.
25 SGCOM Relay common contact, available for connection to the release coil.
GF WELDING 79
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18.3 P65 . Outputs
15 pin female sub.d connector

Pin Signal Description Capacity (I)
1 EVSA Channel A welding solenoid valve 0.3A
2 EVASA Additional opening channel A 0.3A
3 POKA OUT Output Poka Yoke function 0.3A
4 ALSTPA Stepper channel A counter alarm 0.3A
5 ALARM1 Welding diagnostics alarm 0.3A
6 +24TRIMP Common +24 impulse -
9 EVSB Channel B welding solenoid valve 0.3A
10 EVASB Channel B additional opening 0.3A
11 ALSTPB Stepper channel B counter alarm 0.3A
12 ALARM2 Failure alarm 0.3A
13 COMIMP Welding impulse 2A

Pin Signal Function
1 EVSA Channel A welding solenoid valve piloting output.
Activated by the corresponding start, it is protected by an interlock of
2 relays that prevent the simultaneous calling of channel B.
If the Start signal drops before the pressure cycles start, the call is not
acknowledged and the electrodes open.
2 EVASA Channel A additional opening solenoid valve piloting output, also called
pre-stroke or pre-approach.
Activated by CEVASA, it is protected by an interlock of two relays that
prevent the simultaneous calling of the channel B pre-stroke.
3 POKA Output function Poka Yoke

OUT Output active at 24V.
The signal is active when the counter of the spots for piece to weld,
assets on the two channels A and B, has caught up the programmed
value
4 ALSTPA Stepper A alarm. Locks the working cycle.

relevant stepper program.
It can only be restored by resetting the corresponding counter through
input RESASA or by software reset in the Stepper menu (See
programming manual: Stepper).
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Pin Signal Function
5 ALARM1 Indication. Does not lock the working cycle.
Diagnostic class alarm (from E001 to E050).
Usually it resets automatically but it may be locked in the Setup
menu.
See Alarms and Setup in the programming manual.
6 +24TR. Common +24V output of signal COMIMP (P31-13) for SCR priming.
See application diagram.
7 0V Logic I/O 0V.


9 EVSB Channel B welding solenoid valve piloting output.

Activated by the corresponding start, it is protected by an interlock
of 2 relays that prevent the simultaneous calling of channel A.
If the Start signal drops before the pressure cycles start, the call is
not acknowledged and the electrodes open.
10 EVASB Channel B additional opening solenoid valve piloting output, also

called pre-stroke or pre-approach.
Activated by CEVASB, it is protected by an interlock of two relays
that prevent the simultaneous calling of the channel A pre-stroke.
11 ALSTPB Stepper B alarm. Locks the working cycle.

Operates when the spots counter reaches the value set at Stop in
the relevant stepper program.
It can only be restored by resetting the corresponding counter
through input RESASB or by software reset in the Stepper menu.
(See programming manual: Stepper).
12 ALARM2 Machine alarm. Locks the cycle.

It applies to faults, programming errors, connection errors both on
the control and on the machine.
Can be restored by reset from the keypad or from dedicated input
RESAH.
Remains active until the cause is removed.
13 COMIMP Impulse command (See application diagram).

Primer signal for SCR.
The signal is a Sync Open Collector.
14 0V Logic I/O 0V.

0V connection to field

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User’s manual
18.3.1 Circuit breaker release

Relay contacts to activate the release coil of the machine main switch.
It is activated by the control when there is a serious failure on the machine power
system (e.g. SCR running out of welding).
Voltage on contacts: 48V 8A max.
P57 F399-IOB
Circ. breaker rel.
SGNC 12
SGNO 13
K
SGCOM 25
For connection see the application diagrams
JP1: Off
J1: 2-3,
J2: 1-2
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GF WELDING 83
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F414-IOE I/O Expansion Card
Code:33041400
19 F414-IOE I/O EXPANSION CARD

It is a discrete I/O module, at +24Vdc, that integrates 16 outputs and 15 inputs.
This module implements the direct command functions of a tool, or dressing-machine, in order to
operate the automatic tip dressing cycle and the command of the cylinders of block for the
eventual employment of a suspension on mobile arm.
By connecting some specific interlock signals between two welding controls, equipped with the
F414 card, installed into two different bi-gun cabinets, it is possible to operate independently upon
four different guns with just one dressing tool.
The card output can command either a solenoid valve if the dressing tool is a pneumatic one or an
external relay if the dressing tool has an electric engine.
Some specific signals have been conceived in order to show that worn tip replacement is
necessary.
Furthermore, some specific signals have been conceived in order to control air and water
consumption of working station (Energy Save).
Externally this card shows the following elements:
• the most important I/O status LEDs;
• a P67 25-pin Sub-D female connector that supports 16 dedicated outputs and the I/O
common 24V power supply output;
• a P68 25-pin Sub-D male connector that supports 13 dedicated + 2 definable inputs.
All the outputs are protected from short-circuit.
F414-IOE
1.2 Signal status LEDs
P
6
LEDs on the front panel – Functional description: 7
O
LED SIGNAL TYPE ON U
T
P
STATUS STATUS OUTPUT Sequence with current enabled U
T
S
READY READY OUTPUT Control ready (no faults)

RIC. SAL RICHSAL OUTPUT Enable request to welding activated STATUS READY
D
RIC. CON.
CON. CONSALD INPUT Welding consent present

SAL. SAL.
SAL.
P.A. P.B.
RIC. RAV.
RAV. EX
P.A. WALSTPA OUTPUT Channel A tips have reached pre-alarm

CAMB.EX
threshold
RICHEL
P.B. WALSTPB OUTPUT Channel B tips have reached pre-alarm

threshold P
6
RIC. RAV. RICHRAV OUTPUT Tip dressing request active 8
I
RAV. EX RAVEX INPUT Out-of-cycle dressing signal N
P
U
RICHEL RICHEL OUTPUT Tip Changing request active T
S
CAMB.EX CHGEX INPUT Out-of-cycle tip changing signal
84 GF WELDING
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1.3 P67 . Output signals – Functional description
25-pin Sub-D female connector

Pin Signal Description Type
13 +24Vdc Common output 24V
25 +24Vdc Common output 24V
12 0V Common output 0V
24 0V Common output 0V
11 - Polarizing key
23 AIRON Air inlet solenoid valve Energy Save
10 MANEL Tip maintenance Status
22 EVRAV Dressing solenoid valve Tip life
9 ALLRAV Tip maintenance alarm Diagnostics
21 GUNOK Gun in position Tip life
8 NULCURR No current Diagnostics
20 H2OINON Water inlet solenoid valve Energy Save
7 H2OOUTON Water outlet solenoid valve Energy Save
19 FINESAL End of welding Welding cycle
6 RICHSALD Welding request Welding cycle
18 BRAKE B Brake “B” channel Suspension arm brake function
5 BRAKE A Brake “A” channel Suspension arm brake function
17 RICHRAV Dressing request Tip life
4 RICHEL Change tips request Tip life
16 WALSTPA Stepper A pre-alarm Tip life
3 WALSTPB Stepper B pre-alarm Tip life
15 - Not used
2 - Not used
14 - Not used
1 - Not used
P67 – Output signals – Functional description

Pin Signal Function
3 WALSTPB Stepper B pre-alarm. Worn tip indication.

The control activates this output when the pre-alarm threshold value
set in the active stepper (spots counter) is reached.
This does not lock and warns that the counter has nearly reached the
Dressing Request or Tip Changing request.
The message is loaded into the alarms memory.
4 RICHEL Change tips request. Locks the working cycle.
Like the dressing request but concerns tip change. Confirmation must
be made with input CHELOK.
5 BRAKE A Release brake of suspension arm –
Active at 24Vdc ON
This output is activated when it comes activated imput the P66-18 on
card F413IOB.
The output remains active till a successive activation of the same
imput P66-18 or for the time of 10 second.
6 RICHSALD Output on relay contact active at 24V.
At the end of the pressure cycles the control activates this output and
waits for the CONSALD signal (P5-15) that enables welding.
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P67 – Output signals – Functional description
Pin Signal Function
7 H2OOUTON Water outlet solenoid valve. Active +24V.

Output dedicated to the solenoid valve to control the water output from
the welding cabinet hydraulic circuit.
Activated when the Control recognize an active “Enable Signal
(ABSTA/B)”.
De-activated after the time (seconds), programmed by “Energy Save ON
delay” parameter in SETUP menu, is elapsed. Start of counting at the end
of Open Time, and zeroed when a new start cycle is active.
8 NULCURR Diagnostic indication. Does not lock working cycle.
The current value found on the current sensor is null.
Usually it is reset automatically but it may be locked by the Setup menu
See Alarms and Setup sections in the programming manual.
It can be used when it is necessary to operate on faulty welds.
9 ALLRAV Dressing tool alarm. Active at +24V.
It locks the cycle.
It is enabled in case of an anomaly of the tip dressing device.
10 MANEL Tip maintenance. Active at +24V.
It shows that the gun managed by the Control can take the tip dressing
position.
12 0V Logic I/O 0V
13 +24Vdc Logic I/O +24V
+24V output for connection to field.
(see application diagrams)
16 WALSTPA Stepper A pre-alarm. Tip wear indication.
Activated when the pre-alarm threshold set in the active stepper is
reached (spots counter).
This does not lock and warns that the counter has nearly reached the
Dressing Request or Change Tips request.
The message is loaded into the alarms memory.
17 RICHRAV Dressing request. Locks the working cycle.
corresponding stepper program.
Requests the tip dressing operation and subsequent confirmation that
dressing has taken place with input RAVOK.
See Stepper menu for programming conditions and alarms section to
restore.
18 BRAKE B Release brake of suspension arm –
Active at 24Vdc ON
This output is activated when it comes activated imput the P66-06 on
card F413IOB.
The output remains active till a successive activation of the same imput
P66-06 or for the time of 10 second.
19 FINESAL Active +24V
At the end of the hold cycles this output is activated.
20 H2OINON Water inlet solenoid valve. Active +24V.
Output dedicated to the solenoid valve to control the water input to the
welding cabinet hydraulic circuit.
(ABSTA/B)”.
86 GF WELDING
User’s manual
Pin Signal Function
21 GUNOK Gun in position. Active at+24V.

This output is enabled connected with the GUNPOS (P48-18) input and
shows the gun presence on the tip maintenance position.
22 EVRAV Dressing solenoid valve. Active at +24V.
This output is enabled when the Control carries out the tip maintenance
cycle.
On the contrary, it is disabled either in case of a second of delay after the
dressing cycle or immediately in case of ALLRAV (P47-09) anomaly. This
output is used to enable the dressing tool solenoid valve.
23 AIRON Air inlet solenoid valve. Active +24V.

Output dedicated to the solenoid valve to control the air input to the
welding cabinet pneumatic circuit.
(ABSTA/B)”.
24 0V Logic I/O 0V
25 +24Vdc Logic I/O +24V
+24V output for connection to field.
(see application diagrams)
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19.1 P68 – Input signals – Functional description
Sub-D 25-pole male connector

1 -
14 RAVEX Out-of-cycle dressing
2 CHGEX Out-of-cycle tip change
15 CONSALD Welding consent
3 IELEX External tip maintenance interlocked
16 -
4 -
17 -
5 -
18 GUNPOS Gun in position on the dressing tool
6 ENDCYCL Force at end of cycle
19 RESAH Alarm 2 reset
7 CODE4 Program code bit4
20 CODE5 Program code bit5
8 RESRAVA Confirmation dressing performed channel A
21 RESRAVB Confirmation dressing performed channel B
9 SPIN2 Definable input
22 SPIN1 Definable input
10 RAVPOS Gun control in proximity of the dressing tool.
23 CTREV Control of the dressing tool in rotation
11 -
24 -
12 -
25 -
13 -
P68 – Input signals - Functional description

Pin Signal Function
2 CHGEX Out-of-cycle tip change request.

Active at +24V.
This input enables (and disables) the operator’s tip change
request.
3 IELEX External tip maintenance interlocked.
Active at +24V.
It means that the dressing tool is temporarily taken by
another device (or Control).
6 ENDCYCL Normally open, active at +24V.
Needed to force the end of cycle if the machine locks due to
a hardware failure.
7 CODE4 Active at +24V.
Binary code (bit 4) to select welding program to run at Start.
When the Start is active the control reads the active code on
these inputs and runs the corresponding program (see code
table).
88 GF WELDING
User’s manual
P68 – Inputs – Functional description

Pin Signal Function

Binary code (bit 4) to select welding program to run at Start.
When the Start is active the control reads the active code on these
inputs and runs the corresponding program (see code table).
8 RESRAVA Confirmation of dressing performed on channel A. Active at +24V.
Inhibits the alarm warnings, resets the welding spot counter and
increases the dressing counter in the electrode wear program by 1.
This operation can also be performed from the programming keypad
using the stepper menu (see programming manual).
The signal must be active at least for 100ms.
9 SPIN2 Definable input.
Only used on robotized lines.
It is used for the logic verification of inputs CODE0....7 and depends on
how the Setup menu is set.
CAUTION! If it is not used it must be disabled (Setup).
10 RAVPOS Gun control in proximity of the dressing tool.
Normally at +24V
The input at 0V signals that the gun is positioned in proximity of the
dressing tool. Its use inhibits the gun closing till when the correct
position on the dressing tool isn’t reached (GUNPOS signal). If the cycle
start is attempted an anomaly occurs. When it is not used, this input
must be connected to +24V
This signal is employed in substitution to the input CTREV.
14 RAVEX Out-of-cycle dressing request.
Active at +24V.
This input enables (and disables) the operator’s tip dressing request.
15 CONSALD Normally at +24V.
Welding consent, it indicates that the welding machine is ready.
After the guns have closed the control sends output RICHSALD high and
waits for the 24V on this input to make the weld impulse.
When it is not used, this input must be connected to 24V.
18 GUNPOS Gun in position on the dressing tool.
Active at +24V.
This input is active when the gun is positioned on the dressing tool to
execute the tip maintenance.
If this signal is not active for more than 1 second during the
maintenance cycle, an anomaly is signalled and the cycle is stopped.
Normally open, active at +24V.
Binary code (bit 5) to select the welding program to run at Start.
When Start is active the control reads the active code on these inputs
and runs the corresponding program, (see code table).
21 RESRAVB Confirmation of dressing performed on channel B. Active at +24V.
Inhibits the alarm warnings, resets the welding spot counter and
increases the dressing counter in the electrode wear program by 1.
This operation can also be performed from the programming keypad
using the stepper menu (see programming manual).
The signal must be active at least for 100ms.
22 SPIN1 Definable input.
23 CTREV Control of the dressing tool in rotation.
This signal is valid when a passage from + 24V to 0V (and vice versa)
occurs during 1 second.
Otherwise an anomaly is signalled and the cycle is stopped.
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User’s manual
Contacts that have not been described are not used.

For connections see the application diagrams.

JP1 (Off)
J1:2-3
90 GF WELDING
User’s manual
19.2 Program selection codes/network address with parity table
There are 8 inputs dedicated to program codes (bit0-7) for a total of 255 programs, at present it is possible to define 64 (bit0-5).
The table below shows the codes relevant to the first 5 bits (0-5).
Signal Parity Binary code
CODE0
CODE1
CODE2
CODE3
CODE4
CODE5
Even
CODEP
Odd
PROGRAM 64 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63
GF WELDING 91
User’s manual
F377-IOE I/O Expansion Card 33037700
92 GF WELDING
Users’ manual
Code:33038100
20 F381-ETHERNET MODULE WITH KEY

Serial communication card for Ethernet 10BaseT IEEE802.3 networks.
This module enables the welding control to be connected to a serial network of the Ethernet
type for communication towards the WMS centralizer.
It is used as an alternative to the Profibus (F354-PFB) communication card or the Wmsnet
(F355-NET) communication card.
To set the addresses for connection to the network, please consult the programming
manual.
The TCP/IP address of the card is memorized in a "DATA KEY" (DK) device with key located
on the front panel.
The key may be removed to enable the control device to be replaced in case of breakdown
without having to set the address on the replacement control device.
LEDs located on the front panel:

LED Signal Condition
LAN Lan activity ON when data transmission is in progress
LINK Link status OFF when there is a line fault
Characteristics:
Transmission speed: 10Mbyte/s
Connection: RJ45 8 pin connector
F381-ETH
P
1
0
LAN LINK
DATA KEY
GF WELDING 93
Users’ manual
20.1 P10 Ethernet 10Base-T connector

Type RJ45 8-pole female shielded type MDI connection
Pin Signal Function

1 TD+ Positive data transmission
2 TD- Negative data transmission
3 RD+ Positive data reception
6 RD- Negative data reception
12345678
4,5,7,8 not connected
Shield Connected to PE
RJ45 connector
pinning
20.2 Connection cables
20.2.1 Characteristics
Twisted commercial cable for Ethernet 10 BaseT network.
20.2.2 Type of connection

The signal connection depends on the type of connection of the HUB input port used. It
may be a HUB with MDI connection or a HUB with MDI-X connection.
Before making the cable check the type of port present on the HUB.
Connection for HUB with MDI-X port

The connection between the two connectors is "Pin to Pin".
1 1
2 2
F381-ETH 3 3 Remote
4 4 HUB with
MDI 5 5 MDI-X type
6 6 port
7 7
8 8
Connection for remote HUB with MDI port.

In the connection with MDI port the signals are "Crossed"
1 1
2 2
3 3 Remote
F381-ETH 4
4 HUB with
5 5 MDI type
MDI 6
6 port
7 7
8 8
94 GF WELDING
Users’ manual
GF WELDING 95
Users’ manual
APPENDIX A - MAINTENANCE
Maintenance
Replacement of the cards on the control is easy and does not require specific care.
Connections of the cable with the welding equipment cannot be misplaced. You will find the
connector abbreviation on the frontal serigraphy.
To prevent a wrong connection between similar connectors, do not remove the polarizer on
some card connectors.
To ease the connection of the card on the bus it is better to disassemble the card rack from
the case.
Always check if there are any jumpers on the board and if they are properly set.
Modular card replacement

1. Switch off the equipment and disconnect cables;
2. disassemble the inverter from the equipment rack;
3. carefully disconnect the card to be replaced;
4. always check if there are any jumpers on the replacement board and, in case, set
them properly;
5. insert the replacement card checking the P7 three way connector to join the bus
properly;
6. reassemble the card rack in the case and secure it using screws;
7. reassemble the inverter on the equipment;
8. reconnect cables.
F384 CPU board

It is mandatory to insert the F384 CPU card on the P1 bus position. It is connected to the
display module via a 10 way flat.
The P7 three-way connector does not draw from bus the 24V I/O. Instead it draws the
special supply for the programming terminal on the RS485 (P1) port.
Replacement procedure:
3. carefully disconnect the card to be replaced;
4. carefully disconnect the display connector from P3;
5. check the permanent memory buffer battery to be on the replacement card. Check
the JP3 and JP6 jumpers to be set as follows:
JP3: 3-4 and 6-7 connected JP3: 1-2 connected;
6. connect the display flat on P3;
7. insert the replacement card checking the P7 three way connector to join the bus
properly;
9. reconnect cables.
96 GF WELDING
Users’ manual
Modification of a welding program

This operation shall be performed by control device programming trained staff.
Modification time of a program depends on the size of the modification.
If just a single parameter is to be changed, such as the welding current value, the
operation requires about 45” using the HCM4300 programming terminal.
If you have to change many parameters, the average time will be calculated summing 30”
to open the relevant menu and 10” each parameter change.
Single parameter change time: 45" ∼
N... parameter change time: 30" + 10 x N being N the number of parameters to be
changed
Replacing the battery:

Use a lithium battery 3,0V type CR2477N.
The battery is on the CPU card inside a proper battery slot, which allows replacing it
without performing any specific operation.
When you replace the battery the contents of the RAM memory will not be lost. A SuperCAP
type condenser provides to supply power to the RAM memory during replacement time.
Before insert the battery onboard, use a tester to check the battery to supply the proper
voltage.
Replacement procedure:
3. unplug the card positioned laterally on the CPU card;
4. disconnect the CPU card and unplug it tilting it laterally;
5. disconnect the display cable;
6. remove the battery locking spring;
7. remove dead battery;
8. insert new battery;
9. reassemble the battery locking spring*;
10. connect the display cable and insert the card tilting it;
11. insert the card near the CPU. Check P7 to fit properly;
13. reconnect cable.
* It is critical the locking spring to always be in place.
GF WELDING 97
Users’ manual
APPENDIX B – DIAGRAMS AND NETWORK CONFIGURATIONS
Operational diagrams
In this section you will find some control device operational diagram that allow analyzing
timing and synchronization relevant to Start and Emergency conditions in manual o
automatic areas.
1 – START identification in the automatic area use
(1)
24
Start
0
Min 10mS
24
Program code
0
24
Parity code
0
Max 19.8mS (0.99Cycle)
24
EVS
0
Max. 20mS (1Cycle)
24
Analog pressure
0
(1) The program code is stored. Further variations have no effect.
98 GF WELDING
Users’ manual
2 – START identification in manual area use
T1 = 20mS
T1 T1 T1 T1 T1
(1)
24
Start
0
24
Program code
0
24
Parity code
0
24
EVS
0
Call recognition: ΔT Min.40mS - Max.60mS from Start
(1) Start and Program Code must remain stable.
GF WELDING 99
Users’ manual
3 – EMERGENCY condition: main diagram
NB: Emergency signal is engaged at 0V
Not considered: keep Pgm 1
PGM 2 new Start

24
START*
0
Program
code PGM1 PGM2
FINISHING
Hot welding
cycles
24 Closed
EMERG Signal
Open
0
End
sequence 0
Switches to prg. 2
HOLD
SERVO VALVE
0
Switches to prg. 1
Alarm 1
0
*Performed by Robot
100 GF WELDING
Users’ manual
4 – EMERGENCY condition during or out welding pulse
APPROACH PRESSURE WELDING HOLD

24
CYCLES
0
24
CURRENT
0
24 Close
CASE 1 Welding ok No end

sequence
EMERG SIGNAL 0 Open
24 Close
CASE 2 NO welding
0 Open
24
ALARM (If engaged)
0
During an emergency cycle the control device acts as follows:

a started welding is taken to the end; In case of quality anomaly, if the spot repetition is
programmed, all required attempts must be performed;
where a diagnostics signal is generated (alarm 1), it can be reset from PC or HHT;
no signal is stored to state such situation;
the above is not considered an emergency but a standard operation of the working cycle,
during which the cycle must be stopped.
GF WELDING 101
Users’ manual
5 – EMERGENCY condition cut out with STSRT still engaged
24V On
START
Off
0
24V Close
EMERG Signal
0 Open
24V
End sequence
(welding ok)
0
when START=ON; same STANDARD conditions
6 – START condition disabled during welding pulse
24V
START
0
24V
WELD
0
24V
End sequence
0
0 to 99 cycles
programmable
102 GF WELDING
Users’ manual
7 – Proportional servo valve operating diagram
Servo valve parameters description:

OFFSET : 0 - 100 % (engaged only after a reset until cycle start) – Stored in Setup function
EV1 : 0 - 100 % Rated value during welding cycle – Stored in each program
EV2 : 0 - 100 % Pressure change value - Stored in each program
Pressure change after n. cycles, according to selected pressure change mode
START CYCLE START CYCLE

PROGRAM 1 EOCYCLE PROGRAM 2
PGM
EOCYCLE
PGM
ON
EVS
t
OFF
Pressure %
100
EV1, progr. 1 HOLD VALUE
VALUE
75
50 HOLD VALUE
OFFEST = 20 EV1, progr. 2
25
xxxxx
0 t
HARDWARE RESET OR
CONTROL ON
Pressure % = Output pressure as a percentage of the input pressure.
Exemples: with a 5 bar input & EV1 @ 50 %; servo valve output = 2.5 bar
" " " " " 75 % " " = 3.75 bar
" " " " " 100 % " " = 5 bar (servo valve drop not considered)
When the welding program code changes (in discrete physical output, or through a serial fieldbus line such as
Interbus-S, Profibus DP or DeviceNet) the servo valve updates in real time according to selected program, even in
lack of Start signal. This function is always on.
Example: solenoid valve output value proportional to each program change

Pressure %
100
offset
xxxx
0
t
HARDWARE RESET OR WELDING PROGRAM 1 WELDING PROGRAM WELDING PROGRAM

CONTROL ON CHANGE CODE 2 CHANGE CODE 3 CHANGE CODE
All changes without start cycle command
GF WELDING 103
Users’ manual
8 – ENABLE function (Interbus-s)
24V_power supply
signal
P/2
0-10V/4-20mA
ENABLE 24V
Solenoid valve engaged
0V Solenoid valve idle
PA pressure
Interbus input
ENABLE (Bit 2)
Control solenoid
valve
Signal behavior
ENABLE 24V: this function allows controlling the valve when the supply is cut off (fail
safe); the output current pressure does not change.
Serve valve control Interbus input: this function allows driving the servo valve through
the Interbus control input (Aktiv High = ENABLE goes 0V ->); pressure is unchanged.
104 GF WELDING
Users’ manual
9 – Pressure diagnostic control diagram

This operational mode is in relation to PROC/WAIT programming parameter status. Refer to
programming handbook, Electrode forcing diagnostic mode paragraph.
Process in PROC mode
The control carries out the sequence complying with set times. Diagnostics warns about
any pressure error.
Tmax DIAG HOLD
START
PRE
WELDING
CYCLE
1
ALARM1 If pressure is not OK E015
0
Process in WAIT mode

The welding pulse is performed only when the P1 rated value is reached.
Tmax WAIT
START
PRE
Pressure OK
(P1=15Kn)
P1
WELDING
CYCLE
NOTE When parameter %T. Prs =0 function is disabled.
GF WELDING 105

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Integrated Inverter MFDC2 Weld334m

Use and maintenance handbook

Ed.4 – September 2011 Code 39003128

Ph.: 011-3031.277 (Italy Service)

Information inside this handbook belongs to GF WELDING S.p.A.

6 SYSTEM ARCHITECTURE AND HARDWARE PARTS ..................................................................... 21

9 INVERTER INSTALLATION ................................................................................................................... 32

10 POWER APPLICATION DIAGRAM ................................................................................................... 33

14 F375-PS POWER SUPPLY ..................................................................................................................... 54

15 F374-IMF MEDIUM FREQUENCY INTERFACE ..............................................................................59

17 BASIC I/O CARD F399-IOB ...................................................................................................................66

DURING THE CONSULTATION OF THIS HANDBOOK ALL STEPS GENERATING RISK

WARNING Incorrectly performed operation may damage equipment.

DANGER Incorrectly performed operations may lead to serious danger

1.1 Use and conservation of the use and maintenance handbook

Open device only after discharge time

2.2.1 Type with water cooling (600A )

4 FIXING HOLES - Ø7.5

2.2.2 Type with air cooling

4 FIXING HOLES - Ø7.5

3 INVERTER EXPECTED USE CONDITIONS

3.1 Notes on safety connections

3.1.1 Grounding and insulation

3.1.2 Safety against short circuits

1. Ground the welding transformer secondary.

3.2 Forbidden conditions of use

3.3 Expected use conditions

4.1 Danger warning

MAINTENANCE DO NOT SWITCH ON MAINS

This is a class A resistance welding equipment.

4.2 Residual danger

DANGEROUS ELECTRICAL VOLTAGE!

DANGEROUS ELECTRICAL VOLTAGE!

COOLING LIQUID FEATURES (all versions)

PRESSURE AND DELIVERY 0.3 – 0.6 Mpa – 4 - 6 l/m’

600 A INVERTER ELECTRIC FEATURES – WATER COOLING

600 A INVERTER ELECTRIC FEATURES – AIR COOLING

Load Pow er erogation vs. ED % : T air = 40 °C , 4.5 m /s air flow

6 SYSTEM ARCHITECTURE AND HARDWARE PARTS

Using such cards the inverter can:

Below it is shown the inverter architecture.

WMS Ethernet I/O

CPU Fieldbus (Interbus)

6.1 Inverter block diagram

400÷500Vac 3Ph / 690Vac 3Ph+N

6.2 Hardware features

6.2.1 List of available cards for system customization

Power module 400-440Vac – 600A – WATER

Power unit + 4 digit Display + Electrovalve

Inverter control + Analog inputs

10 Mbit Ethernet with Data Key

I/O Expansion Card

Order Inverter denomination

6.2.2 Layout Inverter MFDC2 Weld334mHardware arrangement of the inverter

WELDING CONTROL CARDS

MFDC2 Weld334m Inverter layout

6.2.3 Hydro fluidic system

¼”G rear plugs

Drip-proof quick couplings ¼”G

Example of rear side hydro fluidic connection

NETWORK CABLES ENTRANCE

Optical fiber, ethernet,

REAR SIDE WATER